Mass Concrete

1. Definition:

Any volume of concrete with dimensions large enough to require that measures be taken to cope
with the generation of heat from hydration of the cement and attendant volume change to minimize
cracking.” (ACI)

Such cracking may cause loss of structural integrity and monolithic action, excessive seepage, loss of
durability and aesthetically objectionable. For general constructions any concrete structure having
lateral dimensions of 0.75m or more, may need appropriate mass concreting practices.

Cement Hydration is a very exothermic process, leading to a rise in temperature at the core of very
large pours. (Kelly)
If the surface temperature is allowed to deviate greatly from that of the core, thermal cracking will
develop.
Most codes require a temperature differential of less than 36F(20◦ C) from the surface to the core of
the section.
When dimensions are > 1m or 3ft, temperature rise should be considered.
Common thought is mass concrete principles only apply to large dams. But they apply to any large
pour:
Massive foundations, bridge piers, thick slabs, nuclear plants, structural columns, etc…

2. Mass Concrete – Main Problem:

❑ The reaction between OPC and water is exothermic in nature.
❑ The heat evolved increases the temperature of concrete in the core. Normally surface of
concrete is exposed to atmospheric ambient temperature.
❑ Concrete being low in thermal conductivity, there remains considerable temperature
difference between core portions of concrete and surface of concrete, at least for 4 days,
depending upon the section of concrete member.
❑ This temperature difference or temperature gradient leads to differential thermal
expansion. If the rise in temperature and the subsequent cooling were uniform throughout
the mass of concrete, thermal stresses would not result.

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Thermal Cracking:
❑ Cement hydration produces a rise in internal temperature.
❑ The outer surface cools faster than the core of the section.
❑ By thermal expansion/contraction, the temperature differential induces thermal (tensile)
stresses at the surface.
❑ Stresses > Tensile Strength => Thermal Cracking!

3. Mass Concrete: Why Temperature Rise-

❑ Temperature rise varies by many parameters:

o Cement composition, fineness, and content
o Aggregate content and CTE (Coefficient of Thermal Expansion)
o Section geometry
o Placement & ambient temperatures

Most temp rise occurs in first 1-3 days after placement

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4. Factors Affecting Temp. Rise:
❑ Geometry:
Pours with a large volume: surface area ratio is more susceptible to thermal cracking!
Research has been performed to produce more accurate dimensions for when temperature
rise should be considered
More the ratio of Surface area / cross section area, more susceptible to cracking.
❑ Cement Composition:
Cements used for Mass Concrete should have a low C3S and C3A content to reduce excessive heat
during hydration.
Most Mass Concrete structure do not require early strength, so slower hydration is usually not
harmful to construction.
❑ Cement Fineness:
Cement with a lower fineness with slow hydration, and reduce temperature rise.
❑ Cement Content:
Mass Concrete mixtures should contain as low of a cement content as possible to achieve the
desired strength. This lowers the heat of hydration and subsequent temperature rise. Can be as low
as 100 Kg/m3
❑ Aggregate Content & size:
Coarse Aggregate should be have an MSA of 6in if possible.
A higher coarse aggregate content (70-85%) can be used to lower the cement content, reducing
temperature rise.
Larger the MSA Lower the Cement content & thus lower Temperature rise

❑ Coarse Aggregate Coefficient of Thermal Expansion:

The CTE of the coarse aggregate is the main influence on the CTE of the concrete. Choosing an
aggregate with a low CTE can cut thermal stresses in half.

❑ Supplementary Cementious Materials (SCMs):

SCMs such as Fly Ash, and Slag can greatly reduce the heat of hydration.
Pozzolans such as FA (class F is best > slower hydration) and Slag will produce between 15-50% of
the heat of normal Portland Cement.
Highly reactive SCMs such as Silica Fume and Metakaolin do not substantially lower the heat of
hydration.

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❑ Use of SCMs such as FA and GGBFS is commonly up to 50-75% cement replacement.
❑ High Volume PFA mix is commonly used across the world for Mass concrete in Dams/ Raft /
Bridge piers etc..
❑ Fly ash (class F) can be used up to 35 to 70% as Cement replacement.
❑ GGBFS is Excellent replacement Material for Mass concreting mixes. Can be used up to 50 to
90% as Cement replacement.

❑ Placement Temperature:
Pouring at lower temperatures will reduce the thermal stresses in the section.
Slows hydration > lowers heat of hydration
Lowers temperature differential between the core and the outer surface

❑ Water Cement Ratio:

W/C has a large effect on temperature rise.
Most Mass concrete mixtures have a slump ranges from 50 to 200 m
Lower the W/C ratio Higher the temperature

❑ Pouring Rate:
Pouring rate is crucial in Mass concreting.
Slower pouring rate may introduce cold joints
Further, slower pouring rate may create possibility that the bottom layer get set before next
layer comes on top, This cause transmit of heat from bottom layer to newly placed concrete
& reduce retention of concrete.

5. Mix Design Guideline:

ACI committee 207 lists the following steps to control temperature in mass concrete.
❑ Selection of low – heat –of- hydration cement or blended Portland cement (PPC OR PSC.)
❑ Use of low cement content 120 to 265 kg/m3
❑ Use of High Volume PFA mix or Slag replacement of 65 to 85%
❑ Use of Large size aggregates 75 to 150mm and high aggregate content up to 80% of total
aggregate.
❑ Selection of low – heat –of- hydration cement or blended Portland cement (PPC OR PSC.)
❑ Use of low cement content 120 to 265 kg/m3
❑ Use of High Volume PFA mix or Slag replacement of 65 to 85%
❑ Use of Large size aggregates 75 to 150mm and high aggregate content up to 80% of total
aggregate.
❑ Pre-cooling of mixing water and aggregate to lower the temperature of fresh concrete.
Temperature of aggregate can be brought down up to 50.F (10 ºC)
❑ Post cooling of hardened concrete, through embedded cooling pipes. (Best cooling System)
❑ Appropriate block dimensions for placement, lift height and placing schedules. Lift height
may be restricted to 1.5m
❑ Use of steel forms for rapid heat dissipation.
❑ Proper Curing System to be adopted.

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6. Mass Concrete- Planning & Preparation:
Detailed Planning of Execution of Mass concrete pouring must be done with provide deep thoughts
on all possibilities & resources requirements:
Only proper planning saves from situation out of control.
Mass concrete is activity where you can not have scope to rectify or redo.
Hence, put all your resources & efforts in

❑ Logistics:
▪ Equipments & plants Equipments
▪ Manpower Requirements – Skilled & unskilled
▪ Traffic Movements Plan
▪ Placing Boom – No's & Locations
▪ Check Points
▪ Material Availability & storage
▪ Inter – Location Communication arrangements – walky Talky, Mobile etc..
❑ Illumination Arrangements
❑ Alternate Generator
❑ Dewatering equipments & drain out
❑ Protection System
❑ Refreshments & rest rooms for Labour & staff
❑ Local Authority Permission
❑ Local settlement
❑ Construction Plan:
▪ Select Desired Pour Rate
▪ Calculate efficiency of Batching Plant (Optimum / 2 ) basis – hence no. of
Plants/Agency required + 1 (standby)
▪ Calculate Transit Mixer cycle considering all sequential activity involved
▪ Add 20% additional as standby/ breakdown recovery
▪ Workout No of Placer boom + Pump required to place concrete of desired pour rate
+ 01 as standby
▪ Finalize pouring sequence in line with placing locations of placer booms
▪ work out time required to complete each concrete layer (layer generally 0.50 to 1.0
meter depending upon pour rate)
▪ Fix retention time require for concrete + 1 hr
▪ Supervisors & engineers requirement
▪ Prepare Head person for each activities/location wise like activities for team at Raft
placing location includes checking of reinforcement position/ compaction / insert /
pouring sequence / Formwork stability
▪ Form team of engineers & supervisors for important locations
▪ Assign & explain duties to each team member
▪ Explain relieving procedure & relieving person for each team member
▪ Induct Team for safety requirements & emergency action plan & facilities for rest,
food & refreshments, communication arrangements

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• pre-concreting meeting will be held internally and with concrete supplier to finalize
agreement of the proposed concreting procedure.
• Designated site access routes for concrete supply will be prepared and traffic control
measures implemented. The proper access must be organized to enable a continuous
transportation of the concrete during the entire period of pouring

❑ Technical consideration:
▪ Prepare detailed Specification requirement Plan
▪ Validate Mix design to be adopted after series of confirmation from trials
▪ Set requirement of Placing termperature
▪ Sequence of activity/monitoring at each check point location
▪ At Batching Plant:
▪ Pre-cooling of Aggregates with chilled water spraying 03 hours before pour start &
then at every 03 hours or rise in temperature of concrete at plant
▪ Water temperature should be preferably below 10 degree at all the time (set water
temperature requirement in line with placing temperature)
▪ Add ice into the water for mixing of concrete to reduce the water temperature. The
ice will be added until 8-10 Celsius Degree for water temperature is reached.
▪ The amount of ice added to the water is dependent on the air temperature at the
certain mixing day.
▪ Multiple rapping of Hessian cloth to transit mixer drum
▪ Spray cool water to the trucks mixers to reduce the temperature of the trucks
mixers.
▪ Measure temperature of first batch & all the ingredients, thus set co-relation &
check & reduce particular ingredient temperature if concrete temperature rise than
required.
▪ Batch sheet (autographic batch record) along with delivery challan for each transit
mixer
▪ Monitor & record temperature of water/ concrete & flow at regular interval
If Ice to be added in concrete then should be in form of weighed ice flacks with
equivalent to water to be replaced

❑ Technical consideration:
▪ At site check point:
▪ Batch sheet (autographic batch record) along with delivery challan for each transit
mixer should be verified & recorded.
▪ Monitor & record temperature of water/ concrete & flow at regular interval at site
point
▪ If Ice to be added in concrete at site then should be in form of weighed ice flacks
with equivalent to water to be replaced
▪ Concrete sampling to be done at site as per pre defined frequency
▪ Arrangements of cube moulds/cylinder/ beams etc.. Testing tools will be well
arranged
▪ Any deviation in pre-specified concrete leads to rejection

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• Technical consideration:
▪ At Raft pouring point:
▪ Monitoring of correct placing sequence
▪ Advise action for keep concrete alive to avoid cold joints if required
▪ Monitoring & record of Placed concrete temperature at bottom / core & top
locations during pour
• Initiate protection & curing system at progressively complete locations

❑ Safety Precautions:
▪ Inspection of Equipments & Machinery prior to use & certified by qualified person
▪ All operators and drivers are to be equipped with valid driver’s/operator’s license
▪ Only Authorized driver or operator will be allowed to operate machines &
equipments
▪ Only authorized signalman will be assigned together with the operator or driver
▪ Wearing of the basic PPE will be enforced fully.

7. Post-Placement Protection Techniques:

❑ post-placement techniques to reduce thermal cracking:

1) Cool the core of the concrete to reduce the temperature differential.
2) Insulate the outer surface to reduce the temperature differential.
“If you can not cool then keep it worm”

Insulation after Placement

❑ Insulating formwork after placement is another technique to reduce the temperature
gradient.
❑ By limiting the heat loss from the surface, the difference in temperature between the
surface and the core is minimized.
❑ This is especially important in very cold conditions.
❑ Removing formwork to soon can cause “thermal shock” to the surface, and extensive
cracking will occur.
❑ Metal formwork is very conductive to heat, so additional insulation may be needed to limit
heat loss.
❑ 1 in wood ~= 20 in of additional concrete!
❑ Formwork Should not be removed for minimum 07 days after casting

Effective Insulation System:

• Concrete top surface will be covered with Polythene Sheet (preferably reflective) after
finishing of top surface or just after initial setting of concrete
• The Sheeting to be securely weighed to prevent through wind & minimum of 300mm
overlapping at joint of sheeting
• The Heat reflective Curing compound (Masterkure 181- white) to be applied (by spray or
brush (as per manufacture’s guideline) in two coats, right angle to each other (to ensure no
pores left & no tunneling effect), Surface is ready for application of Masterkure 181- white,
when damp, but not wet, & it can no longer be marred by foot traffic.

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• Thermo coal sheet (1000*500*40mm) will be laid on horizontal surface & be secured by
putting appropriate weight. The surface will then covered with Polythene Sheet
• The Formwork to be remains for Minimum 07 days from all sides to prevent heat loss from
sides
• Normal water curing may adopted after 07 days

Insulation system keeps surfaces from cooling & Uniform heat inside structure