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Manufacturing

R.K  Group has the largest Crushing plant and RMC units with the highest production quantity in and around Bengaluru Since, Aggregate & RMC is used across various sectors such as infrastructure and construction, it is imperative to produce them as per established  standards. And we always focus on manufacturing best-in-class products at our units. Here is the list of our plants where our range of products are manufactured:

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Plants

R.K M- Sand & Aggregates- Bidadi

Located in the Sy no: 5/3, MG Palya Village, Kailancha Hobli, Ramanangar Taluk & Dst- 562109, with a Capacity of 60,000 Metric tons per month and 7,20,000 metric tons per year, it is manufactured in Coarse, Fine, Gsb…etc.

R.K M- Sand & Aggregates- Narasapura

Located in the Lakshmisagar Gate, Narasapura Taluk, Kolar Dist – with a Capacity of 30,000 Metric tons per month and 3,60,000 metric tons per year, it is manufactured in Coarse, Fine, Gsb…etc.

R.K M- Sand & Aggregates- Hosur

Located in the Sy no.70/IE Midithepalli Village, Athimugam Post,Hosur, Tamilanadu- with Capacity of 50,000 Metric tons per month and 6,00,000 metric tons per year, it is manufactured in Coarse, Fine, Gsb…etc.

R.K Blue Metals- Hosur

Located in the Sy no.49/6-7 Venkatesapuram, Hosur Taluk, Tamilnadu- with a Capacity of 30,000 Metric tons per month and 3,60,000 metric tons per year, it is manufactured in Coarse, Fine, Gsb…etc.

R.K Ready Mix Concrete- Katamnallur

Located in the Sy.No.70, katamnallur village, bidrahalli hobli virognagar post Bangalore with Capacity of 18,000 CBM per month and 2,16,000 CBM per year, it is produced in grades such as M-20,M-30,M-40…etc.

R.K Ready Mix Concrete- Bagalur

Located in the Chalagatti Village, Jala Hobli, Baglur-Yalahanka, Bangalore with a Capacity of 18,000 CBM per month and 2,16,000 CBM per year, it is produced in M-20, M-30, M-40…etc.

R.K Ready Mix Concrete- Kodathi

Located in the SY NO.39/3,KODATHI VILLAGE,VARTHUR HOBLI,
BANGALORE EAST-560035with a Capacity of 18,000 CBM per month and 2,16,000 CBM per year, it is produced in M-20, M-30, M-40…etc.

R.K M-Sand & Aggregates(Quality Test)

  • Quality Tests Performed:
    • Sieve Analysis
    • Silt Test
    • Impact and Crushing Value Test
    • Mix Designs for optimum ratio
  • The Sieve Analysis tests are conducted on RK Sand, RK Aggregates 20, 40, 12 and 10 mm every day on samples collected from conveyor belts, stockpiles and loaded trucks.
  • The following equipment are required and is available at all our plants:
    • Sieves of different sizes
    • Sieve Shaker
    • Oven
    • Sampling Cones
  • All our sales personnel are well trained to carry out these tests at customer locations.
  • The Vertical Shaft impactor applies a similar principle of rock-on-rock collusion for crushing.
  • The sand is classified into four zones as per IS 383 norms.
  • Zone I is coarser and becomes finer towards Zone IV.

R.K RMC (Quality Test)

Testing Equipment & standard protocol

Sl. No.

Relevant test and      BIS

Standard

Name of equipment

Minimum no. of units

Calibration frequency  & relevant code

 

 

01.

Slump test

(IS        1199-

1959)

Slump cone test apparatus with all

accessories   such   as   base                                             plate, tamping rod, etc.

3 sets

Yearly IS 1199

 

02.

Compressive strength                  of concrete *(IS 516)

Compression Testing Machine with minimum        2000 kN                   capacity, conforming to IS 14858 *

One no.

Yearly IS 516

 

03.

Preparing concrete test specimens (IS 1199)

Cube moulds of size:

·         150 mm x 150 mm x 150 mm

·         100 mm x 100 mm x 100 mm

60 nos.

Yearly IS 10086

 

04.

Sieve analysis of fine and coarse aggregates (IS 2386- Part I)

IS Test sieves    for fine and coarse

aggregates

·          25 mm, 20 mm, 12.5 mm,

10 mm, 6.3mm, 4.75 mm, and lid pan

·         10 mm, 4.75 mm, 2.36 mm,

1.18 mm, 600 µm, 300 µm,

150 µm, 75 µm, 45 µm and lid pan

one   set  for

coarse               and fine agg. each

Yearly

IS 2386 – Part I

 

05.

Sampling  of

aggregates # (IS 2430)

Sieve shaker for fine aggregates #

One

Yearly

 

Sample divider

aggregates #

for

sampling

of

One

Yearly

 

06.

Unit weight of concrete (IS 1199)

Bulk density pot for fresh concrete (10 lit)

one no.

Yearly

IS 2386–Part III

 

07.

Aggregates Bulk   density ( IS 2386- Part III)

Bulk density pot for fine (3 or 5 lit) and coarse aggregates (7 or 10 lit)

one no each for coarse & fine agg.

Yearly

IS 2386 – Part III

 

08.

Silt content of sand

Graduated glass cylinder (500 ml) for determining silt content

one no.

–

 

09.

Specific gravity of  aggregates

Pycnometer and density basket or Gas Jar for determining specific gravity of aggregates

(P.T.O)

one no.

Yearly

IS 2386–Part III

10.

Other

accessories

Electronic  weighing  balance   of

adequate capacity with accuracy of 1 g.

One

Yearly

Laboratory mixer (min 50 lit)

One

Man. specified

Electric microwave oven / Hot plate (IS 11332)

One

Yearly IS 6365

Concrete compaction equipments (Table vibrator / needle vibrator, tamping rods)

One

Yearly

Curing tank with provision to maintain 27±20 C temperature of water

One

–

Shovels, trowels, flexible spatulas,

meter, etc.

Sufficient nos.

–

 

Verification and Testing Frequency for Aggregates

Delivery documents – Delivery document shall be verified to check delivered aggregates match the purchase order and that their source is correct. Visual inspection shall be done to check normal appearance, shape, presence of excessive fines, impurities etc.

Testing frequencies – Aggregates shall be tested at a minimum frequency indicated below. The specified frequencies are in conformity with provisions in IS 4926 or stringent from the same.

Sl. No

.

Aggregate property/parameter

Type of aggregate

Frequency            of Testing

Relevant IS Standard

1.

Grading

Fine aggregate

Uncrushed

Crushed Coarse aggregate

Uncrushed

Weekly

IS 383-1970

2.

Particle density

Oven dry

Saturated surface dry

Apparent

Both fine and coarse aggregates

3 month ly

IS 2386 (Part 3)

3.

Water absorption

Both fine and coarse aggregates

3 month

IS 2386 (Part 3)

4.

Bulk density

Loose

Compacted

Both fine and coarse aggregates

6

Month ly

IS 2386 (Part 3)

5.

Particles finer than 75 µm

Fine aggregate-

Crushed

Weekly

IS 2386 (Part 1)

6.

Flakiness and Elongation indices

Coarse aggregates

6 month

ly

IS 2386 (Part )

7.

Impact value

Coarse aggregate

Yearly  or

change in

source

IS 2386 (Part 4)

8.

Crushing value

Coarse aggregate

Yearly  or

change in

source

IS 2386 (Part 4)

10.

10% Fines

Coarse aggregate

Yearly or Change in

ü source

IS 2386 (Part

4)

11.

Petrographic examination

Both fine and coarse aggregates

Once in 5 years

Or change in source

 

IS 2386 (Part

8)

12.

Alkali-aggregate reactivity

Both fine and coarse aggregates

Yearly  or

change in

ü source

IS 2386 (Part

7)

13

Soundness

Both fine and coarse aggregates

Yearly  or

change in

ü source

IS 2386 (Part

5)

14

Chloride content

Both fine and coarse aggregates

Yearly  or

change in

ü source

 

15

Deleterious materials

Both fine and coarse aggregates

Yearly  or

change in

ü source

IS 2386 (Part

2)

 LABORATORY

It is necessary to have a laboratory attached to RMC production facility called as field (Plant) laboratory, to carry out the routine testing. In addition there can be a central laboratory or Third party laboratory that can be used to carry out testing. However it shall be ensured that such laboratories have been audited and that the validity of audit has not expired.

The following tests shall be done in field laboratory.

 

  • Slump
  • Plastic density
  • Cube
  • Silt content of sand
  • Bulkage of sand
  • Fineness Modulus of sand
  • Sieve analysis of Coarse Aggregate

RK QC LAB

Process

AGGREGATES

At RK Group boulders are crushed with Five stage configurations consisting of a jaw crusher followed by a cone crusher and finally a vertical shaft impactor (VSI) to obtain aggregates that have a cubical shape and are consistent in the gradation, backed by our best in class plant and machinery with a large fleet of Vehicles. We have a strong production and logistics base. Our products range from 6mm,12mm,20mm,40mm, M Sand, Plaster Sand, Washed M Sand & GSB.

With a robust set up of Quarries and crushing plants, our aggregates are obtained by crushing of parent rock and exhibit better bonding at the interface of aggregates with cement paste.

Advantages:

  • Superior compression strength
  • 100% improvement in labour productivity, substantially therefore reducing labour costs
  • Environmentally friendly
  • Complies with ICI standards 30% reduction in plastering cost

Our Quarrying process typically begins with drilling and blasting the rock into smaller pieces. Bore holes are drilled in the blast site and filled with explosives. The blast breaks up into smaller pieces that are loaded and hauled to the plant.

The plant consists of three circuits, namely primary circuit, secondary circuit, and territorial circuit where in a Five-stage crushing takes place. A 500mm downsize granite rock that is brought from the quarry via operations which involves drilling, blasting, segregation, secondary breaking and transportation to the plant, is fed into the primary circuit consisting of one jaw crusher that sizes down the granite rock to produce 150 mm downsized aggregate. This 150 mm downsize rock is further fed into the secondary circuit consisting of one cone crusher to produce 40mm downsized aggregate which in turn is fed into the territory circuit consisting one vertical shaft impactor that produces sand and aggregate of the required gradation and shape. The installed capacity of the plant is 300 TPH.

Ready Mixed Concrete

At RK Group, Ready Mixed Concrete [ RMC] is produced in its fully automated BVQ certified batching plants-60 M/hr. RK Group owns and operates 3 commercial plants and 4 captive plants with the capability of supplying 2000m3 per day and with a storage capacity of 500 tons of cement & GGBS in each plant with a fleet of 75 transit mixers,15 line pumps, and 2 boom pumps.

RK Group’s experienced logistics team works closely with you to ensure that the concrete of requisite quality is delivered on time and in the appropriate quantities.

RK Group’s concrete has the experience and the ability to design, produce and deliver a wide range of ready mixed concrete variants to meet specific requirements.

  • Fibre Reinforced Concrete
  • Self-compact concrete
  • Self-Dynamic concrete
  • High-performance concrete (micro silica)
  • Temperature controlled concrete
  • Lightweight concrete
  • Screed concrete

Process

STEP 1: IMPLEMENTING THE PRODUCT RECEIVED

  • Receiving facilities for aggregates make it possible for trucks to unload their goods directly into a  M S structure Bins (large funnel-like device) which feeds the product through a conveyor belt.
  • The cement is delivered by bulkers that silos via pneumatic pipes under compressed air pressure.

STEP 2: STORAGE OF AGGREGATES

  • Aggregates are stored in M S structure Bins. Or on the ground. the storage of aggregates allows the batch plant to have several days worth of storage.

STEP 3: ADJUVANTS(ADDITIVES)

  • Admixtures or additives are added at time of manufacturing to obtain in fluidity, and to accelerate or delay setting ….

STEP 4: STORAGES OF CEMENT

  • Cement,GGBS/Fly ash is stored in silos equipped with a dust collection venting system. There are as many as there are types of cementitious.

STEP 5: MIXING

  • The mixer blends the cement, sand, aggregates and adjuvants supplied by the PLC(programmable logic controller) A mixer must contain up to 3m.
  • The time and the quality of the mixing are important factor so as to produce a good product. They are controlled by a programmer.

MANUFACTURING OF CONCRETE

STEP 6: CONTROL STATION

  • The batch plants are all equipped with PLC’s to automate control productions they allow for better selection with rigorous stands of a formulations adapted to the concrete ordered by clients and adapted to the concrete ordered by clients and according to the dosage in water corresponding to the hygrometry of aggregates.
  • Cement sand aggregates water adjuvants are dosage (measured) and weighted to extreme precision.

STEP 7: DELIVERY

  • FRESH CONCRETE is brought to the site via mixer trucks with a capacity of 6to8 m3,in which it is generally mixed before delivery to clients . delivery logistics constitute an essential part of the process because cement’s setting which is limited.

HSE (Healthy, Safety and Environment)

The Health & Safety at Work Act 1974, The Management of Health & Safety at Work Regulations 1999, Quarry Regulations 1999, the Provision and Use of Work Equipment Regulations 1998, the Workplace (Health Safety & Welfare) Regulations 1992. The Health & Safety (Consultation with Employees) Regulations 1996, the Construction (Design & Management) Regulations 2007.

The Directors of RK Group consider Health, Safety & Environmental Management to be a vital component in the success of the business. The Mining Directors are responsible for ensuring effective management systems are planned, delivered, monitored and reviewed. Their involvement in the processes through visible and active commitment sets example that is essential for staff and workforce engagement and promotes safe and healthy working conditions together with minimising impact on the environment. This generates an excellent culture in line with company values that improves our performance standards. RK Group has won several awards from the Govt recognised Mining Department for their pioneer standards in ensuring Safety at Mining quarries and workplace

HSE(Health, Safety and Environment) INITIATIVES AT RK GROUP

We believe that health and safety are an integral part of teamwork and require a lot of participation and commitment from all
levels. We recognize relevant HSE systems as part of our standard operating procedures, with the intention to develop injury-free worksites, thereby assisting us to achieve our business goals.

TRAINING

Various HSE training programs are organized, both in-house and external, thereby ensuring awareness and higher levels of competency amongst all our employees.

SAFETY PROMOTIONAL ACTIVITY

As a part of safety awareness to review the existing HSE systems various safety promotional activities are carry out. This includes “National Safety Day”, “Environment Day”, “Lock out tag out Day”

AUDIT

Safety systems and procedures are established to ensure safe working conditions. Safety audits are conducted at regular frequencies to monitor the compliance of these systems and create awareness within the company.

HSE AWARD AND RECOGNITION

To encourage safe behavior we have instituted the HSE award – a symbol of recognition to showcase our commitment to HSE.