Essential Checklists for Ready-Mix Concrete Plant
Management
As a newly appointed ready-mix concrete factory manager in Qatar, I'm providing a streamlined
set of assessments and checklists to help you take control of operations, ensure quality, and
maintain compliance with industry standards. These tools are designed to address your needs in
construction, real estate, and development, focusing on practical implementation from day one.
Initial 30-Day Assessment & Evaluation Checklist
Plant Compliance & Certification
Confirm current certifications (NRMCA or local Qatar standards).
Review past audit reports and unresolved issues.
Ensure adherence to ASTM C94/C94M for batching and delivery.
Verify compliance with Qatar Construction Specifications (QCS) and environmental
regulations.
Equipment & Calibration Review
Check calibration dates for aggregate and cement scales (should be within the last 6
months).
Inspect water meters and admixture dispensers (calibration within 90 days).
Assess batch controller functionality and accuracy of records.
Materials & Mix Design Evaluation
Gather all active mix designs and supplier certificates of analysis (COAs).
Review aggregate quality (gradation, moisture content) and storage conditions.
Verify cement, SCMs, and admixture compatibility and storage.
Operational & Quality Performance
Analyze historical data on batch accuracy and concrete strength test results.
Identify patterns in customer complaints or delivery delays.
Assess current production capacity and peak-hour bottlenecks.
Safety & Environmental Baseline
Inspect safety systems: guards, emergency stops, and PPE availability.
Evaluate dust control measures and stormwater management.
Confirm compliance with Qatar’s environmental and labor safety laws.
Daily Operations Checklist
Pre-Shift Preparation
Clean mixer, chutes, and hoppers; clear any hardened concrete.
Check aggregate and cement silo levels; ensure no contamination.
Test safety systems (emergency stops, alarms) and verify access to spill kits.
Update aggregate moisture content in batching system for accurate water correction.
Production Monitoring
Verify scale zero and batch weights against tolerances before starting.
Ensure correct mix design parameters are loaded in the controller.
Monitor batching sequence and prevent unauthorized water addition.
Confirm truck readiness and cleanliness before dispatch.
End-of-Day Tasks
Log production volumes and any operational issues.
File batch tickets and ensure all data is recorded.
Clean work areas and secure equipment for the next shift.
Quality Control Daily Checklist
Material Inspection
Conduct aggregate moisture tests at least twice daily; adjust batch water accordingly.
Verify incoming material COAs for cement and admixtures.
Monitor storage conditions to prevent segregation or contamination.
Fresh Concrete Testing
Perform slump tests (ASTM C143) as per project specifications.
Measure air content (ASTM C231) and temperature (ASTM C1064) when required.
Cast test cylinders for compressive strength (ASTM C31) and ensure proper curing.
Record delivery times to ensure compliance (typically under 90 minutes).
Nonconformance Handling
Document any out-of-spec results (slump, air, or temperature).
Implement immediate corrective actions and log for future analysis.
Communicate with clients if quality issues affect delivery.
Maintenance Checklists
Daily Maintenance
Clean mixer and remove buildup from bins and conveyors.
Check oil levels and inspect for leaks in mechanical systems.
Verify dust collector operation and ensure no visible emissions.
Weekly Maintenance
Lubricate bearings, pivots, and moving parts per manufacturer guidelines.
Inspect and adjust conveyor belts and scrapers for alignment.
Clean or replace silo aeration filters to prevent blockages.
Monthly Maintenance
Check gear reducer oil levels and replace if necessary.
Test silo pressure relief valves and bin level indicators.
Schedule professional inspection of electrical connections.
Calibration Schedule
Calibrate scales every 6 months or as per Qatar regulatory requirements.
Verify water meter and admixture dispenser accuracy every 90 days.
Document all calibration activities with certificates.
Safety & Environmental Checklist
Daily Safety Checks
Ensure all machine guards are in place and secure.
Verify walkways are clear and free of slip hazards.
Confirm availability of first aid kits and fire extinguishers.
Enforce PPE usage among staff (helmets, gloves, safety boots).
Environmental Monitoring
Check dust collection systems for effective operation.
Inspect wash water recycling and settlement pits for blockages.
Prevent offsite discharge of waste or spills; maintain cleanup kits.
Fleet Management Checklist (Ready-Mix Trucks)
Pre-Delivery Inspection
Check drum rotation, blade condition, and chute functionality.
Verify water system operation and meter accuracy on trucks.
Inspect tires, brakes, and lights for safety compliance.
Ensure drivers have valid licenses and training per Qatar regulations.
Post-Delivery Actions
Wash drums thoroughly to prevent concrete buildup.
Record water usage and any vehicle issues for maintenance.
Collect and file delivery tickets with customer feedback.
Key Performance Indicators (KPIs) to Monitor
Quality & Compliance
Percentage of batches meeting slump and strength specifications (target >98%).
Rate of on-time deliveries (target >98%).
Customer complaint or rejection rate (target <2%).
Operational Efficiency
Equipment downtime hours (target <5% of operating time).
Material wastage percentage (target <2%).
Fuel consumption per cubic meter of concrete delivered.
Safety & Environment
Number of days without safety incidents.
Compliance with environmental audits and inspections.
Staff training completion rate for safety protocols.
These checklists and assessments provide a robust framework to manage your ready-mix
concrete plant effectively. Tailor them to specific Qatar regulations, client requirements, and
plant capacity to ensure smooth operations and high-quality output. If you need further
customization or details on specific areas, let me know!
