Batching plants, ready-mix concrete (RMC) plants and boom pumps are the mainstay of concreting. Their efficiency impacts the concreting process. In recent years, this trio has seen advancements. But there is still plenty of scope for innovation. New features would help these machines work more efficiently and contribute to sustainable construction. Missing features Consider the increasing use of high-grade concrete in infrastructure and high-rise residential and commercial projects. This requires the use of high cementitious materials like fly ash, ground granulated blast-furnace slag (GGBS), microfine materials, etc, but the capacity of weighers is inadequate for the batch size, which forces the user to use a smaller batch size than the designed batch size, leading to lower output, points out Anil Banchhor, Managing Director & CEO, RDC Concrete (India). “Batching plant manufacturers need to provide two separate weighers for cement and cementitious materials. Also, planetary mixers of 1 cum and 2 cum batch size aren’t available but would be of great use for high-grade concrete because their mixing efficiency is better. And the Indian market could also use a galvanised batching plant to extend the life of the plant, particularly in coastal zones where rusting is very quick and the life of the plant structure is cut short in comparison with other locations.” For his part, Chaitanya Bhagde, Senior Manager, Plant & Machinery, Shapoorji Pallonji, sees scope to introduce self-cleaning technologies in the batching plant mixer unit to minimise downtime and the water and chemicals needed for cleaning. “A plant enabling easy access to critical components is easier to maintain and repair.” “A modular design approach would allow ready-mix and batching plants to be easily upgraded with new features or capacity enhancements, making the equipment adaptable and future-proof,” adds Kulkarni Vaibhav, Senior General Manager, Satec Envir Engineering. “Pop-up batching plants, compact, modular plants equipped with foldable components that can be assembled and disassembled in days and moved between sites, could adapt to different project scales, ensuring quality concrete supply wherever it’s needed. And an onsite recycling system that can turn unused or leftover concrete back into raw materials would create a circular system, cutting down on disposal costs and reducing the environmental impact of construction.” IT enhancements Upgrading to digital touchscreen controls with multilingual support would make RMC and batching plants more accessible to operators with varying skill levels, reasons Vaibhav. He also puts forth the use of an intelligent batching plant that can ‘learn’ from every batch it mixes, adjusting proportions based on real-time feedback, adapting to project requirements or environmental factors such as the weather or altitude on the fly. “Equipping batching plants with sensors and software would enable the real-time monitoring of key parameters such as moisture, aggregate sizes and mixer performance and, thereby, the immediate detection of deviations from optimal conditions and quick adjustments to maintain quality and consistency in the mix,” suggests Bhagde. “Mobile applications that allow remote operation and status monitoring would further enhance convenience and efficiency,” adds Vaibhav. Training gaps To resolve major quality issues, Satish R Vachhani, Consultant Concrete Technologist, Advanced Concrete & Construction Consultants, proposes wider implementation of the optional certification programmes of RMC plants from competent agencies accredited by the Quality Council of India (QCI). The fact that aside from the major RMC players, very few RMC plant brands with a sizable share of the market are QCI agency-certified warrants this move, which could gain momentum from an RMC plant certification awareness programme or seminars for RMC plant owners and concrete buyers. Such a certification programme would cover basic level certification for the production control of ready-mix concrete as prepared by the Building Materials & Technology Promotion Council and the QCI in line with RMC BIS code IS 4926. He also notes that participation in certificate training programmes run by the Ready-Mix Concrete Manufacturers Association needs to be increased in keeping with the growing number of plants and shortage of trained skilled manpower. The onus of training is also on concrete batching plant manufacturers, adds Vachhani. “They should open training centres for batching plant operators and technicians and provide personnel with a basic knowledge of software, concrete technology and minor maintenance. Training operators of existing plants would also considerably help the industry.” Automatic operations There is scope to increase the automation level in batching plants, says Bhagde. “At present, some manual intervention is needed to run and control the system and identify faults.” He believes automating the entire production process with IoT connectivity would help to further optimise processes, improve accuracy, reduce labour costs and enable remote monitoring and control. Further, automated dust control systems, water misting and vacuum pumps enhance worker safety, comply with environmental regulations, and contribute to a cleaner working environment, he adds. “An automated system to precisely measure and add additives during the mixing process would optimise the quality of concrete and allow for specialised mixes, such as high-flow or self-compacting concrete,” adds Vaibhav. Essentially, advanced batching systems could offer precision controls with customisable mix settings tailored to specific structural needs. For example, high-strength or rapid-curing mixes could be programmed into the plant’s interface, ensuring consistency and quality for specialised applications. Differently powered Batching plants powered by solar panels or mini wind turbines would cut operational costs and align with green building standards, continues Vaibhav. Optionals such as solar panels, energy-efficient motors and variable speed drives can significantly reduce operational costs and the environmental impact and lower the carbon footprint, contributing to more sustainable construction practices, adds Bhagde. What’s missing in boom pumps?Mini boom pumps: Instead of relying on high-capacity boom pumps, Kulkarni Vaibhav, Senior General Manager, Satec Envir Engineering, sees scope for mini-boom pumps that could be dispatched to different areas of a large construction site, reducing the need for repositioning and transforming logistics in complex projects like skyscrapers or massive infrastructure builds. Innovative delivery systems: Vaibhav sees a future where a fleet of heavy-lift drones carry small amounts of concrete to difficult-to-access locations, like high-rise structures, working in harmony with ground pumps, and a multi-channel pumping system enables the simultaneous delivery of concrete to different areas on a large construction site. Flexible boom arms: A boom arm that moves as flexibly as a human arm reaching around corners, extending high and bending to deliver concrete in hard-to-reach places, controlled with pinpoint precision, may be of use for intricate architectural projects or restricted urban sites, says Vaibhav. Longer booms: Developing boom pumps with longer booms that can extend further and additional articulation sections for improved manoeuvrability in complex sites would improve their performance, safety and efficiency in concrete placement operations, says Chaitanya Bhagde, Senior Manager, Plant & Machinery, Shapoorji Pallonji. Automation: Bhagde believes that incorporating automated systems that can assist with the positioning and setup of the boom, using sensors and software to calculate optimal angles and positions based on site conditions, would improve accuracy in placement, reduce setup time and lower the risk of human error during operation. Advanced stabilisation systems: In large-scale pours, the weight of the concrete can lead to imbalances that may destabilise the boom pump, observes Vaibhav. “Advanced load balancing technology with real-time monitoring of pressure points could distribute the load evenly, ensuring a safer pumping process.” Bhagde emphasises the need for more advanced stabilisation systems that use sensors to monitor ground conditions and automatically adjust the stabilisers for optimal safety and performance even on uneven terrain. Advanced noise reduction and vibration dampening technologies: Such technologies would improve operator comfort and minimise the impact on the surrounding environment, which is especially vital in urban areas and projects requiring minimal disturbance, says Bhagde. Incorporate regenerative technology: Being energy-intensive construction equipment, boom pumps could benefit from regenerative technologies, adds Vaibhav. “By reclaiming energy during downward movements and using it to power the next operation, they could reduce the overall power consumed.” AI to the rescue: According to Vaibhav, boom pumps equipped with watchdog AI could monitor the surroundings for potential hazards, and automatically halt if one is sensed, thus preventing accidents. Real-time monitoring: A system to monitor pump performance and health in real time, including alerts for maintenance needs, pressure readings and flow rates, would enable the early detection of potential issues, proactive maintenance and continuous operations, and prevent expensive breakdowns and downtime, says Bhagde. Better control Mobile command units with control panels for RMC, batching and boom pump operations could provide a centralised hub for supervising, adjusting and coordinating various processes, enhancing efficiency, says Vaibhav. “And augmented reality glasses allowing operators to see real-time data overlaid on machinery or visualise concrete flow paths in 3D would allow them to operate pumps and plants from a safe distance while seeing precisely how concrete will flow and identifying potential issues before they arise.” That sounds like a winning proposition.