This is a conceptual proposal in which the main objective is to determine the cost and quality effectiveness on the application of modular wet mix and dry mix concrete batching plant. Based on the data collected over the pass years, a detail study was being conducted to determine the various cost factors arising from the setting up of concrete batching plant, production operations, quality control, inventory and delivery of the products to the customers. As this study covers the entire overall operations of a commercial concrete batching plant, the complexity of the various processes and functionalities has to be identified to provide a full understanding on the limitations on the speed, cost, quality, flexibility and dependability.
This proposal is also inline with the company long term strategy of increasing the marketing share by twenty percent annual growth. Therefore, to achieve this goal, various steps have to be taken into consideration such as the speed, cost, quality, flexibility and dependability.
Existing Dry Mix Concrete Batch Plant
Plant Component
The basic components of dry mix concrete batch plant and its related facilities are as tabulated below:-
Item
Descriptions
Remarks
1
Ground Hopper
For feeding of raw material, coarse and fine aggregates
2
Movable Inclined Conveyor
To convey the coarse and fine aggregate to the designated storage compartment
3
Aggregate Storage Bin
For storage on top of the aggregate weighing bin
4
Aggregate Weighing Bin
For weighing of the coarse and fine aggregates
5
Shooting Conveyor
To convey the coarse and fine aggregates at high speed which shoot directly into the mixer drum of the mixer truck
6
Cement Storage Silos
For storage of cement - OPC, PFA and Slag Cement
7
Cement Weighing Bin
For weighing of various cement
8
Water Weighing Bin
For weighing of water
9
Admixtures Weighing Bin
For weighing of admixtures
10
Control Room
To provide staff on the control of the production
11
Water Storage Tank
For water storage
12
Aggregate Stockpile
For storage of coarse and fine aggregates
13
Slump Check Platform
For concrete slump check
14
Wheel Loader
For material handling from aggregate stockpiles to ground hopper
15
Mixer Truck
For mixing of concrete and delivery of finished products to customers
16
QC Laboratory
For quality control and testing
17
Power Supply
To provide power supply to the plants and other facilities either by TNB or generator set
18
Waste Material Storage
To collect all waste material and disposed to designated area
Figure 1 in the Appendix shows a typical dry mix concrete batch plant layout. The ideal size for setting up is plant is 2,950m2, this set up will include a laboratory for quality control, a site office for staff and other facilities such as workshop and weighbridge on material control.
Process Flow of Dry Mix Plant
The process flow of the entire dry mix plant operation per 8 m3 load is as illustrated below:-
Cycle Time per Load = Batching + Mixing & Slump Check + Delivery + Discharging + Return + Queuing
= 5 min + 15 min + 30 min + 45 min + 30 min + 10 min
= 135 min
From the process flow mapping, it is clearly shown that the complete process cycle time for 8 m3 load is 135 minutes. As the plant capacity is 80m3/hour, if the efficiency of the plant is 80%, therefore the plant is capable of producing 8 loads of 8m3-load but all the rest of the processes are done by the mixer trucks from mixing to discharging at site. In order to have a smooth operation flow, the number of mixer truck required by this dry mix plant is calculated as below:
Number of Mixer Truck = 135/60X8
= 18
From the calculation above, 18 units of mixer truck is required for the smooth operation.
Quality of the Product
In dry mix plant, all the pre-determined materials are charged into the mixer drum of the mixer truck, then the mixing and quality check are carried out by the individual mixer truck operator accordingly. The product quality is not consistent as this is done by the 18 mixer truck operators and therefore, quality is becoming a major issue in this type of plant as the requirement of the quality is increasing with the advancement in construction technology. This quality will also hinder the further penetration of market share and jeopardise in achieving the long term strategic goal.
Cost
This operating cost is only covering all the facilities except the raw material cost as this remains consistent either dry mix or wet mix plant. But there are other costs that everyone is aware of such as the maintenance cost of the mixer truck. In this case, the operating cost of the plant is cheap but the mixer truck is much higher as there are 18 units of mixer drums which are having high wear and tear parts as they are used for mixing the concrete. These costs will be tabulated in the comparison and the overall operating cost will be identified.
Flexibility
In term of flexibility, this dry mix plant will have a limitation in producing high grade concrete as the mixing is done by mixer truck. The mixer truck will not be able to mix consistently and thoroughly inside the mixer drum of the mixer truck as the mixing is only dependent on the ploughing and dropping action of the mixer blade on the side wall of the mixer drum. Other than this, it is the same as in other type of plants.
Dependability
The availability, reliability and maintainability of this plant is actually quite similar to the other types of plant available in the market but duration for each maintenance will be a little bit shorter than wet mix plant because the components is less and the mixing is transferred to the mixer truck, therefore the availability is better. The reason for this is, there are 18 units of mixer instead of 1 unit of mixer.
Proposed Modular Wet Mix Plant
Basic Plant Components
The basic components of dry mix concrete batch plant and its related facilities are as tabulated below:-
Item
Descriptions
Remarks
1
Ground Hopper
For feeding of raw material, coarse and fine aggregates
2
Aggregate Weighing Bin
For weighing of various types of aggregates
3
Horizontal Conveyor
To convey the weighed coarse and fine aggregates to Inclined Conveyor
4
Inclined Conveyor
To convey the weighed coarse and fine aggregates to the aggregate transfer bin
5
Aggregate Transfer Bin
For storage on top of the Mixer
6
Mixer
For mixing of concrete
7
Concrete Holding Hopper
For holding of finished product before discharging into mixer truck
8
Cement Storage Silos
For storage of cement - OPC, PFA and Slag Cement
9
Cement Weighing Bin
For weighing of various cement
10
Water Weighing Bin
For weighing of water
11
Admixtures Weighing Bin
For weighing of admixtures
12
Control Room
To provide staff on the control of the production
13
Water Storage Tank
For water storage
14
Aggregate Stockpile
For storage of coarse and fine aggregates
15
Wheel Loader
For material handling from aggregate stockpiles to ground hopper
16
Mixer Truck
For mixing of concrete and delivery of finished products to customers
17
QC Laboratory
For quality control and testing
18
Power Supply
To provide power supply to the plants and other facilities either by TNB or generator set
19
Waste Material Storage
To collect all waste material and disposed to designated area
Figure 2 in the Appendix shows a typical modular wet mix concrete batch plant layout. The ideal size for setting up is also plant is 2,950m2, this set up will include a laboratory for quality control, a site office for staff and other facilities such as workshop and weighbridge on material control.
Process Flow of Modular Wet Mix Plant
The process flow of the entire modular wet mix plant operation per 8 m3 load is as illustrated below:-
Cycle Time per 8 m3Load = Batching + Delivery + Discharging + Return + Queuing
= 5 min + 30 min + 45 min + 30 min + 10 min
= 120 min
From the process flow mapping, it is clearly shown that the complete process cycle time for 8 m3 load is 120 minutes. As the plant capacity is 80m3/hour, if the efficiency of the plant is 80%, therefore the plant is capable of producing 8 loads of 8m3-load in just 5 minutes as the process of mixing is done by the mixer and mixer truck is only used for delivery and discharging at site. In order to have a smooth operation flow, the number of mixer truck required by this dry mix plant is calculated as below:
Number of Mixer Truck = 120/60X8
= 16
From the calculation above, 16 units of mixer truck is required for the smooth operation.
Comparison of Process Flow
Item
Descriptions
Dry Mix Plant
Wet Mix Plant
1
Batching
5 minutes
5 minutes
(Mixing by Mixer)
2
Mixing
15 minutes
(By Mixer Truck)
3
Delivery to Site
30 minutes
30 minutes
4
Discharging at Site
45 minutes
45 minutes
5
Return to Plant
30 minutes
30 minutes
6
Queuing at Plant
10 minutes
10 minutes
7
Total Cycle Time per Load
135 minutes
120 minutes
8
Mixer Truck Required
18
16
By looking at the table above, it is clearly shown that the cycle time per load is reduced by 15 minutes or 11%. The number of mixer truck required to complete the work in progress is also reduced by 2 units, there will be a significant improvement in the whole process flow and this will be reflected in the investment cost and operating cost later.
Quality of the Product
In wet mix plant, all the weighed materials are charged into the mixer of the mixer for mixing and quality check are controlled by the batching operator accordingly of which the product quality is consistent therefore, quality issues can be minimized in this type of plant as the requirement of the quality can be assured to fulfil the modern construction technology. This quality assurance will also help increase the image and market recognition thus, to further penetrate into the untapped market share and also in achieving the long term strategic goal.
Cost
This operating cost is only covering all the facilities except the raw material cost as this remains consistent either dry mix or wet mix plant. Tabulated on the next page is the comparison of the overall operating cost of the whole process flow. It can be shown that the overall operating cost is reduced by RM1.26/m3 or 7.2% and it is very significant and substantial as the annual production is huge. For example, an annual production of 1 million cubic meters will mean a saving of RM1.26 million and so on and so forth, thus increasing the profitability of the sales and competency in the market place.
Comparison on Wet and Dry Mix Plant Operational Cost excluding Raw Material
Item
Descriptions
Unit
Modular Plant (80m3/h)
Dry Mix Plant (80m3/h)
1
Plant Owning Cost
a
Equipment Purchase, RC foundation and Installation Cost
RM
655,763.20
410,000.00
b
Economical service life
month
120.00
120.00
c
Interest &Insurance
%/annum
5%
5%
Total Interest :
RM
327,881.60
205,000.00
d
Total Equipment Cost over service life
RM
983,644.80
615,000.00
e
Total depreciated value over service life
100%
RM
655,763.20
410,000.00
f
Salvage / residue : value
0%
RM
-
-
g
Estimate total Owning Cost
RM
983,644.80
615,000.00
h
Owning cost per month
RM
8,197.04
5,125.00
Plant Capacity :
m3/h
80.00
80.00
Operation Hour per Month :
h/month
275.00
275.00
Target Output at efficiency of :
%
58%
58%
Plant Production :
m3
12,650.00
12,650.00
Owning Cost per cubic meter:
RM/m3
0.65
0.41
2
Mixer Truck
a
Work Content of Mixer Truck
Loading, Mixing and Check Slump
minutes
5.00
20.00
Traveling to &fro and discharge
minutes
115.00
115.00
Time Taken per trip of 8m3
minutes
120.00
135.00
Estimated Time Taken per trip at Efficiency of
80%
minutes
150.00
168.75
Practical Time Taken
h
2.50
2.81
Monthly working hour
h
250.00
250.00
b
Mixer Truck Requirement
Total Production Volume
m3/month
12,650.00
12,650.00
Volume per Trip
m3/Trip
8.00
8.00
Work In Progress
Trips/month
1,581.25
1,581.25
Throughput
hr
250.00
250.00
Cycle Time
hr
0.16
0.16
Work Content
hr
2.50
2.81
Number of Mixer Truck Required
Unit
16.00
18.00
c
Mixer Truck Owning Cost
Machine Unit Price
RM
263,000.00
263,000.00
Total Machine Investment Cost
RM
4,208,000.00
4,734,000.00
Economical service life
month
72.00
72.00
Interest &Insurance
%/annum
5%
5%
Total Interest :
RM
1,262,400.00
1,420,200.00
Total Equipment Cost over service life
RM
5,470,400.00
6,154,200.00
Total depreciated value over service life
100%
RM
4,208,000.00
4,734,000.00
Salvage / residue : value
25%
RM
1,052,000.00
1,183,500.00
Estimate total Owning Cost
RM
4,418,400.00
4,970,700.00
Owning cost per month
RM
61,366.67
69,037.50
Owning Cost per cubic meter:
RM/m3
4.85
5.46
3
Total Facilities Owning Cost
RM/m3
5.50
5.86
4
Variables Cost
a
Power Consumptions
TNB
TNB
Total Power Requirement
kW
158.58
57.84
Plant Operation Hour
h
275.00
275.00
Target Output at efficiency of
%
50%
50%
Power Consumptions
kWh
21,804.75
7,952.31
Unit Cost
RM/kWh
0.39
0.39
Total Power Cost
RM
8,503.85
3,101.40
RM/m3
0.67
0.25
b
Plant Repair and Maintenance
Aggregate Storage Bins
RM/month
300.00
300.00
Aggregate Weighing Bins
RM/month
300.00
300.00
Horizontal Belt
RM/month
87.93
-
Inclined Belt
RM/month
285.78
332.38
Aggregate Holding Hopper
RM/month
-
-
Mixer
RM/month
1,265.00
-
Shooting Belt
RM/month
-
553.97
Concrete Holding Hopper
RM/month
150.00
-
Cement Weighing Hopper
RM/month
360.00
180.00
Air Compressor
RM/month
100.00
100.00
Water Pump
RM/month
200.00
200.00
Control Room
RM/month
150.00
150.00
Total Repair and Maintenance Cost
RM/month
3,198.71
2,116.35
RM/m3
0.25
0.17
c
Mixer Truck
Number of Truck
unit
16.00
18.00
Operating Hours
h/month
4,000.00
4,500.00
Operators Wages
RM/h
12.00
12.00
RM/month
48,000.00
54,000.00
Diesel Price
RM/l
1.80
1.80
Diesel Consumptions
km/l
2.13
1.81
RM/km
0.84
0.99
km/month
63,250.00
63,250.00
RM/month
53,367.19
62,854.69
Truck Repair and Maintenance
RM/km
0.50
0.50
RM/month
6,325.00
6,325.00
Tyres
RM/month
11,385.00
11,385.00
Mixer Drum Repair and Maintenance
RM/month
3,542.00
5,676.28
Hydraulic System
RM/month
1,403.07
1,578.45
Total Cost
RM/month
124,022.25
141,819.42
RM/m3
9.80
11.21
5
Total Variables Cost
RM/m3
10.73
11.62
6
Total Fixed Owning and Variables Cost
RM/m3
16.23
17.49
Total Expected Savings
RM/m3
1.26
-
Flexibility
In term of flexibility, the wet mix plant will have less limitation in producing high grade concrete as the mixing is done by mixer. The mixer will be able to mix consistently and thoroughly inside the mixer as the mixer is specially design for this specific purpose. It can also produce different types of design mix as required by customers. Another advantage is that the supply radius can be increased by 5 km, thus the coverage area.
Dependability
The availability, reliability and maintainability of this plant is actually quite similar to the other types of plant available in the market and the duration for each maintenance will be a little bit longer than dry mix plant because the components is more, therefore the availability is slightly less but this can be eliminated by pre-planned preventive maintenance.
Conclusion
With the study and experience that had been merged and input, it is strongly advisable to convert all the dry mix plant into the modular wet mix plant for the following reasons:-
Cheaper operating cost as justified on the operating cost
Better flexibility for high grade concrete
Less mixer truck requirement
Quality consistency and assurance
All the above implementations will be justifiable to achieve the company long term strategy to provide the highest quality, service at the lowest cost and to increase the market share in the next 10 year.
