Facts and Statistics About Industrial Concrete

Concrete has been used industrially since Roman times. Although the technology was largely forgotten until the mid-18th century, concrete is now the most used man-made material in the world. This article will examine some facts and statistics regarding industrial concrete.

Where Does All of the Material for Industrial Concrete Come From?

The process of making industrial concrete starts with the quarrying of raw materials. Limestone, clay and on occasion shale are heated in a rotary kiln at a high temperature. This chemical reaction produces what is called a clinker, which is cooled, inspected and ground with another material, often gypsum. This product is packaged and shipped to be mixed with sand and aggregates to make a basic concrete. Where available, re-purposed waste materials from steel and electric production can be used to replace some of the cement components.

Composition and Properties of Industrial Concrete

By itself, industrial concrete handles compressive loads quite well. However, when it’s stretched in a tensile setting, the material easily ruptures. This is why in many industrial applications rebar or another reinforcement material is used.

Admixtures are also becoming common in large construction projects. Retarders, which come in many forms, help to slow the curing process. These are useful in applications where engineers don’t want one portion of concrete to start curing before another. When a stronger, lighter product is desired, air entraining agents are used. This also results in a more suitable material for climates where numerous freeze and thaw cycles occur.

Industrial Concrete Hydration: Going From Wet to Dry

The curing process for industrial concrete is called hydration, and depending on factors such as temperature, humidity, and the composition of the materials used, it can take up to several weeks for a finished slab to reach its ultimate strength. To properly cure, poured concrete typically needs to be cooled. This is in large part because the hydration process creates a chemical reaction that releases heat and that could damage the strength of the concrete if it is not cooled. At SEMCO/SEMCOLD LLC we offer various concrete cooling solutions to meet the needs of your project.

How Long Will Industrial Concrete Last?

The Pantheon, the world’s largest unreinforced concrete dome is still standing, almost exactly as it was when it was built some 2,000 years ago. The materials used in that structure are a bit different than those in common use today, so it’s good to take a look at a modern example as well. The Tunkhannock Creek Viaduct in Pennsylvania, completed in 1915, used some 167,000 cubic yards of cement, water and aggregates. Much of it was poured underground to create deep piers, and reinforcement materials were used throughout. The bridge is still standing today, more than 100 years later. At SEMCO/SEMCOLD LLC we understand the needs of projects of all scales and can provide a custom cooling solution to meet your needs.

Taking a Look at the Numbers

It seems as if the appetite for concrete is as strong as ever. In 2014, cement consumption increased by nearly 9.2 million metric tons in developed economies, of which North America was the primary constituent. In the USA, most recent figures show that cement and concrete contributed $10.2 billion to state revenue, and the industry as a whole employs some 490,691 persons. In 2014, the cost of Portland and masonry cement was approximately $98.50 per metric ton.

Concrete structures make for impressive works of architecture. Concrete is also the workhorse material of industrial, able to be used for a full spectrum of construction and industrial projects. After examining the above facts and figures, at SEMCO/SEMCOLD LLC we hope that you will have a new appreciation for the hard, concrete surfaces that people rely on every day.

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Company Profiles for Companies who Need Concrete Cooling Systems

Do you need a concrete cooling system from SEMCO/SEMCOLD LLC? If you are familiar with concrete, you know that as the cement mixture hardens it actually gives off heat because it is an exothermic chemical reaction. The extra heat can cause the hardened concrete to be a less than desirable product. When concrete gets too hot during the curing process it results in lower tensile strength and a higher likelihood of cracking due to expansion.

How do you know what sort of cooling your company needs? In some cases it is enough to add cold water and ice to the cement, but when do you need an actual cooling system? There are many different situations that may call for a cooling system. You can talk to a SEMCO/SEMCOLD LLC representative to find out if your company would benefit from an innovative aggregate cooling system. Otherwise, here are three common company profiles that may benefit from the use of a concrete cooling system.

1. Company with Large-Pour Projects

Is your business working on a project that requires a lot of concrete? This project would be called a large-pour project. The more cement that you pour the more heat that will be given off. In the case of a large-pour project, it may not be enough to just add cold water and ice.

If your company is planning a large-pour project, you need to talk with a SEMCO/SEMCOLD LLC representative in order to find out what sort of cooling system is right for you. No matter if there is only one large-pour project in your company’s near future, you still will need some sort of cooling system. You do not want to end up with concrete that is going to crack and expand.

If you’re going to be mixing a lot of cement and water, you need a cooling system.

2. Company that Requires High Quality and Durable

Some industrial companies put their concrete through a lot. Because of the weight and traffic that the concrete is going to go through, a SEMCO/SEMCOLD LLC cooling system may be needed. If you own an industrial company that needs a concrete that is high quality and durable, you need a cooling system.

Without a cooling system your concrete could be of a lesser quality because of the exothermic chemical reaction. Even though you may not be pouring a large quantity, if you want a superior quality, you still need a cooling system.

Industrial companies that need high quality concrete also need a cooling system.

3. Construction Company that Pours Often

Many construction companies pour a high quantity of concrete. Maybe they do small jobs and large jobs, but if your business is built on the concrete that you offer, you want to make sure that you offer the best product around.

Construction companies that pour a lot of concrete would benefit from a SEMCO/SEMCOLD LLC cooling system because they would be able to guarantee their customer’s satisfaction. If your company doesn’t use a cooling system, there may be times when the tensile strength of the concrete you pour is very low.

Construction companies that pour concrete often would benefit from a cooling system.

To put it simply, if your business deals with concrete often, needs a large amount of concrete or requires that all the concrete is of the highest quality, a concrete cooling system may be just what you need.

Getting the Best

Now that you know you need a concrete cooling system, you want to get the system that is best for your business. SEMCO/SEMCOLD LLC wants every company in search of a concrete cooling system to get exactly what they need. That’s why we make custom cooling systems to fit the needs of our clients. Not only are our systems custom built, but they use dependable and industry-leading technology to ensure you have the best cooling system possible.

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Concrete Aggregate Cooling with Wet Belts

Aggregate cooling is a type of cooling system that cools aggregates in concrete mixture. There are different types of aggregate cooling. One common method is the wet belt system. This method is so popular because it is a cost-effective alternative to sand cooling and other higher costs methods. Using the wet belts allows the concrete to travel along a conveyor belt while being chilled by water. This allows the concrete to be cooled without filling silos full of water, saving space and money. It’s important to know all the options when it comes to aggregate cooling. Every method has its own benefits and drawbacks and some methods are best accompanied by other companion methods.

Why Aggregate Cooling is Effective

Aggregate cooling is effective because it eliminates potential problems that arise during the concrete-making process. Aggregates are mixed together to make concrete, including gravel, sand and crushed stone. The granular minerals need to be cooled so the concrete remains strong and doesn’t crack. The reason that they need to be constantly cooled is because without aggregate cooling, the particles heat up. As the cement mixture combines with water, a chemical reaction causes the granules to give off heat. The aggregate cooling will keep the temperature down and create strong concrete.

Why Aggregate Cooling is Beneficial

As previously mentioned, there is more than one type of aggregate cooling. The two most common types are cooling by air and cooling by water.

Cooling by Air – Cooling by air is done in silos. The concrete is positioned on a belt with nozzles in place below them. The nozzles give off heavy streams of air to blow at the concrete like a strong wind. The air cooling is beneficial because it provides necessary moisture without providing excess moisture. Excess moisture slows down the process because it prevents the concrete from solidifying. The air cooling system is also easy to install. Nozzle attachments just need to be installed to silos that are already in place. They also need little-to-no maintenance over time

Water Cooling – There are two different ways to cool the aggregate mixture by water. These included flooded silos and wet belt applications. With the flooded silo method, the silos are flooded to precool the aggregates. Once they are cooled to the proper temperature, the silo is drained. This method isn’t optimal for a few reason. For one, it takes up more space because larger silos are needed. This also has much larger operational costs. A much larger amount of water is needed and wasted. The wet belt method is the most cost-effective and popular method for cooling aggregates. It’s beneficial because you will use much less water without having to flood the entire silo. Smaller amounts of ice water is splashed onto the conveyor belts and the aggregates are still cooled properly. The flooding method can also cause the concrete to not harden properly. The small amount of water with the wet belt method will keep excess moisture off of the aggregates so the concrete will form properly.

Other Methods of Concrete Cooling

There are other ways to cool concrete. For example sometimes concrete is cooled while it is being mixed on a mixing truck. This is called agitator or drum cooling. However, the concrete is cooled in much smaller quantities since only a small amount can fit in the drum at one time. Post cooling is done when the concrete is already mixed and poured. However, the concrete still needs to be cooled during the mixing process. However, by far the most popular and widely used method of cooling concrete is by cooling the water itself that will be used in the hydration process. Regardless of which concrete method is required, SEMCO/SEMCOLD LLC designs and manufacturers high quality, industry-leading concrete cooling systems. Please contact us to discuss the best system for your needs.

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Concrete Aggregate Cooling with Flooded Silos

There are many different ways that concrete aggregate cooling can be done. In some cases it is enough to add ice and chilled water, but in others you actually have to cool the aggregates using special technology from manufacturers like SEMCO/SEMCOLD LLC. There are different methods of aggregate cooling, but let’s take a look at one popular and effective method in today’s article: concrete aggregate cooling with flooded silos.

Effectiveness of Aggregate Cooling

Pouring concrete, especially for large batches, has its risks. Because the hardening of concrete is actually an exothermic chemical reaction, it gives off excess heat. This can cause the concrete to expand, crack and lose tensile strength. That is why it is necessary to cool cement in the first place. Simply using ice water to mix with the cement is not always enough, especially for large-pour projects.

Aggregate cooling is effective because it cools the granular materials that are mixed in with the cement mix and water. When these materials are cooled before the mixing process, it actually reduces the issues that can arise due to the heat. The mixture starts off cooler, so it doesn’t get as hot. You want to make sure that your cement is very cool.

Benefits of Flooded Silos

When you use aggregate cooling by water, it typically takes a lot of space and equipment. You have to have a conveyor belt to flood, so that the aggregates can get cooled. You then have to have a water removal process and a settling tank. That can take up a lot of space, and depending on your situation, you may not have that amount of space for cooling.

The flooded silo method is beneficial because it doesn’t require as much space. You have silos that your aggregate is stored in anyway, and then you just flood the silo. Typically you want to have at least two silos, so that one can be flooded while another is being drained. Everything happens in that silo from the flooding to the water removal to the settling. It doesn’t take up a lot of space.

How Does It Work?

When you do a lot of large-pour projects, you have to have an effective way to cool your aggregates. Aggregate cooling with SEMCO/SEMCOLD LLC flooded silos allows you to pre-cool a large quantity of aggregates. Your aggregates start in silos, which are then flooded with ice cold water. The water is recirculated through the silos after it goes through a sediment basin. This basin catches mud, and gets the water ready to be reintroduced to the aggregates.

Once the aggregates have been completely removed from the water, they are ready to be added to the cement mixture. Now the aggregates are cooler, which means that the overall mixture is going to give off less heat.

Getting the Technology

Finding a reliable, durable and innovative cooling system is important. You don’t want to spend money on something that isn’t going to work. Thankfully SEMCO/SEMCOLD LLC is committed to helping our clients get exactly the technology that they need. Our commitment to customer satisfaction and quality means that we only provide systems that are industry-leading and dependable. Talk with a representative today to find out what system would be best for your company.

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Facts about Concrete Cooling Systems

Concrete cooling is beneficial in various large pour projects where heat is a contributing factor. Concrete is utilized for a number of different things. From buildings, to residents, to monuments and to various trafficked surfaces, concrete is a strong component and a versatile material. In order for concrete to be created and worked into its various shapes and forms, it must endure specific processes. Take a look at how concrete is made and some of the most commonly used cooling systems.

Creating Concrete

Concrete is created through a combination of aggregate materials and a unique paste mixture. The paste mixture, which is composed of portland cement and water, is combined with the aggregate material. The aggregate material may be either course or fine, which contributes to the different cement textures. As all of the materials mix together, the complete mixture undergoes a cooling process called hydration that causes it to harden. During this process, the material heats up and must be cooled down to be utilized. There are a few different cooling techniques that may be used.

Aggregate Cooling

One way to help make sure that the cement will be able to cool down properly is to ensure that it does not get too hot to begin with. To achieve this, there are two distinctive types of aggregate cooling techniques that may be applied.

Air – For this process, air is continuously blown through the aggregate material to keep it cool during the mixing process and afterwards. In order for the air that is circulating to be most effective, the aggregates must be moist, however they cannot be too damp. To achieve this balance, the air also helps to circulate warm air to dry the materials out a bit so that they may still stick together.

Water – Simply stated, cool water is added to the aggregate mixture to harden the concoction. The water must be at a specific temperature to activate the process, and the right temperature may vary dependent upon the amount of aggregate material. If the water is not naturally cold enough, a cooling system may be needed.

The two methods have their specific uses and advantages. Cooling by water tends to be much quicker than cooling by air, but air cooling is an efficient means of cooling in tight spaces.

Post-Pouring Cooling

Where aggregate cooling begins to cool items at the beginning of the process, post-pouring cooling systems cool the elements towards the end. Usually, piping is laid where the concrete will be poured beforehand. After the concrete has been poured in but before it is completely set, cold water is pumped through the pipes from containerized water chillers. The cold water then cools down the cement from the inside out. Usually, the water enters the pipes at 40⁰ and reaches around 50⁰ by the time it completes its cycle through the piping. This process is usually found to be most effective when used to cool larger cement features, such as dams, fountains and some highways. Despite its effectiveness, this process is usually not the most commonly used, consider the various elements that must be in place for it to work properly, which increases the time, labor and cost associate with the project.

Sand Cooling

Basically, sand is cooled and used to help keep the aggregate mixture cool throughout the hydration process. This form of cooling is often utilized in conjunction with another type of cooling method. The most common types of techniques that sand cooling is added to include: water, ice and aggregate cooling. Depending upon the size and extent of the cooling process, sometimes the aforementioned methods cannot achieve proper temperatures by themselves, at which point the sand cooling method is helpful. However, similar to post-pouring cooling, sand cooling does require specific equipment and procedures that impeded upon the process. For instance, sand cooling requires sand silos or rotary cooling drums, which are both expensive expenditures and require additional time to get the sand to the proper temperature to make the process effective. On the other hand, incorporating this process can help to lower the costs of the cooling methods that it is utilized with.

Depending upon your needs and desires, any of these cooling methods could be beneficial for you in creating viable concrete. Contact SEMCO/SEMCOLD LLC to receive customized cooling systems. They provide superior quality work with excellent customer service.

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A Closer Look at Concrete Cooling Systems: Flake Ice Delivery and Weighing

Because the production of concrete can cause temperatures in excess of 200°F it is very important to have a cooling system in place. Concrete cooling systems ensure that the concrete is strong, uniform and less likely to crack. Part of a concrete cooling system is the flake ice delivery and weighing system. In order to fully understand the cooling system, it is necessary to look at why the delivery and weighing systems are important, how they work, and the different accessories available.

Why the Flake Ice Delivery and Weighing System Are Important

You know that the concrete cooling system is important to help your company make high quality concrete. The way you deliver that ice is also very crucial. If the method used to transport the ice from the ice plant to the concrete itself is inefficient then there is a risk that the ice may melt or stick to the transportation unit. A quality flake ice delivery and weighing system ensures that the ice gets where it is needed at the right temperature and in the correct quantity.

How the Flake Ice Delivery and Weighing System Works

Once ice is produced and stored, it must be delivered to where it is needed. That is where the flake ice delivery and weighing system comes in to play. If the ice cannot be successfully delivered without melting, clumping, or sticking then the efficacy of the entire concrete cooling system suffers. When you use a flake ice delivery and weighing system together you have a higher chance of successfully delivering ice.

First is the delivery component. This is commonly called a screw conveyor. You can choose to use a trough or tube screw conveyor. Both choices have slide gates along the length of the delivery system. These gates can be automatic or manual. They help the ice move along the tube without melting, sticking, or clumping, ensuring that it still has maximum cooling potential when it reaches the concrete.

The next part of the delivery system is the weighing. The weighing hopper discharges ice in a predetermined, adjustable and controlled way. Without the weighing aspect the ice would continue to be transported until manually stopped it, leaving the chance of having either too much or too little ice. With the weighing system the screw conveyor delivers ice to the hopper. Once the chosen weight is reached the system goes through a shutdown sequence. This sequence helps clean out the conveyor, so ice does not remain behind to melt.

Accessories Associated with Flake Ice Delivery and Weighing

There are a few accessories you can think about getting with your delivery system. They include:

  • Cyclone Receiver
  • Diverter Valve
  • Heavy Duty Slide Gate

At SEMCO/SEMCOLD LLC you are able to customize your concrete cooling system which means you can get the parts you need, and you don’t have to get the parts you don’t need.

SEMCO/SEMCOLD LLC Delivers Quality Flake Ice Delivery and Weighing Systems

SEMCO/SEMCOLD LLC will help you figure out the best flake ice delivery and weighing systems for your particular concrete cooling system. Our goal is to ensure that all of our clients have the absolute best system for their particular businesses. A major part of that is ensuring that the flake ice delivery and weighing systems are optimal. Please contact us for more information about our concrete cooling systems.

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Factors that Influence the Efficiency of a Concrete Cooling System

When you purchase any type of machine or equipment, you want it to be efficient. You want it to fulfill the role that you need it for well. When you’re looking at concrete cooling systems, you need to know what factors affect their efficiency. This will help you get the system that is best for you and your business. At SEMCO/SEMCOLD LLC you can build your own customized concrete cooling system. In order to better understand what you need and what influences efficiency, you have to know why concrete cooling systems are important and how different components of the system work.

Why Concrete Cooling Systems Are Important

If you’re a member of the construction industry and you pour concrete regularly, you need a concrete cooling system. This type of system is important because it helps you provide your customers with the highest quality concrete. SEMCO/SEMCOLD LLC wants to provide you with the highest quality equipment and services so that you can provide high quality products and services to your customers. If you don’t have a concrete cooling system, your concrete is susceptible to cracking, low tensile strength, and non-uniformity.

These negative side effects happen when concrete is poured and it is too hot. When you mix cement aggregates with water, the process of making concrete, a chemical reaction occurs. This reaction is largely exothermic, that means that it releases heat. If you have to pour large amounts of concrete, the temperature can exceed 200F. Thus, you need to have dependable, effective concrete cooling systems in place in order to leave your customers with high quality concrete that isn’t weak, crack-prone, non-uniform.

How Different Components of the System Works

Since SEMCO/SEMCOLD LLC offers customizable concrete cooling systems there are of course different variables in these systems. Some main components that can be included in a concrete cooling system are:

  • Water Chilling Plant – Most concrete cooling systems have a water chilling plant. This is used to cool the water that hydrates the cement. The cooler the water used the cooler the concrete’s temperature. That means that using cool water is an efficient way to cool concrete. Not only does this component efficiently cool water, but it is also much more power efficient than it has been in the past.
  • Cold Water Tank – This component is used to store the water that is to be used in the hydration process. Once you have chilled the water in the chilling plant, you don’t want it to warm back up. That means that in order to keep the system efficient you have to have a cold water tank to store the cold water in. To increase the efficiency of this component, you can choose to have it insulated.
  • Ice Plant – Beyond adding cold water in the hydration process, you can also add ice into the mixing drum to help keep the concrete cool. The type of ice used in this part of the system affects the efficiency. The most efficient type of ice is flake ice because it has the largest surface area, so it cools the best. It also melts quickly which helps keep the concrete uniform. The ice plant makes the ice that is used in the cooling process.
  • Ice Storage Bin – Just as the cold water has to be stored, the ice also has to be stored. In order to increase the efficiency of the concrete cooling system, SEMCO/SEMCOLD LLC allows you to choose to add an ice storage bin. This means you can make large quantities of ice and store it until it is needed in the concrete process.
  • Ice Delivery and Weighing – This part of the system effects the efficiency to a high degree. The ice delivery and weighing component delivers a predetermined amount of ice to the mixing drum. In order to be highly efficient it has to deliver the ice in a consistent, reliable way. It may possibly use a blower, rotary valve and/or cyclone receiver.
  • Aggregate Cooling With Water – When you need to keep the mixture extremely cool, you have to use an aggregate cooling system. Aggregate cooling with water is sometimes considered the less efficient method. You have to make sure that the water is at the perfect temperature for the size of the aggregate. It’s also considered less efficient because it can take up a lot of space.
  • Aggregate Cooling With Air – Aggregate cooling with air is more efficient because it can continuously cool the aggregate through valves located at the bottom of the silo. It doesn’t require extra machinery. It also helps maintain a uniform amount of moisture in the aggregate.
  • Sand Cooling – Sand cooling is only used when needed. It is a much more demanding cooling process than any of the aforementioned processes. It requires a highly customized system which SEMCO/SEMCOLD LLC does offer.
  • Post-Cooling – Another uncommon part of a concrete cooling system is post-pour cooling. It runs chilled water through a network of pipes in the poured concrete. This can be effective if done exactly right, but it can also cause irreparable damage if not done properly.

The components you use in your concrete cooling system affect the efficiency of the overall system.

How SEMCO/SEMCOLD LLC Can Help You Customize Your Concrete Cooling System

You may not need or want every single component listed. Each business has its own requirements. We realize that and that is why we are able to help you customize your own concrete cooling system. We’ll help you meet your temperature goals with a high level of efficiency while having only the components that you need. Contact us to discuss the particulars of your concrete cooling system.

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A Closer Look at Concrete Cooling Systems: Aggregate Cooling by Water

In this series of articles, we have looked at different types of aggregate cooling methods for large-pour concrete projects. Concrete cooling is vital to the strength and durability of the concrete. For large projects, you are going to need a comprehensive cooling system, which will be determined by the scope of your project and its application. SEMCO/SEMCOLD LLC understands that you want to get the most out of your project while maintaining your schedule and budget. This article will provide you with a closer look at aggregate cooling by water.

How Aggregate Cooling by Water Works

With larger projects, it is necessary to cool the concrete aggregate on a conveyor belt to get it to the required temperature much more quickly. Basically, aggregate cooling by water is simply putting cool water on the aggregate stockpile. It is a very quick process, depending on the size of the aggregate. If natural water isn’t cold enough to bring the temperature of the aggregate sufficiently low enough, a chilling system can be included.

Although air can do this process, cold water is much quicker and more effective. Installing this system does require specialty equipment, such as a well-functioning dewatering system and flooded cooling belt. In addition, a settling tank is mandatory to the process. However, the investment in this equipment is often minimal compared to other types of cooling processes.

Benefits of Aggregate Cooling by Water

Aggregate cooling by water helps keep your time-frame on schedule. Because it is so reliable, you know that your concrete pouring project will be completed and set when it needs to be. This means that you can keep the subcontractors and other people working on the project on task.

Proper cooling by water is very effective and stable. Your system won’t develop problems down the road when you use aggregate cooling by water. It is less likely to deteriorate over time, which makes the whole process more reliable. Wetting the concrete cools it, so that it doesn’t need as much water to get the required slump. This means less shrinkage as it dries.

Although it does take a great deal of water, the system is actually very small compared to other methods of cooling, which means that you aren’t having to use valuable space on the site to store equipment for your concrete pouring. When you work with an experienced company that has multiple engineers and managers, you get the benefit of their knowledge to keep your system well-designed.

Aggregate cooling by water is cost-effective and budget friendly. This in turns allows you to pass these savings on to the client, which means that they can invest more into the project where it really needs it. You can also work with natural resources, which means if you have available water for cooling, it can be integrated into the system to reduce your overall costs.

Cons of the Aggregate Cooling by Water

Aggregate cooling by water is not appropriate for every site. Although it does tend to be a cost-effective method, some sites may not have sufficient resources. Depending on the project requirements aggregate cooling by water may also not be sufficient to cool the concrete to the right temperature. This method is also not cost-effective for smaller batches. It’s important to look at your particular project and the facilities and resources that you have available to determine if aggregate cooling by water is appropriate for your project.

Find the Right Cooling Method for Your Project at SEMCO/SEMCOLD LLC

SEMCO/SEMCOLD LLC offers precise applications and methods for your project, designed to your specifications, including environmental concerns when applicable to keep the project eco-friendly. We have an extensive background in industrial cooling and freezing that allows us to come up with innovative solutions for your project. Please contact us so that we can come up with the best concrete cooling system for your company, whether that system incorporates aggregate cooling by water or a different process.

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A Closer Look at Concrete Cooling Systems: Aggregate Cooling by Air

Concrete cooling systems are used to ensure that the concrete product you provide is strong, durable, less likely to crack, and completely uniform. They are necessary because concrete is best when it is cool, and the chemical reaction that occurs during the hydration process is exothermic, which means that it releases heat. If you don’t have a cooling system in place, the temperature can exceed 200°F.

There are many different types of cooling systems. SEMCO/SEMCOLD LLC knows that not every business has the same needs, so we will help you customize a system to best fit your business. There are various methods of concrete cooling to choose from. One effective component of many concrete cooling systems is aggregate cooling by air. Let’s take a look at what aggregate cooling by air is and how it works.

About Aggregate Cooling by Air

Aggregate cooling in general is the lowering of the temperature of the materials, or aggregates, used to make the cement mix. This helps ensure that the concrete will stay cool when it is being made. Aggregate cooling can be done in two ways—by water or by air. In this instance, the one that is being discussed is cooling by air.

Aggregate cooling by air is particularly useful at construction sites that don’t have much space. This is because the aggregates can be cooled in their existing silos and without a dewatering system. This makes them a great choice at many worksites.

How Concrete Aggregate Cooling By Air Works

Aggregate cooling by air requires that an exact, defined airstream is blown continuously through the aggregates in the silos. Nozzles at the bottom of the silo are used to guarantee that the air distribution is specific. The aggregates have to be moistened during this process, but you don’t want the moisture to exceed what is required.

Aggregate cooling by air lets cold air get streamed through the silo, and as it passes through the silo and over the aggregates it is warmed up again. The warm air carries out the added moisture that is in the silo. This helps ensure that no additional moisture will be left behind on the aggregates, thus allowing you to control the aggregate’s environment from moisture to temperature.

More Advantages of Concrete Aggregate Cooling by Air

Not only does the aggregate cooling by air help you control the moisture in the silos, but there are other benefits to using this type of cooling system:

  • Continuous Process – With an aggregate cooling by air, a continuous process can be achieved. This means that you do not have to worry about the aggregates reaching a temperature that is too high because they can always be cooled.
  • Low Operational Costs – Cooling by air is a comparatively cheap cooling option.
  • Low Cost of Investment – Not only is this option cheap to operate, but it is also a much less expensive option to set up than many other systems. This is in large part due to the fact that air aggregate cooling does not require a separate dewatering system to remove excess moisture.
  • Mobile Set-up – This system doesn’t require as much space as other systems, which means you are able to use the equipment you already have. This allows for a more mobile set-up than the other cooling options.

SEMCO/SEMCOLD LLC Delivers Quality Aggregate Cooling Systems

At SEMCO/SEMCOLD LLC we want you to get the absolute best service and system possible. For some clients this will mean an aggregate cooling by air system, while other clients will benefit more from a aggregate cooling by water system, or a concrete cooling system that does not focus on the aggregates at all. Please contact us to discuss your needs so that we can come up with a system to best address them.

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A Closer Look at Concrete Cooling Systems: Post-Pour Cooling

The exothermic chemical reaction that takes place during the mixing of concrete can cause temperatures to exceed 200°F. When concrete is poured at such high temperatures this typically results in reduced tensile strength, tendency to crack, and non-uniformity. This means that high pouring temperatures can lead to low quality finished concrete.

SEMCO/SEMCOLD LLC wants to help your business produce the best concrete possible. This means that you have to have a concrete cooling system. There are many different customizable aspects of a concrete cooling system. In order to get the best system for your projects it is important to understand all the various concrete cooling methods. Let’s take a look at one of the final lines of defense for cooling concrete: post-pour cooling.

About Post-Pour Concrete Cooling Systems

Post-pour cooling systems do exactly what the name suggests: these systems are used to cool concrete after it has been poured. Generally containerized water chillers are used to pump cold water through a piping system. When water is released from the containers it is normally at about 40°F. By the time it makes it through the pipes it is at about 50°F.

These chillers are similar to chillers used to cool the mixing water. The difference is that these are a bit more mobile. As the construction progresses, you have to be able to move the chilling containers so the newer parts can be chilled post-pour.

When Post-Pour Cooling Is Necessary

In huge concrete structures such as dams, foundations and some concrete highways concrete has to be cooled after it’s been poured. After the concrete is poured, but before it is completely solid, cooling helps shrink the concrete which reduces the possibilities of cracking. However, while post-pour cooling is useful and important for these very large concrete projects, it is not typically the primary concrete cooling system. For most concrete projects sufficient cooling can be accomplished by cooling mixing water and aggregates prior to pouring. However, in situations where the concrete won’t cool adequately using these traditional measures alone, a post-pour cooling system is extremely useful and important.

Options for Post-Pour Cooling

When you’re looking at putting some sort of post-pour cooling system in place, you have to consider your options.

  • Cooling Pipe Size – One thing you have to consider is the cooling pipe size. It is important that you work with a company like SEMCO/SEMCOLD LLC who can help you choose the right pipe. If this system is not put together just right it can reduce the quality of your concrete.
  • Spacing – Another option you have to keep a close eye on is the spacing of the pipes. Each project may require different spacing to optimize the post-pour cooling technique.
  • Temperatures – The temperature of water that you use can also be an important option. If any of these details are off, it can cause irreparable damage to the concrete.
  • High Initial Costs – Another thing to consider as you look at these options is that post-pour cooling has a high initial investment cost.
  • High Operating Costs – It also has a high operating cost because the volume of water used is generally quite high.

There are many options that you have to consider in a post-pour cooling system.

SEMCO/SEMCOLD LLC Delivers Quality Post-Pour Cooling Systems

SEMCO/SEMCOLD LLC wants your business to be the most productive that it can be. That means that we want to help you customize the ideal concrete cooling system for your projects. If post-pour cooling is the right choice, SEMCO/SEMCOLD LLC can help you get exactly what you need. Regardless, we will help you determine the best concrete cooling system, whether it involves post cooling or not.

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