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

In this series of articles, we have looked at different types of 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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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 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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A Closer Look at Concrete Cooling Systems: Sand Cooling

Concrete cooling systems are extremely important for companies and businesses that work with concrete, especially large-pour projects. During the hydration process, a chemical reaction occurs that is highly exothermic. That means that it releases heat. The temperature can exceed 200°F. When concrete is poured at such a high temperature this can cause major problems. The concrete tends to be less durable, more prone to cracking. Such concrete is also weaker and non-uniform. That’s why it is extremely important to use a concrete cooling system to offset these temperature rises.

Concrete cooling systems are not all the same and sometimes the temperature requirements may vary depending on the project. When the temperature needs to be extremely low, you can’t use a run of the mill cooling system. Instead a more extreme option such as a sand cooling system may be used. This article will help you understand what sand cooling is and when this type of concrete cooling system is necessary.

About Sand Cooling Systems

Sand cooling is one of the least common forms of concrete cooling systems. This is in part because it is often unnecessary, especially for typical concrete projects, and it is also a more expensive option than many other concrete cooling systems. It requires a highly customized, sophisticated set-up. The sand is usually cooled in either a rotary cooling drum or sand silos.

It is also important to note that even in systems that do utilize sand cooling, it is still used with other methods of cooling. Many times ice or cold water is used to help cool down the sand. The sand helps keep the concrete thoroughly cooled during the entire process.

When Sand Cooling Systems Are Used

A sand cooling system is used when chilled water, ice, or aggregate cooling just won’t be enough. Since sand cooling is used in conjunction with other cooling methods, it is important to note how these methods are completed and when sand cooling comes in.

  • Water Cooling – Water chilling plants can lower water temperatures from 113°F to 32°F. There are normally three or four stages in this cooling process.
  • Ice Cooling – Flake ice or plate ice can be used in ice cooling systems. Plate ice is better for cooling larger areas. Flake ice tends to be a more efficient cooling agent because it has a higher surface area per ton of ice.
  • Aggregate Cooling – Aggregate cooling can be done with air or water. Air is better for sites with limited space. A water system needs a wet belt and dewatering systems, but air can use existing silos./li>

When these cooling systems can’t keep the temperature lower enough or provide a thorough enough cooling, sand cooling systems may be necessary.

SEMCO/SEMCOLD LLC Delivers Quality Sand Cooling Systems

Sand cooling systems are highly customized, and it can be expensive. However, at SEMCO/SEMCOLD LLC we take pride in providing the best systems and options at the best price possible. If sand cooling is going to be your best option, SEMCO/SEMCOLD LLC will be able to let you know and help you through the process. Contact us to discuss the particulars of your business and your concerns and we will be able to work out a solution that fits your requirements.

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Is Post-Pour Cooling Always Necessary in Concrete Cooling Systems?

If you often work with concrete you probably already understand the importance of having a reliable concrete cooling system in place. Otherwise, the high temperatures caused by the exothermic chemical reaction during the production of concrete can cause the final product to be less durable, more susceptible to cracking, non-uniform, and not as strong. However, there are many different options available for concrete cooling and you may be unsure exactly what you need.

One such component of some concrete cooling systems is a post-pour cooling system. In order to understand if you need this type of cooling, you first have to know what post-pour cooling is and then you can ascertain if you need it or not.

What is Post-Pour Cooling?

Post-pour cooling is a system that cools concrete after it has been poured. This type of system is generally used with extremely high volumes of concrete such as with big dams, large foundations, and some concrete highways. The system uses containerized water chillers and a piping system to cool concrete from the inside.

Pipes are laid in the area where the concrete is going to be poured. After the concrete is poured, the pipes are inside. Water is released into the pipes from the containerized water chillers. The water normally begins at about 40°F and ends at about 50°F.

The chillers that are used are similar to chillers used to cool the mixing water. However, these containers are a bit more mobile. This mobility allows you to make sure that you get water to every part of the concrete. As the project progresses, you can move the water to the newer parts.

Why is Post-Pour Cooling Generally Not Needed?

There are a few reasons why post-pour cooling is generally not used:

  • High Start-up Cost – The initial investment for post-pour cooling is quite high. This tends to keep people from using it unless it is absolutely necessary.
  • High Operational Cost – Since water is continuously run through the pipes until the massive amounts of concrete are completely cooled, the operational costs is also quite high.
  • Delicate Process – One of the biggest reasons why post-pour cooling is generally not used is that the process is quite delicate. There are a number of factors—pipe size, spacing between pipes and temperature of water. If each of these factors is not just right, your concrete is more susceptible to cracking.

The bottom line, however, is that post-pour cooling is generally not used because it’s not necessary. For most concrete applications other, standard methods of concrete cooling, will be sufficient to properly cool the product. However, when more intensive cooling is needed, post-pour cooling is a great option.

SEMCO/SEMCOLD LLC Can Customize Your Concrete Cooling System

Whether you need post-pour cooling or not, SEMCO/SEMCOLD LLC can customize your concrete cooling system. We realize that not every business is the same, so not every business needs the same cooling system. When you work with SEMCO/SEMCOLD LLC you get the option to purchase exactly what you need. We strive to provide you with the best machinery, products, and service possible for your individual needs. If you believe you need a post-pour concrete cooling system, or any type of concrete cooling system, contact us and let us help you get the system that is right for your company.

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Is Aggregate Cooling Always Necessary in Concrete Cooling Systems?

The curing and hardening of concrete is a chemical reaction that occurs via hydration as the cement mix forms strong bonds with water. This chemical reaction is an exothermic reaction, meaning that it gives off heat as a byproduct. For large-pour concrete projects this can result in serious problems as the concrete expands, develops a temperature gradient, or experiences reduced tensile strength and cracking. To overcome this problem concrete, particularly for large projects, must typically undergo a cooling process.

One effective method of concrete cooling is aggregate cooling. Let’s take a look at what aggregate cooling is, how it works, and whether or not it is always necessary for concrete cooling systems.

What Is Aggregate Cooling?

To understand what aggregate cooling is, it is first necessary to understand what aggregates are. The term “aggregates” refers to the inert granular materials that are present in the mix. These typically consist of sand, gravel, or crushed stone. When the aggregates are combined with the cement mix and water together these ingredients combine into concrete. Thus aggregate cooling refers to the cooling of these inert aggregate materials. By cooling these materials prior to the mixing process, the temperature rise that occurs due to hydration during the mixing can be partially offset, thereby reducing or eliminating the potential problems discussed above.

How Are Aggregates Cooled?

There are two broad methods of cooling aggregates: cooling by water and cooling by air.

Cooling by Water – Cooling by water involves the use of chilled water to cool the aggregate materials. This is most often accomplished via the flooded silo method or by wet belt applications. In the flooded silo method the silo in which the aggregates are stored is literally flooded with chilled water, thereby cooling the aggregates. However, this necessitates water removal which, depending on the particular setup, system, and resources available might be burdensome. Thus, another alternative is the wet belt method which cools the aggregates with chilled water as they travel along a conveyor belt, thus avoiding full silo flooding and minimizing excess water.

Cooling by Air – Cooling by air offers the advantage of removing the need for a dewatering system. In air cooling a series of air nozzles are installed in the silo where the aggregates are stored and a defined air stream is established. The aggregates are then moistened and the cold air is blown past them, cooling them with evaporative cooling and removing the moisture in the process.

What Other Concrete Cooling Options Exist?

Aggregate cooling is only one of several broad concrete cooling approaches which include:

  • Aggregate Cooling – As discussed above.
  • Drum or Agitator Cooling – Cooling occurs in the agitator drum or mixing truck during the mixing process itself.
  • Water Cooling – The water used for hydration is cooled separately prior to mixing.
  • Post Cooling – Cooling occurs after the concrete has already been mixed and poured.

Is Aggregate Cooling Necessary?

So is aggregate cooling necessary? The answer is it depends. It depends on the size and requirements of the pouring project and the efficacy of the other cooling approaches used. Often for small- or mid-size pour projects aggregate cooling is not necessary. Ultimately some companies opt to avoid or minimize aggregate cooling by instead focusing on other concrete cooling methods as discussed briefly in the previous section.

SEMCO/SEMCOLD LLC Provides Dependable Concrete Cooling Systems

SEMCO/SEMCOLD LLC provides dependable, industry-leading concrete cooling systems that may or may not incorporate aggregate cooling depending on the particular client’s and project’s needs. We are committed to helping our clients get the system that best fits their requirements and will discuss their aggregate cooling and other concrete cooling options to ensure the best results. Our clients can count on us for outstanding concrete cooling systems.

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The Advantages of Aggregate Cooling by Air for Concrete

It is important for concrete to have proper heating and cooling systems in place. The aggregate mixture is initially heated to combine the different parts and create the concrete itself, and then it is cooled to allow the mixture to set. However, if there is a large difference between the heated and cooler temperatures, the concrete could be subject to premature cracking. To avoid this, companies utilize aggregate cooling processes to cool down the particles before they set. Cooling by air has become a popular option. Take a look at the process and the advantages of aggregate cooling by air to see for yourself why it is an excellent choice.

What is Aggregate Cooling by Air?

The design of the air cooling system is what makes it so effective. It utilizes the silos that are already in place to complete the cooling process. Strong air nozzles are installed at the bottom of the silos, and they provide a constant air stream at the appropriate temperature to provide maximum cooling. The process is so effective at cooling the aggregate materials that moisture must be added to ensure that the concrete does not become too dry. As the cooling air moves through the silo it warms up, creating the needed moisture. Therefore, the cooling system actually performs double duty by both cooling the concrete while also providing needed moisture.

Different Advantages

Being that aggregate cooling by air works with the silos that are already being utilized, that dramatically cuts down on installation costs. Also, with the air system being multi-functional, it substantially decreases the use of extra energy, which in turn lessens production costs. These factors in themselves prove to be enough of a cause to utilize this system. However, along with the cooling system working in conjunction with the equipment that is already in place and it serving double duty, there are a few more advantages of utilizing this system.

  • No excess moisture: Since the cooling air also creates the necessary moisture, no additional moisture sources are needed. This helps to ensure that the concrete does not receive excess moisture, which could slow down or even prevent the solidifying process.
  • Mobile set-up capabilities: The cooling by air system is a mobile system, so it can be transported and applied to different silos, enhancing its usefulness within a company, as well as making transport a hassle-free affair when necessary.
  • Continuous process: The blown air naturally completes all aspects of the cooling process, providing a continuous flow with low maintenance requirements. This aspect makes air cooling energy efficient and an proficient process for companies to implement.
  • Quick installation: Unlike water cooling systems that require the installment of large machinery parts, cooling by air just requires the attachment of the air nozzles to the silos. This allows for quick installation and dismantlement when necessary. It also requires less maintenance than a standalone cooling system.

Outlook

The aggregate cooling by air system has very strong characteristics. As such, it is a popular choice for cooling concrete. The use of air is not only energy efficient but is environmentally safe, making it a sustainable choice for long term use. It also lowers operating costs and limits the necessary equipment that companies must invest in and maintain. Concrete manufactures large and small can greatly benefit from these factors. Those extra funds can be reallocated to increase production, which in turn would increase profit. Simply stated, air cooling proves to be a wise investment. For these and other reasons, use of this cooling system has grown over the years and shows no signs of slowing down.

It is clear why aggregate cooling by air is a great choice for cooling concrete. It has proven to be a sustainable process with minimal added equipment, easy portability, multi-functional properties and energy efficiency. These and other advantages give those companies that utilize this system greater leverage and help to keep operation costs low. No matter the size of an organization, it can benefit from implementing an aggregate air cooling system for cooling its concrete. The air cooling system’s quick yet resourceful process is not only impressive but helpful to the continuance of the company’s operations. SEMCO/SEMCOLD LLC provides comprehensive concrete cooling solutions including systems that utilize aggregate cooling by air.

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The Advantages of Aggregate Cooling by Water

If the temperature of the concrete is too high when it is applied to a structure or a certain area, its durability and strength are compromised. In most situations, the cooling process can be completed by adding ice and chilled water to the actual concrete mix. However, in some cases, this process is insufficient and the aggregates need to be cooled as well. This is where aggregate cooling by water comes in. The advantages of aggregate cooling by water are numerous, and this process is applicable to construction projects everywhere.

The Cooling Process

The most reliable and efficient way to cool concrete aggregates is to place them on a belt conveyor along with some ice water. Once this is done, the aggregates can generally reach a temperature of 5 degrees Celsius within just a few minutes. However, the rapidity of this process is largely affected by how big the aggregates are. For instance, an aggregate that is at least 150 millimeters in size may take up to 35 minutes to cool, while an aggregate less than 80 millimeters in size may only require one to eight minutes to reach an optimal temperature.

One of the advantages of aggregate cooling by water is that the process can be completed much quicker than if it needed to be done with a cold stream of air. However, in order for the aggregate cooling process to take place properly, the cooling belt must first be equipped with a dewatering system. Additionally, these belts require a setting tank to properly handle the cooling process.

After the belts of the cooling system have ice water added to them, the liquid eventually makes its way to a sediment basin. Here, the mud, or sand, is separated from the water. Eventually, this water is chilled to an extremely cold temperature.

Faster, Reliable Cooling

As mentioned above, cooling the aggregates before application using water can speed up the cooling process and ensure the durability of the concrete once it is used. However, there are many other benefits associated with this process. For example, the aggregate cooling process is not difficult to set up. This means that those working on a project that requires concrete can cool the aggregates shortly after the need to do so arises.

Additionally, the tools and equipment needed to cool aggregates by water do not require a significant investment. These systems also do not require a ton of space to store. This means that those who specialize in concrete cooling can complete the process without sacrificing valuable space in their work area to cool aggregates before application.

Customer Benefits

Although the advantage of aggregate cooling by water mainly benefit those working directly with the concrete, the process has several different benefits for those who initiated the project as well. First, those who need to have the concrete pouring process completed on a certain day are more likely to stay within their timeframe if they take advantage of aggregate cooling. This ensures that other people working on the project are able to complete their part quickly, instead of being delayed by problems with the concrete.

Second, when water is used during the aggregate cooling process, it ensures that the concrete does not develop significant problems in the future. Since proper cooling can help concrete set properly after it is placed in a predetermined area, those who needed the concrete will likely find that it is less likely to crack or deteriorate over time. This also ensures that other structures placed on top of the concrete are secure.

Finally, aggregate cooling by water is a cost-effective process. Not only does this save the company responsible for cooling the concrete money, but it also helps the client reduce its overall project budget. The savings of aggregate cooling by water often translate to the client. As a result, the client may be able to dedicate more funds to aspects of their project that could benefit from a greater amount of capital.

SEMCO/SEMCOLD LLC Provides Quality Concrete Cooling Systems

Aggregate cooling with water is simply one aspect of some concrete cooling systems. Other systems may utilize aggregate cooling with air or may not focus on aggregate cooling as a cooling method at all. Regardless of the concrete cooling system and method being used SEMCO/SEMCOLD LLC provides quality concrete cooling systems that are suitable for a full array of different situations and applications.

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Why Flake Ice Is Ideal for Use in Concrete Cooling Systems

Concrete is a strong, versatile material that is extremely popular and commonly used in a wide array of different large-scale commercial and industrial projects. Such major projects are often dubbed “large-pour” due to the significant amount of cement they pour at once to harden into concrete. However, such large-pour jobs generate a massive amount of heat, which if left unchecked can easily compromise the structural integrity and strength of the finished concrete. Fortunately there is a solution: concrete cooling systems that utilize flake ice.

Why Is Flake Ice the Industry Standard?

People automatically understand that when it comes to cooling ice is a very effective method. However, those outside of the concrete or industrial cooling industries may wonder why flake ice is the industry standard. The reason is that flake ice possess a number of very positive qualities that make it extremely successful for concrete cooling. Consider the following:

Flake Ice Is Energy Efficient

By far one of the most important reasons that flake ice is a good choice for concrete cooling is that flake ice is very energy efficient. Energy efficiency is key to getting the most value and benefit from the ice. Flake ice is so energy efficient for several key reasons including:

  • It has a higher relative surface than any other type of ice. More surface area equals more contact points for cooling.
  • Flake ice can be sub-cooled below freezing. This allows 100%, sometimes even more, of its latent cooling energy to be used on the concrete.
  • Flake ice is removed from the ice drum by shearing, as opposed to other loosening methods such as hot gases. This prevents energy loss from the hot gas heat.

Flake Ice Is Easy to Work With

Another important quality of flake ice is that it is very pliable and easy to work with. Because it is sub-cooled it remains “dry” and does not stick together in clumps, or form larger chunks that might otherwise clog equipment. The lack of clumping also allows the flake ice to retain its high relative surface area and preserve the energy efficient traits already discussed.

Flake Ice Melts Quickly

While concrete cooling is extremely important for large-pour projects it is also crucial that any ice used for cooling be thoroughly and completely melted during the cement-mixing process. If pieces of ice remain unmelted during mixing this can lead to weakness and non-uniformity in the finished concrete. Flake ice is a good choice for concrete cooling because its tiny size results in very rapid melting and averts the problems associated with incomplete melting.

Flake Ice Is Easily Automated & Conveyed

Along with being resistant to clumping and easy to work with, flake ice is also very easy to use with automated ice rake systems and is further easily transported and conveyed along throughout the system and into the cement with efficient equipment like blowing systems and screw conveyors. This results in a concrete cooling system that is very reliable without being labor intensive.

Flake Ice Is Economical

Flake ice is also a very economical choice, in large part due to the reasons discussed above. For example its energy efficiency saves energy costs and ensures the most value for the ice. Meanwhile its small size and rapid melting time ensures that mixing times are not extended, thus putting less strain on equipment and minimizing service and repair costs while often extending the life of the equipment. Its easy of use and suitability for automation also keep labor costs down and allow workers to spend their time and attention on other tasks.

Flake ice has established itself as the industry standard for large-pour concrete cooling systems and in the face of its many advantages and uses that primacy is almost certain to continue. SEMCO/SEMCOLD LLC designs and custom builds high quality concrete cooling systems that utilize flake ice and allow our clients to reap the full benefits these systems offer. Our systems are fully designed with each client’s needs in mind, ensuring that they get the most dependable and effective system possible for their applications.

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