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CP002 REV 1

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BATCHING CONCRETE/MORTAR
VISUAL SLUMP ASSESSMENT
ADJUSTMENT OF MIX DESIGNS

1. PURPOSE

1.1 This procedure describes the methods and controls that are used by concrete production
personell.

2. RESPONSIBILITY

2.1 Batching

2.1.1 It is the Plant Operator’s responsibility to ensure that this procedure is followed and he is
accountable to the Plant Supervisor.

2.1.2 The Plant Supervisor assumes the responsibility for all concrete batching.

2.1.3 The Plant Supervisor takes ultimate responsibility for this procedure.

2.2 Visual Slump Assessment

2.2.1 The Plant Operator must ensure that the correct slump is achieved.

2.2.2 The Truckmixer Operator is responsible for checking the slump of a load in the drum and
for reporting any variance from the specification.

2.2.3 The Plant Supervisor takes ultimate accountability for the correct workability (i.e. slump)
of the concrete produced by the plant.

2.3 Adjustment of Mix Designs

2.3.1 The Plant Operator is responsible for the adjustment of mix designs.

2.3.2 The Plant Supervisor, when he takes over batching.

2.3.3 Ultimate responsibility for this procedure rests with the Plant Supervisor.

3. APPARATUS

3.1 Personal computer linked to the IBM mini host computer and to the plant operating
system.
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4. METHOD

4.1 At the start of each shift it is critical that a plant pre-start check is performed prior to
batching (see procedure CP001).

4.1.1 Loader Operator Plants (CMS/TMS)

a) Central Despatch schedules deliveries of concrete/mortar referring to the


information provided on the TMS Screen Schedule as supplied by Central
Orders. Batching is therefore planned accordingly.

NOTE: For Plants not co-ordinated by Central Despatch, the above is not applicable.

b) The Confirmation Slip (for the first load of a particular mix to a customer, that
day) is completed with the relevant information.

c) When the relevant truck number appears on the bottom of the CMS Batching
Screen, indicating that the CMS has received all of the information for the load
from the TMS, the Plant Operator then keys in the truck number on the Batching
Screen.

d) The Mix Recipe is displayed and the Raw Materials are then weighed individually
as follows:

( i) The stone mass is displayed automatically on the outside display and is


weighed off by the Loader Operator to within 50 kg of the theoretical
mass.

( ii) The sand required is then displayed automatically on the outside display
and is weighed off by the Loader Operator to within 50 kg of the
theoretical mass.

(iii) The cement is weighed off by the Plant Operator to within 5 kg of the
theoretical mass displayed on the Batching Screen.

(iv) The water is weighed off by the Plant Operator to within 5 kg per m³ of
the theoretical mass displayed on the Batching Screen, less 30 litres of
water held back for moisture variation in the aggregates water taken @
checkpoint MUST be recorded on CMS mixer log.

(v) The Plant Operator then sets the relevant admixture dispensing units as
required on the Mix Recipe on the Batching Screen.

NOTE: At no time may the maximum water figure given on the computer screesn be
exceeded by 5 litres per cube.

4.1.2 Conventional Plants : CMS/TMS (overhead aggregate bins)

The same applies as for Loader Operator Plants except that the stone and sand is
weighed off by the Plant Operator.

4.1.3 Should tolerances be exceeded, the following procedure is to be implemented:


CP002
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a) Stone: Discharge excessive stone into the loader bucket and place on
the stockpile.

b) Sand: Where possible, sand is to be removed manually. At a plant


where this is not possible, the Technical Department is to be contacted
for the required mix design alteration.

c) Cement: Retain excessive cement in the weigh hopper and include in the
following load. Where the cement type differs,
reschedule for a load with a similar cement type.

All alterations to the original mix proportions are to be noted on the manual Mixer
Log as well as on the CMS generated mixer log and signed off by Plant
Supervisor.

4.2 Visual Slump Assessment (CMS/TMS)

4.2.1 After the load has been charged into the mixer drum the TMO collects his Delivery Note
and proceeds to the slump checkpoint. Before getting out of the cab, the TMO checks
on the Delivery Note for the slump required. He then speeds the drum up to the required
revs (12 revs per minute) allowing the load to mix thoroughly. A minimum of 5 minutes
required before a visual slump check is done.

4.2.2 At the checkpoint he unhooks the platform and ensures that it is secured by the safety
catch before stepping onto it.

4.2.3 The TMO then checks the slump. If it appears that more water is required, he is to
request from the plant Operator on how much can be added. Water is then added by the
Plant Operator until the required slump is attained. The Plant Operator is to ensure,
within the designed criteria, water is added.

4.2.4 If the slump exceeds that specified by more than 15 mm, the TMO must inform the Plant
Operator so that the load can be adjusted accordingly.

4.2.5 On completion of the slump check, the TMO then returns the platform to its original
position.

4.2.6 The TMO then adjusts the drum control so that the drum rotates slowly, even when the
motor is at high revolutions, to enable the drum to turn while the truck is on the way to
site (one full turn every minute).

4.2.7 The TMO then completes his time sheet by noting the final slump assessment and the
amount of water added at the checkpoint in the appropriate column on the time sheet.

NOTE: At no time may the maximum water figure given on the computer batching screen
be exceeded by 5 litres per cubic meter.

4.2.8 The Plant Supervisor/Operator will do random slump checks with TMO on a daily basis.
Minimum of 8 per day or 1 hour whichever is the greatest.
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4.3 Adjustment of mix designs : (CMS/TMS)

4.3.1 Adjustments may only be made under the following circumstances:

- compensation for moisture in sand and crusher dust


- compensation for water held in stone
- dry outs
- compensation required when specified slumps are readily available with water
less than “Batch Mass” (Design Mass).
- Compensation required when specified slumps are not obtainable when using
maximum allowable water after consultation with Technical.

a) Compensation for moisture in sand and crusher sand

Ascertain sand and crusher dust moisture in accordance with the procedure as
described under Plant Pre-start checks.

Input the moisture into CMS.

b) Compensation for water held in stone

See under Plant Pre-start Checks .

d) Dry out concrete

( i) Should it be necessary to dry out loads exceeding the specified slump by


25 mm, the strength range of 10 to 30 MPA, add dry materials as per the
following table.

Load Size m³ 1 2 3 4 5 6
OPC 60 120 170 220 270 320
Dune 90 170 250 340 410 500
Plasticiser (ml) 180 360 510 660 810 960

( ii) Should the strength of the mix to be dried out exceed 30 MPA, contact
the Technical Department.

(iii) Quantities of new materials batched for drying out must be recorded on
the CMS Mixer Log.

NOTE: Plants that stock dune sand must use dune sand for dry outs
except for paving and exposed aggregate mixes and special mixes, with
consent of the Technical Department.

No dryouts to be done on the following without consulting technical.


 Poolbeton
 Colour beton
 Aquabeton
 Exposed aggregates
 Paving mixes
 Power floated mixes

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Dry out retarded/long life mortars.

( v) Should it be necessary to dry out a load of retarded mortar add further


air-entrainer proportionate to the extra cement added e.g. taking a cls 2
mortar (1422), the standard cement content might be 246 kg/ m³ and the
standard dosage of air-entrainer might be 819 ml/ m³. This is then
equivalent to 333 ml of air-entrainer per 100 kg of cement. Now, for
example, if you dry out a load by adding a further 120 kg of cement, you
will then need to add a further 1,2 x 333 = 400 ml of air-entrainer.

NOTE: When batching a part load, add further air-trainer by 0,5 litres/ m³.
(500 ml per cubic metre of product)

e) Compensation for change in stone size

This is not possible on the CMS. Contact Central Orders who will, where
necessary, arrange with the Sales and Technical Departments to have a new mix
recipe/order downloaded to the plant.

f) Compensation required when specified slumps are readily available with


water less than “Batch Mass” (Design Mass)

( i) Determine and input moisture contents into CMS by replacing relevant


menu on CMS.

( ii) Ensure that allowance has been made for “water in stone”.

(iv) Should the above not have the desired effect, contact the Technical
Department immediately.

g) Compensation required when specified slumps are not obtainable when


using maximum allowable water

( i) Determine and input sand moisture contents into the CMS.

( ii) Ensure that the input stone moisture is correct.

( iv) If a slump is still too low (dry) after all the allowed water has been added,
the Plant Operator must report this to the Technical Department.

4.4 Special factors:

( i) When mortar or similar product is to be batched the procedure is the same as for
concrete except that stone is not included in the mix.

( ii) 100% recycled water may be used in concrete/mortar.

(iii) Batching value added product.


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5. APPLICABLE STANDARDS

5.1 SABS 878: Ready Mixed Concrete

5.2 SABS 1200 G: Concrete (Structural)

5.3 Required batching tolerances -


Cement and Lime : + or – 5 kg/load
Water : + or – 5 kg/ m³
Sand : + or – 50 kg/load
Stone : + or – 50 kg/load

5.4 Slump tolerance: 25 mm or 30% of specified slump as per SABS 878.

- the internal company target slump tolerance, however, is 15 mm.

6. REFERENCE DOCUMENTS

Delivery Note (CP002/1)


Confirmation Slip (CP002/2

7. CONTROLS/LIMITS OF AUTHORITY

7.1 No deviation from this procedure is permitted.

7.2 In the event of difficulty with any aspect of this procedure, contact your DSM and/or the
Technical Department.