Lesson Learned Day

Mass Concrete

Prepared By: Ali Al Hammadi

 Introduction

What is “mass concrete”?

Any large volume of cast-in-place
concrete with dimensions large
enough to require that measures be
taken to cope with the generation of
heat and attendant volume change
to minimize cracking.”
 Identifying Mass Concrete Elements

Because the definition is vague,

many agencies have developed
their own criteria.
Mostly used definition is “any
concrete element having a least
dimension greater than or equal to
3 ft (0.9 m) would be considered
mass concrete”.
Some agencies use different
minimum dimensions ranging from
0.5 to 2.0 m depending on past
experience.
 Discrepancies

• Not identifying mass concrete elements

• Unavailability of specifications for mass concrete elements
• Improper concrete mix design
• Improper logistical planning/organization
• Unavailability of approved thermal control plan and/or insufficient
thermal control measures
• Not performing concrete temperature monitoring
 Concerns of Mass Concrete

Concrete generates heat as it

cures due to the hydration of the
cementitious materials, the
majority of which occurs in the
first few days after placement.
This heat creates two primary
concerns for mass concrete
placements: Thermal Cracking
and High Temperature.
 Concerns of Mass Concrete

The heat of hydration can not escape

as quickly as it is generated. The
varying rate of heat generation and
dissipation causes the interior of a
concrete placement to get hotter
than its surface. This generates
thermal stresses in concrete and
consequently cause cracks when the
tensile strength is exceeded.
Thermal cracking reduces the
durability of the concrete and, if
significant, may affect the structural
capacity of the concrete.
 Concerns of Mass Concrete

High temperatures change the

cement hydration reactions forming
unstable hydration products referred
to as delayed ettringite formation
(DEF). These products can eventually
expand within the concrete and cause
significant cracking. This is a long-
term effect that may not occur for
months or years after the time of
construction.
 Specifications
• Identification of mass concrete elements shall be specified (such as minimum
dimension, or cement content…)
• Specify the maximum temperature and maximum temperature difference.
– Maximum temperature limit is usually specified at 70 C; however, higher
temperatures may be specified for mixes containing high percentages of
ggbs or fly ash
– The maximum temperature difference is a function of concrete
mechanical properties such as thermal expansion, tensile strength,
elastic modulus as well as the size and restraints of the concrete element.
A limit of 39 C is usually specified for concretes made using limestone
aggregates (BS 8110)
• Specify maximum concrete temperature at the time of placement.
– ACI recommends a value between 24 C and 38 C
 Specifications – Mix Design
Optimal concrete mix design is the easiest way to minimize thermal control
costs and produce concrete meeting the requirements of the structure
with respect to economy, workability, dimension stability, freedom from
cracking, low temperature rise, adequate strength and durability. The
following should be considered:
• The total cementitious materials content should be as low as possible
• Avoid use of high early strength cements (Type III)
• Incorporation of mineral admixtures such as ggbs and class F fly ash
• Avoid the use of accelerating chemical admixtures
• The use of larger and better graded aggregates
• Selection of low thermal expansion aggregates such as limestone or
granite
• The water to cementitious materials ratio should be as low as
reasonably possible
 Planning

It is essential that planning between the designer, contractor and concrete

producer begins at an early stage to forestall potential problems
For large volume pours the following points need to be resolved in advance:
• Establish authority, responsibility, planned activities and communications
for each party concerned
• Agreement on approved material sources and mix details
• Provision for standby equipment
• Access to site
• Setting a fixed start date

The most important point is to ensure that there is adequate back-up plant
available to maintain continuity in all stages of delivery, distribution,
compaction and finishing of concrete
 Planning

• Capability - All those involved in the casting of concrete must be

made aware of the importance of their link in the chain of:
– Production
– Delivery
– Distribution
– Compaction
– Curing
• Planning Meeting - There should be a formal meeting between
all involved at all levels to inform and advise the objective being
to highlight critical aspects of the construction process, and in so
doing to forestall potential problems
 Planning
• Plant – The main considerations for mass concrete:
– Maintenance of a high rate of placement
– Distribution over a large area (no. of pumps, boom length…)
– Back-up must be available for all essential items of plant
• Labor – Sufficient labor must be allocated to each stage of the casting process and
back-up teams must be available
• Material Supply –
– The contractor must advise all material suppliers well in advance and obtain
assurances that the necessary rates of supply will be met
– It is advisable to utilize more than one concrete plant in the event of one plant
unable to maintain supply
• Access –
– Access to the site will depend not only on geography, but also the time of day,
day of the week, and possibly the time of year.
– Consideration must be given to possible delays due to heavy traffic, road works,
etc and the benefits which may be achieved by working non-standard hours.
 Planning
• Timing – The timing of the pour may be significant in a number of ways:
– It will determine the ease of access to the site
– It will determine availability of plant and concrete supply
– It will have effect on the workability of concrete and subsequent performance in-situ
• Quality Assurance –
– QA system should encompass all measures necessary to maintain and regulate the
quality of the construction process
– It should include inspection and testing of materials and fresh and hardened concrete,
as well as documented procedures for production, placing and curing of concrete.
– The QA should involve designer, contractor and materials supplier in order to be
effective
• Contingency Plan –
– The contractor should have a contingency plan for stopping the pour at any stage and
incorporating joints
– The plan should be prepared in conjunction with the planning of the concreting
sequence
 Thermal Control Plan
Thermal Control Plan describes the procedures to be used to
minimize temperature differentials within the concrete. Such
procedures incorporate:
• Optimal concrete mix design:
– As explained in “Specifications – Mix Design”
• Pre-cooling:
– Cooling the batching water
– Use of ice as part of the mixing water
– Shading the aggregates stockpiles and
cooling them
– Arrange with supplier to avoid delivery of
hot cement
 Thermal Control Plan

• Pre-cooling:
– Using light-colored mixing and hauling
equipment, and spraying the truck
mixers with a water mist
– Scheduling placements when ambient
temperatures are lower (at night)
– Reducing the temperature in the
immediate placing area with fog spray
or shading
– Placing concrete using the stair-
stepped process
 Thermal Control Plan
• Post-cooling:
Control of concrete temperatures may
be effectively accomplished by
circulating cool liquid (usually water)
through thin-walled pipes embedded in
the concrete. This can reduce the
peak temperature by a significant
amount; it also accelerates the
subsequent heat removal during early
ages.

• This method can have high initial and

operating costs, but benefits can often
outweigh these costs if cooling pipe
size, spacing, and temperatures are
optimized properly
 Thermal Control Plan

– The duration of this initial

cooling period may be as short
as several days or as long as
one month. Subsequently the
concrete temperature usually
will increase again; if the
increase is significant, one or
more additional cooling
periods will be necessary

– It is important to emphasize
that significant internal and
surface thermal cracking can
result if post-cooling is
improperly designed or
performed.
 Thermal Control Plan
• Post-cooling:
Embedded Pipes
– Materials – Aluminum or thin-wall steel tubing has been used successfully for
embedded cooling coils. PVC and Plastic pipes may also be used
– Spacing – Pipe coils are usually placed directly on and tied to the top of the
previous hardened concrete lift. Thus the vertical pipe spacing typically
corresponds to the lift height. Horizontal spacing would usually follow the
same vertical spacing.
– Pipe loop layout – Individual pipe runs may range from 183 to 366 m. Longer
pile runs are less effective because the water warms up in the pipe as heat
is transferred

More information on post-cooling system is available in ACI 207.4R

 Thermal Control Plan

• Surface Insulation:
Insulation or insulated formwork is often used to warm the concrete
surface and reduce the temperature difference, which in turn minimizes
the potential for thermal cracking. For most mass pours, surface
insulation does not appreciably increase the maximum concrete
temperature, but it can significantly decrease the rate of cooling.
Insulation often has to remain in place for several weeks or longer.
Removing it too soon can cause the surface to cool quickly and crack.
Many types of insulation materials are available such as expanded
synthetic material (polystyrene or urethane), mineral wool blankets,
single-ply polyethylene enclosures, ponding…
 Thermal Control Plan
• Monitoring Concrete Temperatures:
Temperature monitoring should be performed to ensure that the thermal
control measures are keeping the temperature and temperature differences
within the specified limits. Monitoring also provides information so that
additional insulation can be added to reduce the temperature difference, if it
is too high.
Commercially available systems such as plastic-sheathed thermocouples
with an appropriate logger can be used to monitor concrete temperatures.
At a minimum, concrete temperatures should be monitored at the hottest
location in the placement (typically geometric center), and at the center of
the nearby exterior surfaces (at a depth of 50 to 75mm below the surface).
 Thermal Control Plan

• Simulating Heat of Hydration:

Test methods have been developed to measure concrete heat of
hydration and its rate versus concrete curing age.

This makes for a powerful planning tool in optimizing concrete

placements, saving costs through fast track construction, value
engineering and trouble shooting. This is accomplished through:
 Thermal Control Plan
– Considering different curing plans (formwork and insulation types)
– Varying concrete placing temperatures
– Varying weather (air temperature and wind speed) or imposed curing
temperatures (precast)
– Simulating in-place strength to fast-track or thermal cracking specs
– Simulating in-place setting properties, including criteria for flat-work
finishing, saw cutting and slip-forming

Furthermore, it is a unique indicator of both the quality and the

performance of cement, cementitious materials, and chemicals in
concrete.
For more information, refer to Quadrel iTesting – Heat Signature
(www.quadreliservice.net)
 Conclusion

In order to avoid an extra cost of money

and waste of time, the mentioned
methods are the most common practices
to be used.
Thank you

Prepared by: Ali Al Hammadi