ACI India Chapter Webinar On Mass Concrete 2020-10-16

ACI India Chapter Webinar 10/16/2020
Mass Concrete
16 October 2020
Jerzy Żemajtis, 248-848-3159

jerzy.zemajtis@concrete.org
Mass Concrete
How big is big?
1
Concrete Cracking
Jerzy Zemajtis, PhD, PE, is a Senior Engineer
at ACI. His role at ACI is to provide technical
and administrative support to ACI's Technical
Committees. He received his BS and MS in
civil engineering from the Technical University
of Gdansk, Poland, and his PhD in civil
engineering from Virginia Tech.
Mr Zemajtis worked as a Structural Engineer

in Virginia Beach, VA, and Vancouver,
Canada, and as a Civil/Materials Engineer at
Construction Technology Laboratories in
Chicago, IL, before joining the ACI
Engineering Department in 2010. He is a
Jerzy Zemajtis, PhD, PE licensed engineer in Washington and British
Senior Engineer, ACI Columbia.
Concrete Cracking
You can use your computer audio or switch

to phone call.
Type questions in the Questions box.
Our panelist will address questions during

the Q&A session.
This webinar is being recorded.
1
Mass Concrete
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2
Mass Concrete
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Mass Concrete

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4
Mass Concrete
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14
14
…let’s get back to our presentation
Mass Concrete
How big is big?
15
5
Mass Concrete
Outline
• What is mass concrete?

• Concrete temperature
• Factors affecting mass concrete
- Materials
- Size
- Construction
• Submittals (ACI 301 Specifications)
• Further reading
16
16
What is mass concrete?
Crystal Springs Dam (completed in 1890) – located in San Mateo County, California – courtesy of nwcultural.com
17
17
Hoover Dam (1931-1936) – near Boulder City, Nevada – courtesy of the U.S. Bureau of Reclamation
18
18
6
Mass Concrete
D>3 m
(10 ft)
Piers for the San Francisco-Oakland Bay Bridge, courtesy of John Gajda, CTLGroup
19
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Mat foundation, courtesy of Carrasquillo Associates
20
20
Dictionary definition of Mass:

- A coherent, typically large body of matter with no definite shape
- Bulk, size, expanse, or massiveness
Mass
Size
Concrete
Correct…
but incomplete
21
21
7
Mass Concrete
Definition (ACI CT-18)

any volume of structural concrete in
which a combination of dimensions of
the member being cast, the boundary
conditions, the characteristics of the
concrete mixture, and the ambient
conditions can lead to undesirable
thermal stresses, cracking, deleterious
chemical reactions, or reduction in the
long-term strength as a result of
elevated concrete temperature due to
heat of hydration.
22
22
Interpreting the Definition of Mass Concrete
Materials
Mass Concrete
Concrete Temperature Size
Construction
(Environmental)
23
23
Specification Requirements (ACI 301-20)
• Section 8 of ACI 301-20 covers

mass concrete.
• Sections 1-5 are also applicable:
- General requirements
- Formwork and formwork accessories
- Reinforcement and reinforcement
support
- Concrete mixtures
- Handling placing and constructing
• ACI presentation on specifications
24
24
8
Mass Concrete
Specification Requirements (ACI 301-20)
SECTION 8—MASS CONCRETE

8.1—General
8.1.1 Scope—This section covers requirements for mass
concrete as designated in Contract Documents.
8.1.2 General requirements—Unless otherwise specified in
this section or in Contract Documents, requirements of
Sections 1 through 5 are applicable for mass concrete.
8.1.3 Temperature limits—Unless otherwise specified, the
following temperature limits shall apply for mass concrete
placements:
• (a) Maximum temperature in concrete after placement shall
not exceed 70°C (160°F).
25
(b) Maximum temperature difference between center and
surface of placement shall not exceed 20°C (35°F).
25
Concrete Temperature: ACI 301-20
Maximum temperature in concrete after placement shall

not exceed 70ºC (160ºF)
• Reason for limit: Delayed Ettringite Formation (DEF)
which is a form of internal sulfate attack
• Expansion and formation of gaps around aggregate
particles T < 70ºC
(160ºF)
DEF, courtesy of CTLGroup concrete pier cross-section (mid-height)
26
26
Maximum temperature difference between center and

surface of placement shall not exceed 20ºC (35ºF)
• Reason for limit: Thermal gradients  thermal stresses
• Thermal stress > concrete tensile strength → cracking
ΔT< 20ºC
(35ºF)
Cracked bridge pier, courtesy of TxDOT concrete pier cross-section (mid-height)
27
27
9
Mass Concrete
Thermal Deformation – Mechanism

70
Inside 35 °C
60
Temperature
30 °C
Temperature Rise, °F
50
25 °C
40
20 °C
30
15 °C
20
10 °C
10 5 °C
0 0 °C
0 1 2 3 4 5 6 7 8
Days Source: IS 128.03T (PCA)
28

70
Inside 35 °C
60
Temperature
30 °C
50
25 °C
40
20 °C
Form Removal
30
15 °C
20
Surface Temperature
10 °C
10 5 °C
0 0 °C
0 1 2 3 4 5 6 7 8
29

70
Inside 35 °C
60
Temperature
30 °C
50
25 °C
40
20 °C
Form Removal
30
15 °C
20
Surface Temperature
10 °C
10 Unprotected 5 °C
surface cools fast
0 0 °C
0 1 2 3 4 5 6 7 8
30
10
Mass Concrete

70
Inside 35 °C
60
Temperature
30 °C
50
25 °C
ΔT > 20°C
40
(35°F) 20 °C
Form Removal
30
15 °C
20
Surface Temperature
10 °C
surface cools fast
0 0 °C
0 1 2 3 4 5 6 7 8
31

70
Inside 35 °C
60
Temperature
30 °C
50
25 °C
ΔT > 20°C
40
(35°F)
20 °C
Form Removal
30
Protected surface 15 °C
20
Surface Temperature
10 °C
surface cools fast
0 0 °C
0 1 2 3 4 5 6 7 8
32

70
Inside 35 °C
60
Temperature
ΔT < 20°C 30 °C
50 (35°F)
25 °C
ΔT > 20°C
40
(35°F)
20 °C
Form Removal
30
Protected surface 15 °C
20
Surface Temperature
10 °C
Protected surface
10 Unprotected cools slowly, 5 °C
surface cools fast no cracking
0 0 °C
0 1 2 3 4 5 6 7 8
33
11
Mass Concrete
• Mass concrete temperature must be monitored

• Place one sensor and a backup at:
1) The center of the largest portion of placement
2) depth of 50 mm (2 in.) from center of nearest
exterior surface
3) Shaded location to monitor ambient
temperature
2
• Monitor temperatures hourly
1
• Compare temperatures with limits
Shaded 3
temperature sensor, courtesy of www.FLIR.com.
location
mid-height of pier
34
34
2
1
average daily
ambient temp 3
mid-height of pier
1 :should not exceed 70ºC (160ºF) Temperature

1 – 2 :should not exceed 20ºC (35ºF) limits
1 – 3 :is less than 20ºC (35ºF) → stop temperature control
Contractor must submit a thermal control plan

35
35
• Mass concrete temperature must be controlled

• If limits are exceeded during construction,
immediate actions must be taken
• Do not place additional concrete until cause of
problem is identified and corrected
• Temperature control measures must be maintained
until:
(internal or core temp.) – (ave. daily ambient temp.) < 20ºC (35ºF)
36
36
12
Mass Concrete
Monitoring Concrete Temperature
70 °C
60 °C
50 °C T
40 °C
27 °C
22 °C
ΔT
11 °C ΔT
0 °C
Source: John Gajda & Ed Alsamsam, “Engineering Mass Concrete Structures”
37
37
Factors Affecting Mass Concrete
Concrete Temperature
Materials
Size
Construction
38
38
Materials: Mixture Proportioning
• What is needed for mass concrete mixture

designs?
- Strength & durability
- Workable design
- Economical design
- Low temperature rise
• Heat is generated by cementitious materials
• Adjust mixture ingredients to reduce heat
generation (cement)
39
39
13
Mass Concrete
Materials: ACI 301-20
• Meet general material requirements (see section

4.2.1 of ACI 301-20)
Use:
• Moderate to low heat of hydration cement (Type II)
• Cement + Class F fly ash
• Cement + slag
• Cement + Class F fly ash + slag
Do not use:
• Type III or ASTM 1157 HE (High Early-Strength)
40
40
Materials: Cementitious Materials
• Use cementitious material that generates low heat
Fly Ash Fly Ash Slag Silica

SCM Metakaolin
Class F Class C Cement Fume
Effect on heat
energy
• Quantity and type of cementitious material affect

heat generation
• Reduce mass of cement in a mixture
41
41
Materials: Determining Temperature Rise
• How do we determine
temperature rise?
- Test mixture proportions
(trial blocks) Courtesy of John Gajda, CTLGroup
- Prediction (thermal) models

- Or both
• When should either be used

and why?
Courtesy of Christopher Bobko
42
42
14
Mass Concrete
Simplistic Method for Determining Temperature Rise
Temperature rise = (Cement + SCM x fSCM) x fcement

Equivalent Cement Content
fSCM fcement
Class F Fly ash 0.5 Slag (0-20%) 1.0-1.1 0.14 - 0.16
Class C Fly ash 0.8 Slag (20-45%) 1

All units are in US
Silica Fume 1.2 Slag (45-65%) 0.9 customary units
(lb/yd3, ºF, etc…)
Metakaolin 1.2 Slag (65-80%) 0.8
Adapted from John Gajda & Ed Alsamsam, “Engineering Mass Concrete Structures”
43
43
Concrete mixture contains:

• 550 lb/yd3 cementitious materials content (325 kg/m3)
• 25% Class F fly ash
fSCM
• Type II cement (low heat)
Class F Fly ash 0.5
(285 kg/m3)
Equiv. cement = 0.75 x 550 + 0.25 x 550 x 0.5 ≈ 481 lb/yd3
fcement
Temperature rise = 481 x 0.14 ≈ 67ºF (37ºC)
0.14 - 0.16
Concrete Temp = 80ºF + 67ºF ≈ 147ºF

(27ºC + 37ºC = 64ºC)
44
44
Mixture 1 Mixture 2 Mixture 3 Mixture 4
(385 kg/m3) (325 kg/m3) (325 kg/m3) (325 kg/m3)

550 lb/yd3; 550 lb/yd3;
650 lb/yd3; 550 lb/yd3;
Cementitious Type II cement; Type II cement;
Type II cement; Type II cement;
Materials Content 25% Class F fly 70% slag
no SCM no SCM
ash cement
(385 kg/m3) (325 kg/m3) (285 kg/m3) (280 kg/m3)

Equivalent Cement
650 lb/yd3 550 lb/yd3 481 lb/yd3 473 lb/yd3
Content
Temperature Rise 91ºF(51ºC) 77ºF (43ºC) 67ºF(37ºC) 66ºF (37ºC)
Maximum Internal
Concrete 171ºF 157ºF 147ºF 146ºF
Temperature (77ºC) (69ºC) (64ºC) (63ºC)
45
45
15
Mass Concrete
Cement Content & Temperature Control Time
• Reducing cement content reduces temperature

control time
82 ºC
360 kg/m3
71 ºC 300 kg/m3
240 kg/m3
60 ºC
49 ºC
38 ºC Internal temp. – avg. daily ambient temp. < 35ºF (20ºC)
27 ºC
Average daily ambient temperature
16 ºC
Source: John Gajda & Ed Alsamsam, “Engineering Mass Concrete Structures”
46
46
Materials: Determining Temperature Rise
• More advanced methods are available

• Chapter 4 of ACI 207.2R (Schmidt Method)
- Predicts temperatures, temperature
differences, cooling rates, etc…
- Takes into account other factors such as the
volume-to-exposed surface ratio (V/S)
• Commercial Software
47
47
Materials: Admixtures & Aggregate
Aggregate: Too big !

• Use the largest maximum
size aggregate
• Optimize aggregate gradation
Reduce
(use denser gradations)
cementitious
Admixtures: content of mixture
by improving
• Water-reducing admixtures
workability
• Air-entraining admixtures
• Retarding admixtures Reduce the likelihood of
cold joints
48
48
16
Mass Concrete
Materials: Aggregate
• Thermal stresses are a function of the coefficient of

thermal expansion of concrete
• The coefficient of thermal expansion of concrete is
a function of the mineralogy of the aggregate
Coefficient of thermal expansion
of concrete
(per millionths per ºF) (per ºC)
Quartzite, Chert 6.6-7.1 12·10-6 to 13·10-6
Sandstone 5.6-6.6 10·10-6 to 12·10-6
Granite and
3.8-5.3 6.8·10-6 to 9.5·10-6
Gneiss
Limestone 3.1-5.1 5.6·10-6 to 9.2·10-6
49
49
Materials
Size
Construction
50
50
Size – Placement Dimensions
• For placements with large minimum dimensions,

internal heat cannot escape as rapidly as it is
generated
ACI 301-20 Default Commonly prescribed in

Requirement specifications
1.2 m 0.9 m
(4 ft) (3 ft)
• Size alone is not sufficient to identify “mass concrete”
51
51
17
Mass Concrete
Placement Thickness vs. Equivalent Cement Content
0.15 0.30 0.46 0.61 0.76 0.91 1.07 1.22 1.37 1.52 1.68 1.83 1.98 2.13 2.29 2.44 2.59 2.74 2.90 3.05 m
150
180 Not mass concrete
210
235
265
295
…so, can you give us
325
355
385
something meaningful?
415 Mass concrete
445
475
505
535
565
595 kg/m3
Source: John Gajda, “When Should Mass Concrete Requirements Apply?”, Aspire Magazine, Summer 2015
52
52
Materials
Size
Construction
53
53
Materials
Concrete
Construction
Temperature
Size
• Assume size and mixture proportions cannot be

changed
• Predicted temperatures exceed limits
54
54
18
Mass Concrete
Construction
• Batching, mixing, placing, and

curing
• Temperature control could be
achieved through:
- Construction Management
- Insulation
- Precooling
- Postcooling
55
55
Construction Management
• Protecting the structure from excessive temperature

differentials by:
- Placing concrete during cool weather or at night
- Use of lifts
Courtesy of John Gajda, CTLGroup
56
56
Insulation
• Used to control temperature differential

• Slows escape of heat at the exposed surfaces
• Horizontal surfaces - blankets
• Formed surfaces:
- Cover forms with blankets
- Build insulated forms (foam insulation, etc…)
57
57
19
Mass Concrete
Insulation
Courtesy of Carrasquillo Associates
Courtesy of Mark Bloschock
58
58
Precooling
• Involves reducing concrete

temperature during
batching/mixing
• Precooling aggregate by
misting or sprinkling water Courtesy of Qanbar Ready Mix
• Using chilled water or

shaved/crushed ice
• Cooling concrete using liquid
nitrogen
Courtesy of Portland Cement Association
59
59
Precooling
• ACI 305R, Guide to Hot Weather Concreting

5.2 Temperature control of concrete (5.2)
Temperature of concrete can be reduced by 1°(F or C)

by any of the following:
8°reduction in cement temperature
4°reduction in water temperature
2°reduction in aggregate temperature
60
20
Mass Concrete
Postcooling: Cooling Pipes
• Consists of circulating a cool liquid through thin-

walled pipes
• Accelerates heat removal:
- Reduces peak temperature
- Reduces temperature control time
• Cooling pipes are uniformly distributed
• Closer pipe spacing more rapidly remove heat
61
61
Courtesy of John Gajda, CTLGroup
62
62
Courtesy of Gerard M. Nieblas
63
63
21
Mass Concrete
Construction: Temperature Control
• Which temperature control method should be used?

• Cost and expected temperature rise are the main
factors in determining choice of method
Insulation Controls temperature differential
Reduces concrete temperature before concrete is

Precooling
placed (at the batch plant)
Actively reduces concrete temperature after the
Postcooling
concrete is placed
• Are there any ACI 301 (specifications) requirements?
64
64
Materials
Concrete
Size Temperature
Execution
Design phase, Construction phase, governed by material and

governed by design construction specifications
codes
• Temperature control is part of the construction phase
• Contractor must identify mass concrete before
placement
65
65
Submittals: ACI 301-20
The contractor shall submit a thermal control plan

which includes information and data about:
• Concrete mixture proportions
• Calculated or measured concrete temperatures
• Equipment and measures to monitor and control
temperature
• Curing plan and duration
• Formwork removal procedures and how curing will be
maintained to not exceed temperature limits
Refer to section 8.1.4 of ACI 301-20 for details
66
66
22
Mass Concrete
How big is big?
It’s not a BIG Deal
67
67
How big is big?
It is not about size, it is

about concrete temperature
68
68
Mass Concrete in ACI Documents
• ACI Committee 207: Mass Concrete
69
69
23
Mass Concrete
Mass Concrete – Other References
• “Mass concrete for Buildings and

Bridges”, Portland Cement
Association
• “When Should Mass Concrete
Requirements Apply?”, John
Gajda, Aspire Magazine, Summer
2015
• “Engineering Mass Concrete
Structures”, John Gajda & Ed
Alsamsam
70
70
Save the Date: October 25-29, 2020
71
A Gift from ACI!
One-year subscription options

choose one of the following:
• ACI Collection of Concrete Codes, Specifications, and Practices

1 •
•
Always up-to-date
Includes historic codes and specifications
• ACI University All-Access Digital Subscription

2 •
•
Webinars and on-demand courses
220+ courses
• ACI Concrete Repair Digital Subscription

3 •
•
65+ codes, specifications, guides, reports
16+ educational publications and 33+ courses
72
24
Mass Concrete
Thank you
For the most up-to-date information please
visit the American Concrete Institute at:
www.concrete.org
Membership Questions
E-mail: ACICustomerService@concrete.org
73
25

ACI India Chapter Webinar On Mass Concrete 2020-10-16

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ACI India Chapter Webinar 10/16/2020

Jerzy Żemajtis, 248-848-3159

Mr Zemajtis worked as a Structural Engineer

You can use your computer audio or switch

Type questions in the Questions box.

Our panelist will address questions during

This webinar is being recorded.

• A technical and educational society dedicated

Architects | Consultants | Contractors | Educators | Engineers

ACI Members are engaged, informed, and stay up-to-date by

Current Individual Member Benefits

• Concrete International - hard copy and electronic

Current Individual Member Benefits

• Concrete International - hard copy and electronic

Current Individual Member Benefits

• Concrete International - hard copy and electronic

Current Individual Member Benefits

• Concrete International - hard copy and electronic

More than 250 online learning modules supporting:

Current Individual Member Benefits

• Concrete International - hard copy and electronic

From finishers and technicians, to supervisors,

That’s over 400,000 individuals certified since

A Gift from ACI!

One-year subscription options

• ACI Collection of Concrete Codes, Specifications, and Practices

• ACI University All-Access Digital Subscription

• ACI Concrete Repair Digital Subscription

American Concrete Institute is a Registered Provider with The American Institute

This program is registered is registered with AIA/CES for continuing professional

American Concrete Institute is registered as a Preferred Provider with the

The American Institute of Architects has approved

…let’s get back to our presentation

How big is big?

• What is mass concrete?

What is mass concrete?

What is mass concrete?

What is mass concrete?

What is mass concrete?

Mat foundation, courtesy of Carrasquillo Associates

What is mass concrete?

Dictionary definition of Mass:

What is mass concrete?

Definition (ACI CT-18)

Interpreting the Definition of Mass Concrete

Specification Requirements (ACI 301-20)

• Section 8 of ACI 301-20 covers

Specification Requirements (ACI 301-20)

SECTION 8—MASS CONCRETE

Concrete Temperature: ACI 301-20

Maximum temperature in concrete after placement shall

DEF, courtesy of CTLGroup concrete pier cross-section (mid-height)

Concrete Temperature: ACI 301-20

Maximum temperature difference between center and

Cracked bridge pier, courtesy of TxDOT concrete pier cross-section (mid-height)

Thermal Deformation – Mechanism

Thermal Deformation – Mechanism

Thermal Deformation – Mechanism

Thermal Deformation – Mechanism

Thermal Deformation – Mechanism

Thermal Deformation – Mechanism

Concrete Temperature: ACI 301-20

• Mass concrete temperature must be monitored