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Strength. Performance. Passion.

Management Mass Pour Raft Foundation


PT. Holcim Beton

"Innovative concrete solutions, proudly delivered by people you can trust"

Holcim Beton, 2013-02-13

2013 Holcim Beton

Why
we have to put more concern
Holcim Beton
Period

Project

Volume
(M)

Status

May 2007

Menara Bakrie

9,070

Completed

Jul 2007

Kuningan Place

6,431

Completed

Aug 2007

Kuningan Place

3,278

Completed

Sep 2007

Labuan 2

3,747

Completed

Oct 2007

Plaza Indonesia 1st

6,421

Completed

Oct 2007

Plaza Indonesia 2nd

6,755

Completed

Nov 2007

Labuan 2

5.792

Completed

Jan 2008

ST Regis

6.000

Completed

Feb 2008

ST Regis

6.000

Completed

Sep 2008

Kemang Village

6.000

Completed

Apr 2009

Kemang Village

6080

Completed

Mar 2013

Provident Park

7200

Completed

Beton Tebal dan Volumenya Besar


Holcim Beton, 2013-10-06

2013 Holcim Beton

What are focus&


1. Heat of Hydration and Thermal Crack (low initial temperature,
different temperature and peak temperature)
2. Mix Design (low cementitious material, low w/c ratio, initial setting time)
3. Plastic Settlement and bleeding ( low slump )
4. Cold join ( initial setting time and pouring method)
5. Pouring management plan to ensure delivery, unloading,
pouring and compacting to avoid cold join

Holcim Beton, 2013-10-06

2013 Holcim Beton

Temperature calculation Reff. ACI 305 R 99

Holcim Beton, 2013-02-13

2013 Holcim Beton

Exercise 1
Material Temperatur (o C)
Cement
70
Fly Ash
45
Agregate
30
Water
29

Initial Temperature w/o ice = 35.45 (o C)


Initial Temperature with ice (20 Kg) = 31.16 (o C)
Ada penambahan kenaikan suhu 2-3 o C untuk 1
jam perjalanan

Holcim Beton, 2013-02-13

2013 Holcim Beton

Low Initial Concrete Temperature &.


Typical initial concrete temperature: 37 0C
To achieve low initial concrete around 1oC (ACI 305R-11)
can be done by lowering the temperature as follow:




Cement 8 oC or
Water 4 oC or
Aggregate 2 oC

Holcim Beton, 2013-02-13

2013 Holcim Beton

Different Temperature
Maximum different temperature 20 oC between layer

Holcim Beton, 2013-02-13

2013 Holcim Beton

Monitor Temperature - Thermo Couples


Plastic
Styrofoam/polystyrene 2.5+2.5+5 cm
Curing Compound
Beton

50 C

Temperature
Monitoring

Mass Pouring

2013 Holcim Beton

Estimated peak Temperature

Tp = To + (Cement Content/100) x f
Tp = peak temperature
To = Fresh Concrete Temperature
f = (100 120 C : Fly Ash Concrete)
(120 140 C Normal Concrete)





Example:
Cementitious content 400 Kg
To
= 35.45o C
Tp
= 35.45o C + (466/100) x 12





= 91.37o C

To prevent crack related to heat hydration, the difference of temperature per layer
() should be < 20 oC. Insulator has to be installed.
Thermo couples reading on every 4 hours should started 12th hour up to 36th hour
then reading on every two hours after 36th hour.

Cement
content
Peak
temperature
(0 C) 400 Kg
88.01 MIX 15 % FA

Holcim Beton, 2013-10-06

Initial
cc
35.45

fa
396

70

constanta FA Constanta depth 2-4 m


0.6
12

2013 Holcim Beton

Mix Design (low cementitious material, low w/c ratio, initial setting time)

Holcim Beton, 2013-02-13

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Data Trial Mix

Perkembangan Kuat Tekan Trial Mix Fc 35 Mpa Fa 20% February 2013


160%
140%
120%
100%
80%
60%
40%
20%
0%

Pondok Indah
Kembangan
Rambutan

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Perkembangan Kuat Tekan Trial Mix Fc 35 Mpa Fa 25% February 2013
150%
130%
110%
90%
70%
50%
30%
10%
-10% 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Providence Park

Pondok Indah
Kembangan
Rambutan

2013 Holcim Beton

Reference Project Adiabatic Fc 35 Mpa with Flyash 20 %


80.0

Titik bawah

70.0

titik tengah

60.0

titik atas

50.0

t1mid-bottom

40.0

t2mid-up

30.0
20.0
10.0

25-Feb

24-Feb

23-Feb

22-Feb

21-Feb

20-Feb

19-Feb

18-Feb

17-Feb

16-Feb

15-Feb

14-Feb

13-Feb

12-Feb

0.0

Peak Temp on 71.7C on 3rd day after Pouring


80.0

Titik bawah

70.0

titik tengah

60.0

titik atas

50.0

t1mid-bottom

40.0

t2mid-up

30.0
20.0
10.0

25-Feb

24-Feb

23-Feb

22-Feb

21-Feb

20-Feb

19-Feb

18-Feb

17-Feb

16-Feb

15-Feb

14-Feb

13-Feb

12-Feb

0.0

Peak Temp on 75.8C on 2nd day after Pouring

Providence Park

2013 Holcim Beton

Pelaksanaan
Penempatan titik pengujian suhu dengan termo couple

Providence Park

2013 Holcim Beton

Point 8
100
Celcius

80

Mid

60

Top

40

Bottom

20

Mid-Top

0
0

10

15

20

25
to Hour

30

35

40

45

50

Mid-Bottom

Peak Temp on 81C on 39 hour after pouring, t max 19.8 0 C

Point 9
100
Celcius

80

Mid

60

Top

40

Bottom

20

Mid-Top

0
0

10

15

20

25
to Hour

30

35

40

45

50

Mid-Bottom

Peak Temp on 82C on 33 hour after pouring , t max 19.4 0 C

2013 Holcim Beton

Preparing at site project


Cleaning waste concrete cuci talang truk mixer & waste sampling and
check slump test
Coordination community by project
Coordination Policy by Holcim
Supporting area for check slump test, sample and central dispatch :

Tend
Chair & Table
Computer
Power and Listrik

Survey access road condition


Survey project location
Provide washout facility
Survey traffic and safety

PT Holcim Beton, 2013-05-28

2013 Holcim Beton

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Supply Chain
Batching Plant Holcim Beton
NO

BATCHING PLANT

NUMBER
OF TRUCK

PLANT CAPACITY

CYCLE
TYME

SITE PLANT

40 M3/HOURS

15 mnt

KUNINGAN

16

60 M3/HOURS

40 mnt

KAMPUNG
RAMBUTAN

21

56 M3/HOURS

45 mnt

PLUMPANG

25

84 M3/HOURS

60 mnt

KEMBANGAN

25

84 M3/HOURS

60 mnt

For continunos supply for mass pouring raft foundation will be


available total truck 93 units .

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Traffic Management

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2013 Holcim Beton

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Plant Plumpang
Holcim Beton

Plant Kembangan

PT Holcim Beton, 2013-05-28

Plant
PlantRambutan
Plumpang

Plant Kuningan

2013 Holcim Beton

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Delivery System
Dispatching System

Central Dispatch Center will be manage and planning concrete from our
batching plant
Track monitoring truck with GPS system
Computerized batching system with command batch
Central Dispatch on Site
Project

PT Holcim Beton, 2013-05-28

2013 Holcim Beton

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Course Aggregate & M Sand Source

Maloko Quarry
Type
Production Capacity
Capability
Number of trucks
Trucks capacity

: Stone Crusher
: 1000 m3/day
: 500 m3/day
: 68 units
: 24 m3

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Sand Source
Sands Quarry at Lampung
Capacity
: 15000 m3
Capability to supply : 500 m3/day

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Suggestion Mass Pouring Raft Foundation Method


1. Pit Lift raft slab thickness

: 4000 mm

Pouring method : Slab will divided by vertical segment with 3 layer


1st Layer maximum thickness
: 900 mm
2nd Layer maximum thickness
: 900 mm
3rd Layer maximum thickness
: 2200 mm

2. Other massive raft slab thickness : 2500 mm


Pouring method : Slab will divided horizontal segment than pour by
full depth methode or layer by layer
Full depth with considering of cold join and segregation
Layer by layer with considering of cold join and unloading method

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Truck line up

Holcim Beton, 2013-02-13

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Traffic Management
Cycle time to Project Pondok Kemba Rambut
(min)
Indah
ngan
an
Loading at plant
Check Slump
To Project
Test Slump
Queue
Unload
Out of Project
Return
Total

10
2
45
5
5
10
5
30
112
1.87

5
2
60
5
5
10
5
45
137
2.28

5
2
60
5
5
10
5
60
152
2.53

Plant

No of
Truck
11
23
27
#DIV/0!
#DIV/0!
62

0
-

Production Capacity (M3)


Loading at plant
No of Load per Hour
Load Size
Rate Prod/hour
(m3/hr)
% Contribution
Total

10
5
5
0
0

Pondok Indah
Kembangan
Rambutan
Total

0
-

Cycle
time to
Project
112
137
152
0
0

Loading
Time

Concrete Pump Capacity

10
6
7

5
12
7

5
10
7

0
0
#DIV/0! #DIV/0!

No of CP
Capacity/CP/hour
Total Capacity/hour

4
25
100

42

84

70

#DIV/0! #DIV/0!

Experience Factor

62%

80%
34

100%
84

70%
49

0%
0%
#DIV/0! #DIV/0!

Holcim Beton, 2013-02-13

unit
m3/hour
m3/hour

161.29 m3/hour
167

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Quality Control
1. Check temperatur
2. Slump test
3. Taking sample

Following ACI Standart for frequency


sample as below :
...
...
....

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Course Aggregate & M Sand Source


Maloko Quarry
Type
Production Capacity
Capability
Number of trucks
Trucks capacity
Distance from Project

Holcim Beton, 2013-02-13

: Stone Crusher
: 1000 m3/day
: 500 m3/day
: 20 units
: 22 m3
: 75 km

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Curing Method
1. Before pouring all area should be cover by terpaulin to prevent from rain
direct and exposure to sun
2. Right after complete finishing surface, concrete cover by plastic sheet
and 3 layer of sterofoam
3. Sterofoam will use to manage different temperature 20 C and to
accelerate time to reach steadily and stability temperature

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Conclusion
Key success of Mass Pouring is team work of main contractor,
CM, concrete supplier, concrete pump, and other related
parties
Supply continuity
To keep () < 20 oC and prevent thermal crack, monitor of
temperatur through thermo couple and period of insulator
release within time calculated.
Work safely and meeting the quality

Mass Pouring

2013 Holcim Beton