Why Concrete Cooling Is Necessary For A Successful Project

Companies having concrete work done may have heard the term ‘concrete cooling’ used before. For some people who are unfamiliar with the concrete industry this term may have seemed confusing or surprising. Many people may have been left wondering why concrete cooling was necessary at all. Below is a discussion of why concrete cooling is important, what problems can arise from concrete that is too hot, which projects may be most in need of cooled concrete, and what factors can influence concrete temperature.

The Chemistry of Concrete

Though in casual conversation some people may use the terms “concrete” and “cement” interchangeably, it is important to understand the distinction. Cement is the mixture that, when combined with water, forms the material known as concrete. Concrete formation itself is accomplished through a process known as cement hydration. This essentially refers to the chemical bonding of cement aggregates with water. Concrete cannot harden and strengthen without hydration.

All chemical processes can be classified as either endothermic, meaning they absorb heat and thus lower the temperature of their surroundings, or exothermic, meaning they release heat and thus raise the temperature of their surroundings. The process of cement hydration involves mostly exothermic chemical reactions. Thus as hydration occurs the concrete gets hotter. In some applications concrete temperatures may exceed 200°F.

Problems Associated with Hot Concrete

As concrete hardens the process is known as curing. Unfortunately high curing temperatures for concrete can result in reduced tensile strength and performance. It is well documented that concrete that cures at temperatures of 95°F or higher will have significantly less strength than concrete that is cured at around 70°F.

Part of the problem is that concrete that is curing will expand at higher temperatures. This results in a less dense setting, thereby reducing the strength of the concrete. This is especially a problem in large-pour settings where the inner concrete may be significantly warmer than the outer concrete, sometimes by as much as 10-20°F, resulting in non-uniform density and weak spots.

Another problem associated with hot concrete is related to water evaporation. As most people are well aware, water evaporation occurs much more quickly at higher temperatures than at lower temperatures. Thus as the temperature of the concrete rises, more and more water is evaporated. Unfortunately since the process of cement hydration relies on water this can create serious problems and may prevent some of the cement from ever fully hydrating.

Industrial Applications Are Particularly Vulnerable to High Concrete Temperatures

Industrial settings are among the most vulnerable to problems associated with high concrete temperatures. This is because industrial settings often require large-pour applications, which as discussed above often results in higher concrete temperatures and potentially non-uniform density and reduced tensile strength and performance. Another reason that industrial settings are particularly vulnerable to strength problems associated with high concrete temperatures is because industrial settings require very strong concrete to begin with. Thus any weakness could prove catastrophic in an industrial setting, whereas in lower-demand settings it may not prove problematic. In industrial settings often the safety and integrity of the entire facility is dependent on the performance and strength of its concrete.

Factors That Affect Concrete Temperature

The temperature of concrete is most significantly affected by the water used in the hydration process. Thus concrete cooling methods often involve cooling the mixing water prior to hydration. However, the temperature of the cement aggregates is also important and by pre-cooling the aggregates lower hydration temperatures can also be achieved. Another method of concrete cooling is drum cooling, which involves cooling the concrete mixtures as it hydrates. Naturally many concrete cooling systems involve using these techniques in conjunction with each other for maximum performance.

SEMCO/SEMCOLD LLC is an industry leader in providing industrial cooling systems, including for the purpose of cooling concrete. Our systems can be fully customized based on the particular needs and preferences of each of our clients. Please contact us for more information about concrete cooling.

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Simple Ways to Increase Concrete Cooling Efficiency

Cooling is an important part of large-pour concrete projects. The process of mixing cement aggregates with water actually causes a chemical reaction to occur. This is a primarily exothermic reaction, which means that the reaction gives off heat. For small-pour projects this isn’t much of an issue because the reaction is smaller — however, even with small-pour projects, the quality of the concrete can often be improved with concrete cooling — but for large-pour projects in which temperature can easily exceed 200°F efficient concrete cooling is a must. When concrete is poured at such a high temperature the end product is going to be of a low quality.

Many construction companies are looking for an efficient concrete cooling system because they want to be able to provide their clients with top notch services and products. At SEMCO/SEMCOLD LLC we want to help you provide your clients with the quality concrete they deserve. Customization is a great way to increase concrete cooling efficiency.

Aspects of Concrete Cooling Systems

SEMCO/SEMCOLD LLC offers fully customizable concrete cooling systems. There are many different methods of concrete cooling which may include some or all of the following components:

  • Aggregate Cooling – There are two main types of aggregate cooling, either by water or by air. Aggregate cooling helps keeps the temperatures extremely low. Because you’re looking for efficiency, you should turn to the aggregate cooling with air because it allows you to continuously cool the aggregate with less space whereas the water has to be cooled and takes up a large amount of space.
  • Cold Water Tank and Water Chilling Plant – It helps to use cold water in your mixing process. The cold water tank can keep the water from your water chilling plant cold. The experts at SEMCO/SEMCOLD LLC will tell you that you need to have an insulated cold water tank to increase the efficiency of your concrete cooling system even more.
  • Ice Delivery and Weighing – Having the right system here can really increase the overall efficiency. This system delivers a predetermined amount of ice to the mixing drum. It makes the system more efficient because it can deliver ice in a consistent and reliable way.
  • Ice Plant – If your ice plant can make flake ice, you will have a more efficient cooling. Flake ice has the largest surface area, which allows it to cool the best, but it also melts quickly to keep the cooling uniform.
  • Ice Storage Bin – Having an insulated storage bin for your ice will allow you to make large quantities of ice at a time.

At SEMCO/SEMCOLD LLC we can help you build the most efficient concrete cooling system for your needs.

Concrete Cooling System Customization from SEMCO/SEMCOLD LLC

Every business has its own requirement, but every business also wants to be able to be the most efficient. With the customization offered at SEMCO/SEMCOLD LLC, you will be able to create the concrete cooling system that will be the best for you. Not only will the system do what you need it to, but it will also allow you to provide your clients with what they need. Contact us today to learn more about how you can make your concrete cooling system more efficient.

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Major Concrete Cooling Considerations

Every industrial large-pour concrete project has its own unique specifications. Local geography, climate, and architectural design are a few factors that may impact your project. If you have a large-pour concrete project coming up, you’re likely thinking of what you can do for the best chance of success, not just for the duration of construction, but for the long term. One of the most important things you can do is properly cool your concrete. Consider these following major factors.

The Need for Concrete Cooling

Concrete has been used industrially since Roman times, and many such structures are still standing, thanks to careful calculations and clever project management. You can’t argue with the fact that the hydration process produces an immense amount of energy. A 6 feet wide, 80 feet deep concrete shaft releases more energy than two bolts of lightning, and such excess heat, if unmanaged, can result in a product with reduced strength and increased tendency of cracking.

New Technology Can Help

A relatively new development is the measuring of concrete’s heat output during the curing process. Before a pour, wires can be installed to read the soil’s temperature. After the material is in place, the current reading from the same probes can be used to calculate the initial heat output of the fresh concrete. Engineers can use this data to predict the long-term reliability of the slab. While this may not be necessary for most concrete projects it is emblematic of the advances in technology that allow projects to run more smoothly and yield better results than ever before. At SEMCO/SEMCOLD LLC we keep up with the latest technological developments, and will work with whatever project specs you have.

Manage Costs

When it comes to questions like how low should you go in regards to water temperature, which components of concrete should be cooled, and how long should a post-pour cooling program last, a definite consideration is its cost. Here is a look at a couple of your options in terms of what we can do to meet your cooling needs:

  • Water Chilling – During the mixing process, water can be chilled to as low as just a couple of degrees Fahrenheit above freezing. In most cases, the lower the temperature drop, the more costly.
  • Aggregate Chilling – Cooling down the gravel or other small stones to be used in your mix can help in certain applications. There are at least two different methods: flooded silo or air chilling. Lowering the temperature of aggregates is not required for all projects, so check with your engineers to decide if it’s worth the additional investment.
  • Post-Pour Cooling – Post-pour cooling methods are typically among the most costly cooling methods and are generally only used in large-scale projects.

SEMCO/SEMCOLD LLC Provides Industry-Leading Concrete Cooling Systems

Concrete cooling is a great way to ensure a safe, durable end product. Contact SEMCO/SEMCOLD LLC to learn what we can do to help you meet not just the building code, but deadlines, and budget requirements as well. All of our systems are fully customizable and can be designed with your particular specs in mind.

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4 Problems Caused by Improper Concrete Cooling

In industries where concrete is used, it is important for workers to understand the extreme importance of properly concrete cooling. If proper cooling methods are not used, a number of problems can occur, including a weaker finished product that is irregular and more susceptible to cracks and other damage. In addition, temperatures that are too high can interfere with the chemical process involved when cement becomes concrete. In this article let’s explore 4 serious problems that can be caused by improperly cooled concrete.

Improper Concrete Cooling Is Often Weaker

Concrete that has been created under overly high heat conditions is not as strong as it could be. The process of hardening concrete is called curing, and generally when concrete is cured at temperature above 70 degrees Fahrenheit, the strength and resilience of the concrete is greatly reduced. This is due to the chemical reaction that happens when concrete is formed. Temperatures that are too high can speed this process up, which does not allow for proper crystal formation within the material. This can be a disaster in many industries where durable, reliable materials are required.

Improperly Cooled Concrete Is often Irregular

When concrete is poured over a very large area and is prepared at temperatures that are too high, this can lead to an irregular material that is weaker in some places than it is in others. This is because of the temperature differentials caused by a concrete creation process that is too hot, and thus, goes too fast. In the same way that weak concrete is a hazard, uneven concrete poses similar risks, especially when the project is of the large-pour type. In these cases, central areas of the concrete may be a drastically different temperature than outer areas.

Improperly Cooled Concrete Is in More Danger of Cracking

Weak concrete is a very real problem. If concrete is less dense because of poor cooling practices, it can be more susceptible to cracking. Depending on the location of the concrete, this can possibly be catastrophic and could result in major accidents, injuries, costly property damage, and facility outages as the damage is repaired. Any industry where extremely strong, hardy concrete is required, a cracking hazard can be dangerous and costly.

Improperly Cooled Concrete May Not Undergo Full Hydration

To understand this negative outcome of improper cooling, one needs to understand first how concrete is formed. Concrete starts with a mixture called cement, which, when combined with water, undergoes a chemical transformation and becomes concrete. This process is called hydration. When temperatures are too high some of the water needed for the hydration process is in danger of evaporating, leaving some of the concrete un-hydrated.

There are a wide variety of ways that you can properly cool concrete to avoid any of these negative outcomes. Different concrete cooling methods involve different processes and equipment and may range in complexity from simply using colder water to full-scale post-pour cooling using a network of pipes inside the pour concrete – and many other techniques in between. The good news is that regardless of how large the project is, the concrete absolutely CAN be fully and adequately cooled, improving its quality and durability. SEMCO/SEMCOLD LLC designs and manufactures high quality, customizable concrete cooling systems. Contact us for more information and to discuss your concrete cooling needs.

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How to Know When It’s Time to Replace Your Concrete Cooling System

If your industry involves concrete work, you are already aware of the importance of having concrete properly cooled before it hardens, or cures. Because the process of mixing cement with water to obtain concrete is a chemical process that releases heat, concrete will be very hot unless it is cooled through a specially designed system. Let’s take a look at some factors that could indicate it is time to upgrade or replace your current concrete cooling system, but first let’s also take a quick look at why concrete cooling is necessary.

Why Is Concrete Cooling Necessary?

Concrete that cures at higher temperatures will be less dense, since the heat will cause greater expansion; since heat distribution tend to be uneven, the concrete’s density will also be uneven. High temperatures also cause water to evaporate faster, leading to insufficient hydration of the concrete and a reduction in tensile strength. These two factors cause weaker, more brittle concrete; in industrial settings, where concrete strength is essential, this flaw can be disastrous. For this reason, companies engaging in concrete construction and other concrete projects use concrete cooling systems such as those manufactured by SEMCO/SEMCOLD LLC to bring their concrete to an appropriate temperature.

Concrete Cooling Methods

There are several types of cooling systems and methods available today, each of which has its own set of advantages and disadvantages. The simplest method is adding cold water and ice to the water that will be mixed with the cement. This method requires calculating the necessary temperatures based on the quantity of material. Using a cooling system to bring the water’s temperature down is quicker and more efficient, especially in the case of larger quantities. Water cooling is achieved by flooding the silos with cold water and draining them once the mixture is cooled, which uses a lot of space and is wasteful of water. Another effective method is the wet belt system, which uses small amounts of ice water transported by conveyor belts.

Another way of cooling the concrete components, or aggregate, is via cold air that is circulated throughout the materials. This method takes more time than cooling the water, but is optimal in small, enclosed spaces since it doesn’t require a separate system of removing the water.

Air and water cooling are often supplemented by sand cooling to ensure that the mixture’s temperature stays cool throughout the process. Sand cooling is particularly useful for large projects. Sand cooling systems may include rotary cooling drums or sand silos. This method has the advantage of achieving cooler temperatures for longer times, at lower energy costs; however, it involves expensive equipment and more time in order to cool the sand.

A less frequent method is post-pouring cooling, which involves laying pipes before the concrete is poured, then sending cold water to circulate through the pipes after they are covered with the concrete. This method is very expensive and time-consuming. Typically, it is only employed for supersized projects like dams or highways.

No matter which concrete cooling system you have in place, it is highly important to ensure that it stays in good working order. It is crucial that it be repaired or replaced as necessary and that maintenance concerns are not ignored.

Risks of Inadequate Cooling

One of the clearest indicators that it could be time to replace your concrete cooling system is if the concrete is being inadequately cooled. A suboptimal system will produce inferior concrete, create potential safety concerns, and raise energy costs. If you find that your concrete quality is not up to standards, especially with what you expect from your cooling system, that is a clear indicator it’s time to make some changes.

Frequent Repairs

Going hand-in-hand with inadequate cooling as a key indicator of the need to upgrade your system, is frequent repairs. While regular maintenance is a must, and periodic repairs may be routine, an uptick in problems and rising maintenance costs can indicate that your system is nearing the end of its life. Eventually repairs or part replacements won’t be able to fully fix an issue or will be needed far too often to be cost effective. It is thus essential to know when it is time to replace your system entirely. Eventually the cost of repairs will outweigh the cost of purchasing a new system, especially if frequent breakdowns delay your projects’ schedules and overall productivity.

Outdated Technology

How long have you been using the same cooling system? With today’s rapid advances in technology, it may be time to see if a newer system will meet your needs better. Improvements in energy efficiency, precise temperature calibrations, and delivery mechanisms can make a new customized SEMCO/SEMCOLD LLC system a worthwhile investment.

Rising Energy Costs

Take a look at your energy. If your system is using increasingly more water and energy to obtain the same results, it is a sign that it is deteriorating. Not only will increasing utility costs soon outweigh the expense of a new system, but continuing to use a decreasingly functional system will inevitably compromise the quality and integrity of the concrete. A system with poor energy efficiency can also be a major black eye for a company that wants to market itself as energy or eco-friendly.

Subpar Performance

Always monitor your system’s performance, carefully checking that your concrete has been cooled to its appropriate temperature. Consistent failures to achieve goal temperatures, or taking increasingly longer to achieve them, are indications that your system is no longer coping with its workload. Whether your system has deteriorated, or its workload has changed or increased, this is a clear sign that it is no longer the right system for you.

Changing Needs

Finally, if your company has dramatically changed the quantity or nature of its concrete projects, it may be time to reconsider whether your existing equipment is still the most appropriate. Do not let inertia carry you along into continuing to use older equipment just because it still works. If the direction of your company is changing, it may be time to look into a new SEMCO/SEMCOLD LLC concrete system that will be fully customized to your current needs.

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