Monday, November 29, 2021

Cover Story

RMC & EQPT

TECH-ENABLED ECO-EXPANSE

 

The use of ready-mix concrete in modern constructions is an environmentally responsible choice providing users with energy-efficient buildings by combining isolation with high thermal mass and low air infiltration. It is preferred in the residential construction sector due to the advantages, such as savings in labor requirements and supervision costs, faster construction, and uniform, consistent, and assured quality of concrete. Benefits such as reduced cost of labor and sight supervision coupled with easy pouring methods involved in readymix construction are expected to attract more consumers in the future. These features also augur well for the holistic growth of the industry by offering a boost to RMC equipment demand, which is already being driven by hi-tech advancements..., writes Prerna Sharma

 

The global ready-mix concrete market size is projected to reach $1,118.5 billion by 2027, at a CAGR of 8.2% from 2020 - 2027. According to Mordor Intelligence report, the Indian ready-mix concrete market size was over $15 million in 2020. The market is projected to register a CAGR of around 9% during the forecast period (2021-2026). COVID-19 negatively impacted the market in 2020. According to IMF, the nation’s GDP declined to 10.30% in 2020, marking the first significant decline in about ten years, and it is projected to reach 8.8% growth by 2021. In 2020, the construction industry in the country had come to a standstill due to the COVID-19 impact, as most of the construction sites were running at 50% of their capacity. With the use of ready mix concrete, the on-site requirements for installing the concrete plant are eliminated, thereby cutting out the storage problems and labor costs associated with it. The wastage of materials for the manufacturing of concrete is also avoided. No labor has to be put in for the production of concrete at the site. As concrete is readily available for construction purposes, the time required for concrete production is saved. Better quality concrete as per customized requirements is readily got. The cost of production of concrete is reduced. Noise levels and dust pollution on-site are reduced.

 

GROWTH DRIVERS

High strength and durability increase the uptake of ready-mix concrete in residential and commercial construction projects. Additionally, the proliferating construction industry in developed regions boosts the ready-mix concrete market size alongside increased commercial and residential construction activities.

According to Grand View Research report, the construction industry is fostering its efforts to manage and reduce its carbon footprint affecting the environment severely. CO2 footprint is a paramount challenge in the development of concrete formulations. Most homebuyers prefer to use ready-mix concrete for its significant advantage over other concrete materials, such as cost-efficiency, high durability, ease-of-maintenance, and cost-savings. The product is widely being used as a substitute for traditional concrete because of greater convenience, ease of use, and enhanced quality. Moreover, low inventory cost, wastage reduction, and efficient utilization will lower the overall project cost. Thus, it is likely to impact the demand on a positive note.

Many industry players are increasingly developing tailor-made admixtures that can combine technical performance and carbon footprint reduction. Like many markets associated with the construction industry, the readymix concrete industry was severely affected by the COVID-19 crisis. Favorable government policies for the production and initiatives for infrastructure development projects are major readymix concrete market trends. Moreover, substantial R&D investments made by manufacturers in product development substantiate the readymix concrete market share.

 

HUGE EMPHASIS ON SUSTAINABILITY

As per the CII-Godrej Green Business Centre study, Significant efforts have been made by the leading ready mix concrete manufacturers to reduce GHG emissions by increasing the proportion of additives in RMC such as flyash/slag to reduce the OPC consumption and improving the energy efficiency of the manufacturing process. In India, the percentage of additives varies from 5% to 50% for various reasons, as understood from our extensive interactions with the industry. The GHG emissions per m3 of concrete production range from 0.08 – 0.12 ton/m3 of concrete. Considering an estimate of 7-9 % of total OPC cement produced in the country is used for RMC, a total of approximately 12 – 15.5 Million Tons of GHG/ annum could be attributed to the current RMC production in the organized sector.

Similarly, talking about the global expanse, National Ready Mix Concrete Association (NRMCA) began publishing its carbon footprint benchmarks in 2014. One measure of the NRCMA’s progress has been the more efficient use of Portland cement, resulting in a reported 20% carbon footprint reduction associated with ready mix.The concrete industry has embraced the cloud-based, open-access Embodied Carbon in Construction Calculator (EC3). This data-driven tool uses the construction industry’s Environmental Product Declarations (EPD) database, allowing architects, engineers, owners, contractors, building material suppliers, and policymakers to quickly evaluate Embodied Carbon (EC) in project specifications.The EC3 Calculator creates The Carbon Leadership Forum (CLF), an industry-academic collaboration hosted by the University of Washington focused on reducing the embodied carbon in building materials. The American Concrete Institute Foundation is an association partner.According to the Forum, the EC3 tool “allows for supply chain-specific analysis of embodied carbon data, utilizing the first searchable and sortable database of all United States and Canadian EPDs for concrete, steel, wood, glass, aluminum, insulation, gypsum, carpet, and ceiling tiles. The technology is revolutionizing the review of material or product environmental metrics by creating digital EPDs and translating all declarations into that form for viewing and analyzing project data.”

This indicates that the ready mix concrete sector offers enormous and cost-effective intervention opportunities for improving the Green performance of the product, thereby reducing GHG emissions significantly so that total emissions attributable are pushed to the lower end of the above range.

 

ENGINEERING MARVEL

Tremendous strides have been made globally and in India to discover sustainable & innovative materials for construction. To give you an instance, according to a leading US construction magazine, 42 Broad is a 16-story mixed-use development near New York City being built with Insulating Concrete Form (ICF). ICFs sandwich a reinforced concrete wall between forms made of rigid polystyrene insulation that stay in place after the concrete hardens. There are several taller ICF buildings in Canada, but at 16 stories, 42 Broad will be the tallest in the US. The real innovation on this project is penalizing the Amvic ICF blocks and using HelixTM steel fiber reinforcement. The ICFs are assembled off-site in a nearby plant and arrive at the jobsite as custom panels up to 50 feet long, resulting in labor and time savings on the job site, helping the owner to occupy the building early. This process is possible by using steel fibers in the ready mixed concrete to replace the horizontal reinforcing steel, which eliminates costly horizontal rebar slices.

Polypropylene fibers are generally incorporated at much lower dosage rates than steel fibers, typically less than 1kg/m3, and are essentially used to modify the plastic properties of concrete to minimize plastic cracking problems. They also contribute to improved abrasion resistance, enhanced impact resistance, and increased spalling resistance in fires. The use of polypropylene fibers has grown steadily since the 1980s, and estimates suggest that over 5% of all ready-mixed concrete in the UK now incorporates such fibers. From a producer’s perspective, the fibers are easy to handle and easy to add to the concrete, although care is required to ensure that the effects on consistency strength are accounted for.

LafargeHolcim is one of the first companies to commercialize bendable concrete with a product called Ductal®. Ductal® is an ultra-high-performance concrete (UHPC) that incorporates fibers into the concrete mixture to improve strength and ductility along with a host of other benefits. LafargeHolcim distributes the premix powder, fibers, and admixtures necessary to produce Ductal® to their partners, who then mix it into concrete. LafargeHolcim states that they use “high carbon metallic fibers, stainless fibers, poly-vinyl alcohol (PVA) fibers or glass fibers” to increase the concrete’s ability to withstand tensile loads and deformation. Ductal® is also less porous than conventional concrete, making it more resistant to chlorides, acids, and sulfates. It is also generally much more impermeable to water, making it ideal for roofing as well. In addition, Ductal® has self-healing properties. This bendable concrete has been thoroughly researched and is commercialized.

With the help of advanced R&D, ACC is developing an innovative range of ready mix concrete solutions to cater to the varied requirements of customers. These solutions enjoy a rapid setting time of ~2 hours. Therefore, these products are finding wide market acceptance. Innovative products like ACC Suraksha NX anti-washout concrete is helping the company create more substantial brand equity in Tier-II cities. The company has recently launched four new ready-mix concrete products – ECOPact, ACC Thermofillcrete, ACC Suraksha NX Antiwashout Concrete, and ACC ADMIX – during the Covid pandemic. ACC Suraksha NX Anti washout Concrete enables customers to pour the concrete without worrying about the high-water table in their foundation. The product mix has a rapid setting time of about two hours and maintains the desired properties of concrete even when poured on surfaces with high-water content. ACC Thermofillcrete can dissipate heat and help lower the cost associated with excavation, backfilling, and compaction. A concrete with additive mixture range, ACC Admix range is a new generation polymer designed to impart exceptional performance in concrete. ECOPact, a ready-mix green concrete for sustainable and circular construction, was brought from the parent LafargeHolcim. The innovative manufacturing process reduces CO2 emissions entirely.

 

JSW has recently added RMC to its portfolio. JSW Concrete is a tailor-made product manufactured at its captive plant using new-age technology from Schwing Stetter based on standard required specifications. This method lessens the time interval for production & increases the efficiency of mixing for a wide range of applications. The prepared concrete mix is poured into the transit mixers mounted over the truck and delivered to the worksite. Since a large part of the crude material is sourced from its cement plants, it permits exceptional process control over the quality and consistency of our product. The RMC business foray follows the Greenproducts ethos of JSW Cement and will launch unique eco-friendly concrete for use in various commercial construction projects. As part of its commitment to reduce carbon emissions, JSW will use its green cement and Indian Green Building Certified (IGBC) certified product, GGBS, while sourcing other necessary raw materials from locations within proximity to its RMC plants to ensure sustainable construction.

Choosing site-mix concrete looks cost-effective initially, but it is susceptible to multiple problems during and after construction, leading to expensive repairs and poor durability. Various issues like poor work-ability, honeycombing, inconsistent strength, cracks & seepage are unavoidable with regular site-mix concrete. These problems erode customers’ trust in a company’s competence and cause irreversible damage to its reputation.

 

In line with this, UltraTech has recently introduced DuraPlus –an amazing concrete with the ability to fight multiple problems such as honeycombing, seepage &cracks to protect the structure’s durability. Its unique mix design incorporates the right blend of ad-mixtures, ensuring fast execution, superior finish, and excellent durability.

The world is slowly leaning towards recycling rather than making new materials from scratch to save resources. The same thing holds for concrete. Green Sense Concrete, made by BASF, is designed to go well with the environment and a contractor’s budget. This concrete is ideal for building owners who want to switch to green materials because of its high percentage of recycled materials. Moreover, this type of concrete is known to improve its performance characteristics.

 

Rapid Drying Concrete: What’s better than concrete drying right away? Every construction company can benefit from this type of concrete, especially when they need to meet tight deadlines. This type of concrete is more known as ‘Aridus’ and is the first ready-mix concrete solution that eliminates floor covering failures from moisture. Another way of speeding up the concrete drying process is with the use of polyaspartic coatings. Contractors can apply this type of coating in high humidity and temperatures below 50 degrees Fahrenheit. This type of coating is durable and prevents degeneration from UV light, abrasions, and chemical spills.

Light-Transmitting Concrete: This concrete innovation contains thousands of optical fiber strands placed in the concrete made up of fine materials. The optical fiber strands send artificial or natural light into the space closed off by the translucent concrete, divided into blocks following the casting. For commercial buildings with dark pathways, using this type of concrete can improve overall safety for people walking on it.

 

Easy Fille from Nuvoco is low strength, easily pumpable lean concrete ready-mix that is a preferred alternative to compacted fill, PCC for foundation base with low comprehensive strength and backfill in construction sites. It evens the surface under the foundation concrete. It is easy to pump. Therefore, it does not require compaction. Highly flexible flow helps adjust the setting time. It has a superior load-carrying capacity compared to granular fill. Faster placing helps in faster job completion. Easy Fille also prevents void formation during placement and is easily & quickly removable for repair

 

 

SMART EQUIPMENT DEMAND SEEING A SURGE

Computerization, advances in material measurement, and the availability of advanced admixtures facilitate the readymix concrete companies to design and produce complex, technically demanding concretes that were simply unachievable even a decadeback. Increasing environmental awareness has brought significant changes to the design of modern concrete production units, with new plants being enclosed and no waste ever leaving the site as concrete and water recycling units become the norm.

 

Schwing Stetter India has unveiled its state-of-the-art Self-loading Mixer – SLM 4600. It caters to higher output requirements of concrete batching, mixing, and placing in the urban development Segment. Fitted with the latest CEV Stage 4 Engine, it provides excellent fuel savings while adhering to the latest emission norms. It is incorporated with IoT and telematics and is for domestic consumption and global requirements. Telematics ensures precision in batch output, lesser mixing time improves the overall output.Innovative Drum Design ensures less wear and less maintenance, and ergonomically designed structure provides safety to man and machine.It is best-suited for infrastructure projects across rough terrains and a boon for contractors who have taken up smaller projects, where optimized equipment investment is essential.

 

Putzmeister is known to provide best-in-class equipment that is engineered to last. The company’s machines and plants combine high performance, durability and low maintenance with economy, able technical supervision, customization and innovative technologies that are constantly updated as per the latest research and development and market requirements. Putzmeister offers a range of concreting equipment – Batching Plants, Transit Mixers, Concrete Pumps and Shotcrete equipment for tunnel construction. The company has over 60 years of experience in providing construction solutions to its clients, and a deep commitment towards continuous R&D. Over the years innovations introduced by Putzmeister have gone on to become industry standards. Internationally, Putzmeister has introduced a hybrid Truck Mounted Boom Pump – Putzmeister iONTRON. This is the world’s first emission free truck mounted concrete pump. With the Putzmeister iONTRON it is possible to pump concrete on construction sites without producing any emissions. Depending on the local electricity mix, CO2emissions can be reduced by up to 100 %. Working in electric mode is very straight forward: one simply has to plug the connector into the site power supply and start pumping – no additional batteries required!

 

The most striking feature of the KYB-Conmat Batching Plant is faster & easy erection / dismantling at site. It has all welded frame structure & comes fully assembled from the factory in three parts. It can be installed at the site with an ordinary “Pick & Carry” crane available locally. It requires only a few hours for installation. Engineered to perfection, KYB-Conmat Batching Plant requires minimum maintenance, thus assuring continuous performance. The company has invested heavily in state-of-the-art designing & manufacturing techniques to make the equipment, which is not only efficient but also performs in harsh conditions. Sleek-designed KYB-Conmat Batching Plant requires minimal installation area & minimum civil works and, hence, good savings for the customers.

 

The SANY SBP 60F concrete batching plant utilizes an advanced modular, containerized design that enables easy assembly and dismantlement and quick, easy transport. The batching plant uses the new and improved Twin Shaft Mixer, which outputs an even, high-quality mix at high efficiency and low maintenance cost. The centralized lubrication system for the twin-shaft mixer has a patented closed self-lubricating end shaft design. It is easy to maintain, and the mixer unit operates for extended service life.The 60m3 concrete batching plant offers the latest variable frequency drive control system for skip bucket control. Aggregates are safely and efficiently loaded to the mixer, making work more productive.The 3.2x2.2m control cabin is spacious and even air-conditioned. The built-in superior control system gives users complete control over the batching plant.

 

Equipped with German technology & machinery, CHAVDA Infra Pvt. Ltd’s RMC plant allows brisk construction through mapped delivery programmed at the site. The RMC plant has a capacity of 60 cu.m/hr and is equipped with a ‘Schwing Stetter’ twin shaft mixer. For the strong supply chain between construction sites, improved GPS connectivity, networking, and Integrated control panels for stationary pumps, the plant is geared up with an advanced MCI 550 control system with SCADA software. Despite providing a standard range of concrete from M7.5 to M40, the company also manufactures Lightweight Concrete mixtures made with lightweight coarse aggregate, which creates lighter versions of standard concrete mixtures and provides numerous benefits to the real estate industry.

 

The ACP 120 by Apollo Inffratech Pvt. Ltd. is integrated with a host of built-in features for enhanced productivity and a wide range of applications. It is equipped with a heavy-duty, field-proven engine, world-class hydraulic components, and an intuitive control system. It is the ultimate machine in its class in meeting production and application needs.The ACP 120 is equipped with automatic electronic controls. The automatic steering control guides the front of the machine for precise alignment. The grade controller positions respective lift cylinders for precise grade. A slope control positions the rear lift cylinder to maintain a precise slope. The automatic controls are also supplied with manual overrides and are easy to operate and adjust.A technically advanced, hydrostatic, direct-traction drive eliminates the need for many mechanical drivetrain components, thereby ensuring lower maintenance costs and smoother operation. The ACP 120 is supplied with quick-change mechanical moulds that can be replaced in 30 minutes or less.Operation is easy with the ACP 120’s fingertip controls. The operator has exceptional sight lines to the formed concrete, enabling quick adjustment of speed and vibration when necessary. The machine’s design allows easy access to machine components.

 

AJAX concrete Slip-Form Pavers are import substitutes working in line with the Government of India’s plan of Atmanirbhar Bharat where the company is also working in this area to align itself to be self-reliant and have as many as components locally and make it a Made in India Product for the world. AJAX Boom Pump is another marquee product resonating with the ‘Made in India’ theme. The Concrete Boom Pumps have been revolutionizing the construction of large commercial and residential buildings and structures. AJAX’s Boom Pumps have overseen deployment in various applications. They have been proficient for urban mega infrastructure projects, commercial and office buildings, high-rise segments, commercial retail spaces, bridges, airports, and various projects under the Smart Cities’ initiative led by the Government of India.
 

MMX by SIMEM stands for Mobile Mixing excellence. The concrete batching and mixing plants can ensure an hourly output capacity of 130 m3 of high-quality concrete and have a structure that allows for easy transport with generic vehicles. The support structures of the aggregate and mixer modules are all pre-assembled, pre-wired, and automated. Thus, configuring the modules from the transport to the working position is extremely easy and fast. This movement is fully automated by theuse of hydraulic and pneumatic actuators. The aggregate module only needs one vehicle to be transported as hopper walls and containing walls for ramp collapse into the aggregate module.Mixing and dosing modules are transported as one unit thanks to the patented movement. Access to the mixer is made easy thanks to a patented system of rails and hydraulics that moves the weighing devices. When a thorough cleaning of the mixer is necessary, it’s possible to move the weighing devices from the work to the transport position, making accessible the internal part of the mixer for a more thorough cleaning or the changing of wear parts.

 

All these technological developments reflect an unparalleled growth for ready mix concrete in construction. As companies capture latent opportunities, ensuring sustainability will be their crucial objective, and ready mix concrete will find greater mention in addressing these growing needs.

 

 

Fast Facts
Readymix concrete was first used almost a Century ago on a construction site in Baltimore, in the US. In many developed countries; it now accounts for over 50% of all the cement used in construction. With an estimated worldwide annual output of 4 billion cubic meters, concrete is the most widely used construction material globally thanks to its unique combination of versatility, economy and durability.
  • The ready-mixed concrete industry has responded to challenges by:
  • Reducing pollution and emissions dust emissions cut by 90% over the last 20 years
  • 18% reduction in carbon dioxide to the air
  • 46% reduction in sulphur dioxide
  • 17% reduction in oxides of nitrogen
  • 60% saving in particulate matter.

 

 

 

Currently RMC Sector is growing at a rate of 15-20% YOY and we expect that this will go above 20% YOY in upcoming years. Currently we are growing at 26 % CAGR and expected to grow at the faster pace in coming years. In India, the use of RMC is still at a relatively nascent stage as compared to that of many developed countries. Therefore we can see increase in use of RMC in coming years. India’s infrastructure development is going up as per latest budget announcement and government plans to restructure the national highways, airports and Metro rail projects. This bores well for ready mix industry.

ANIL BANCHHOR, MD & CEO, RDC CONCRETE (INDIA) PVT LTD

 

 

 

Schwing always have been on the innovative path and its quick adaptability to the emerging trends in technology. Schwing Stetter will shortly launch a slew of New products in the forth coming EXPOS, as a extensive research has gone into the customer requirements for various capacities and embedding the latest in technology for improved performance. Our R&D center in a continuous innovation, designs plants to mix high grade concrete for high rise buildings, to handle Low temperature concrete for Dams, Nuclear power plants and other high strength Projects and we continue to be in the front line to bring in innovative products.

V. G. SAKTHIKUMAR, MD, SCHWING STETTER INDIA

 

 

 

Putzmeister offers not only the most suitable equipment, but also the best service and application support to help our customers get the most out of their equipment and improve their profitability. Our team supports Putzmeister equipment and Sany concrete pumps. We have a higher ratio of service engineers and technicians per customers to ensure that our customers’ needs are addressed promptly – 90% of our service cases are resolved within 24 hours. We also offer an operations and maintenance service for the more challenging projects – customers can free up vital resources and leave the output and maintenance to our team of experts.

WILFRIED THEISSEN, MANAGING DIRECTOR, PUTZMEISTER INDIA

 

 

 

AJAX, the World’s largest SLCM Manufacturer that believes in “CUSTOMER FIRST” focus always formulates any breakthrough strategy keeping their stakeholders’ interest in mind that should forever be a win-win situation for the customers as well. AJAX takes up pro-active role in improving the availability of financing for their customers by means of long-term tie-ups with banks and non-banking financial corporations (NBFCs) routed through our dealerships Pan India

JAGADISH BHAT, MD & CEO, AJAX ENGINEERING




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