Placing concrete in low temperatures

1. Specification of concrete works in low temperatures

Ambient temperatures of +5oC are considered low temperatures, as far as the construction of concrete elements is concerned. Temperatures below +10C affect the properties of the concrete mix and of the set of concrete. In general, reduced temperatures, in particular, involve the following: overextended setting time, especially for cement types with normal strength gain (N) and a high content of mineral additives significantly slower process of gaining strength This entails major risks and significant inconveniences in the performance of construction works. Reduced strength of the composite in the initial period requires a longer formwork time, a prolonged construction cycle and slows down the rotation of formworks or inhibits the use of more formworks. The most serious problems, however, may occur at sub-zero temperatures. If no appropriate measures are undertaken, a single instance of the freezing of the concrete within the initial twentyfour-hour cycles following the placing often causes disruption of the structure, as the concrete sets too slowly. As maintained by T. C. Powers [4], a recognised expert in the field of concrete, at temperatures of approx. -10C, 90% of water undergoes a change of phase. National regulations specify the so called critical temperature, at which 50% of water freezes, at -1C. It is widely known that ice crystallisation causes the initial water volume to increase, directly leading to stress in the material, which significantly exceeds the strength (mainly tensile strength) of young concrete. On the other hand, frozen water does not contribute to the hydrolysis and hydration of the binding agent. Unprotected concrete is thus unable to gain the required strength fast enough. Performing concrete works at low temperatures is duly considered one of the greatest challenges in concrete technology. Over the years, certain methods, some more effective than others, have been developed: o modifying the composition and the procedure of making the concrete mix o heat retention method o re-heating method o method of heat insulation elements Each methods goal is to reduce the time required for the concrete composite to reach the so called relative strength (critical strength) and full strength. Relative strength allows the material to resist the destructive effect of concrete freezing, provided that the water from the environment does not penetrate the material. When water penetrates the concrete (as a result of rain or snow fall, snow melting, etc.) it must reach its full strength before freezing. Approximate strength values, identified as the compression strength of materials, are provided in table 1, after Jamroy [1]. Strength type Relative Full Compression strength [N/mm2] for cement CEM I CEM II, III, IV and V 2.0 8.0 5.0 10.0

Table 1. Recommended concrete strength values ensuring resistance to the negative effects of freezing In practice, the most frequently applied approaches are the modification of the composition and the procedure of the concrete mix, and the heat retention method. The procedure and the conditions to be met when applying the two methods are described below.

2. Practical approach to placing concrete in sub-zero temperatures

One of the simplest methods of improving the concretes strength gain dynamics at low temperatures is to use chemical admixtures. The widely known accelerators and anti-frost admixtures operate based on 2 main mechanisms: they reduce the temperature at which water changes its phase (ice crystallisation), and accelerate the solution of the cements active phases, which initiates the hydration of the binding agent and speeds up the materials strength gain Chryso Polska Sp. z o.o. offers highly effective admixtures from this group, the so called Xel series: CHRYSOXel AD CHRYSOXel 650 CHRYSOXel GTX CHRYSOXel 384 and CHRYSOSpolos X. These admixtures significantly boost the strength gain of young concrete, which is decisive for the elements resistance to frost and/or deformation. Technical advisers at Chryso Polska Sp. z o.o. can provide the results of many comparative tests, which define the strength gain, ranging from a few dozen to over one hundred per cent, for the various admixture compositions. Other similar purpose admixtures available on the market were also found to be effective. Anti-frost admixtures allow the concrete to quickly reach its appropriate resistance to freezing at ambient temperatures as low as -10C. However, certain limits for which specific composition and admixture requirements apply should be established. These are well illustrated by standards [6] in table 2 for, among others, the minimum temperature of the concrete at the time of placing.
Ambient conditions or composition Requirements properties Air temperature ranging from -3C to Concrete mix temperature: +5oC +5C As above; in addition, cement content of < 240 kg/m3 or cements with low Concrete mix temperature: +10oC hydration temperature Concrete mix temperature: +10C; in addition, temperature of Air temperature: < -3C +10C for three, 24-hour cycles; otherwise, provide sufficient protection until the required strength is reached. Air temperature: < +5C Concrete mix temperature: + 30oC 3 Cement content: 270 kg/m , w/c 0.6; Curing temperature of the setting mixture: +10C for at least three external moisture penetration prior to days (fast-set concretes with high hydration temperature) or until the concrete freezing compression strength of 5.0 N/mm2 is reached

Table 2. Recommended temperatures of the concrete mix delivered to a construction site and recommended compression strength necessary to ensure the required resistance The recommendations form an essential part for correctly constructing a given object/element at low temperatures. Even the most effective procedures may fail to produce the desired effect, if other recommendations are not met. Therefore, applying chemical admixtures or heat insulation elements is necessary. These measures, however, are merely stages in a broader process. A successful end product is the sum of appropriate actions taken at individual stages. Steps necessary to achieve the required mixture parameters and produce set concrete: I. Designing the mix composition: Selecting cement type and quantity: fast-set cements (R) are recommended; if possible, avoid cements with high content of blast furnace slag (and mineral additives)

 Selecting admixture type and quantity: liquidising or anti-frost admixtures it is recommended to reduce the quantity of water and use a higher than required concrete class; when using the concrete class corresponding to the class required for normal conditions, it is necessary to use an anti-frost admixture;

II. Mix production:

The temperature of the mix leaving a concrete-mixing plant: using heated-up components; frequently, the make-up water is heated up or the places for storing the aggregate is covered with roofing; particular attention must be paid in the case of frozen aggregates (melting ice consumes a substantial portion of heat from its environment)

III. Transporting the concrete mix:

Reducing heat loss of the mix during transport to the construction site: special installations on mobile concrete mixers (among others, heating up the mixer with exhaust fumes); eliminating vehicle stoppages; minimising the exposure of the mix to cold air (pump transport, cover, short mix discharge time);

IV. Installing formwork and placing the concrete mix:

Selecting the type of formwork and heat insulation: tar board, covering the formwork, can delay the concretes temperature decrease; widely available and used heat and wind insulation materials: mineral wool and polystyrene foam, straw or reed matting, canvas tarpaulin, thick foil, etc. For higher requirements, the type and thickness of the insulation material can be specified by using the physical properties of the structure itself (heat conductivity and penetration factors). After placing the concrete, ensure that the curing conditions are met; monitor the actual temperatures of the elements and the tightness of the insulation elements on the formwork. Re-vibration of the concrete mix is often used as an effective method to reduce the effects of concrete freezing in the initial phase of setting. The procedure should be conducted once the mix has thawed and a temperature of approx. +10C has been reached. For even better results, use mixes with lower cement content [2]. The elements should be shielded from ambient moisture, such as rainfall and water splashes. External heating methods include heat generators, radiators or air blowers.

V. Removing the formwork

The time of removing the formwork or the time when the concrete reaches an appropriate resistance to sub-zero temperatures can be determined by way of an experiment. It is a common practice to leave sampled material to cure in similar conditions; this enables credible monitoring of the condition of the concrete in the structure and eliminates risky methods involving approximate estimation of parameters of the cement composites exposed to low temperatures.