TEMPERATURE PREDICTION OF CONCRETE VIA

NUMERICAL ANALYSIS

Project No: STR/2017/039

By

H.P.RATHNAYAKA
PG/E/ST/2017/039

Supervised by

Dr. H.D.YAPA

Department of Civil Engineering

Faculty of Engineering
University of Peradeniya
Peradeniya 20400
Sri Lanka
February, 2018

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 ABSTRACT

Concrete is the most widely used man-made material. Large volume of concrete used
in construction industry. Use of High strength concrete is getting popular in Sri Lanka also.
Due to use of high strength concrete in large volumes, temperature rise is an important
parameter. Effect on temperature rise are early thermal cracking, induce tensile stains in the
concrete, reduction of water tightness, reduction of durability and reduction of strength.
Temperature prediction methods still been developing due to construction methods,
formwork types, cement chemistry, cement fineness, supplementary cementing materials
(SCMs) and chemical admixtures are differ from place to place. So these temperature
prediction methods may need to be adopted to local condition. Methodology of this research
is Formulation of FE model, Validation of FE model with experimental data, Experiments
on industry used concrete mixtures to develop adiabatic curves and Composition of Set of
guideline to control temperature in typical structures.

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 ACKNOWLEDGEMENTS

The success and final outcome of this research required a lot of guidance and assistance from
many people and I am extremely privileged to have got this all along the completion of my
research. All that I have done is only due to such supervision and assistance and I would not
forget to thank them.

I respect and thank Dr.H.D.Yapa, for providing me an opportunity to do the research work
in “Temperature Prediction of Concrete via Numerical Analysis” and giving us all support
and guidance. I am extremely thankful to him for providing such a nice support and
guidance, although he had busy schedule managing the corporate affairs.

I owe my deep gratitude to Dr. J.A.S.C. Jayasinghe and Dr. C.S.Bandara, who took keen
interest on our project work and guided us all along by providing the comments, information
and reviewing.

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 TABLE OF CONTENTS

ABSTRACT .......................................................................................................................... 2
ACKNOWLEDGEMENTS .................................................................................................. 3
TABLE OF CONTENTS ...................................................................................................... 4
LIST OF FIGURES ............................................................................................................... 5
LIST OF TABLES ................................................................................................................ 6
CHAPTER 1 .......................................................................................................................... 7
INTRODUCTION ............................................................................................................. 7
1.1 Heat Generation in Fresh Concrete ................................................................... 7
1.2 Objectives .......................................................................................................... 7
CHAPTER 2 .......................................................................................................................... 8
LITERATURE REVIEW .................................................................................................. 8
2.1 Introduction ....................................................................................................... 8
2.2 Composition and Hydration of Portland Cement .............................................. 8
2.3 Measuring temperature rise in concrete............................................................. 9
2.4 Adiabatic temperature measurement ................................................................. 9
2.5 Semi adiabatic temperature rise ....................................................................... 10
2.5 Heat loss compensation ................................................................................... 12
2.6 FE Model ......................................................................................................... 15
CHAPTER 3 ........................................................................................................................ 16
MATERIALS AND METHODS .................................................................................... 16
3.1 Methodology.................................................................................................... 16
3.2 Develop adiabatic curves ................................................................................. 16
3.3 Experimental data in to modeling.................................................................... 17
CHAPTER 4 ........................................................................................................................ 19
RESULTS AND DISCUSSIONS ............................................................................... 19
4.1 Results ............................................................................................................. 19
4.2 Discussion........................................................................................................ 20
WORK SCHEDULE ........................................................................................................... 21
REFERENCES .................................................................................................................... 23

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 LIST OF FIGURES

Figure 4.1: Biodegradation of 2-nitroaniline during an ANSBR cycle ..... Error! Bookmark
not defined.
Figure 2.1: Adiabatic test apparatus .................................... Error! Bookmark not defined.

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 LIST OF TABLES

Table 4.1: Inhibition test results (2-nitroaniline = 100 mg/L) ............ Error! Bookmark not
defined.

You are free to add a LIST OF ABBREVIATIONS page if necessary.

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 CHAPTER 1

INTRODUCTION

1.1 Heat Generation in Fresh Concrete

One of the most important factors associated with thermal cracking in concrete is the
evolution and distribution of the temperature increase throughout the section at any time
after casting. The temperature increase is a direct result of the heat evolved from the
hydration of the cement. The hydration reaction of cement is exothermic in nature and results
in a significant production of heat inside the hardening concrete.

The purpose of an introduction in the report is to justify the reasons for writing about your
topic. Your goal in this section is to introduce the topic to the reader, provide an overview
of previous research on the topic, and identify your own hypothesis. Literature should be
cited in the text by the author's surname and year of publication: e.g. “Smith (1997)
reported ...” or “This result has been observed by at least one other worker (Smith, 1997)”.
When there are two authors, the citation is as such: e.g. (Lim and Chee, 1997). But when
there are more than two, all other authors except the first are indicated by the Latin
abbreviation ‘et al.’, for example “Tan et al. (1997) discovered...”

1.2 Objectives

Main objectives of this research are,

▪ Formulation of FE model
▪ Validation of FE model with experimental data
▪ Experiments on industry used concrete mixtures to develop adiabatic curves
▪ Composition of Set of guideline to control temperature in typical structures

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 CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

Under Literature Survey a comprehensive review was done on previously performed

research for following sections,
▪ Adiabatic temperature rise
▪ Semi adiabatic temperature rise
▪ Heat loss compensation
▪ MIDAS model development and validation process

2.2 Composition and Hydration of Portland Cement

Portland cement is a composition of several different chemicals: SiO2, Al2O3,

Fe2O3, MgO, SO3, C3A, C3S, C2S and C3AF are the main components of Portland
cement. The proportions of these components change in different types of cements.
The major compounds of Portland cement are C3S, C2S, C3A and C3AF. These
constituents have different contributions in heat of hydration of cement. Table 2-2 shows
heat of hydration of main components of Portland cement as reported by Cannon (1986).
These numbers have been originally determined by heat of solution method by Lerch and
Bogue (1934).
Table 1.1: Specific Heat of Hydration of Individual Compounds of Portland Cement
Compound Specific Heat of Hydration (cal/gr)
C3 S 120
C2 S 62
C3A + gypsum 320
C3AF 100

Heat of hydration of Portland cement can be calculated as the sum of specific heat
of each compound weighted by the mass percentage of the individual compound
(Swaddiwudhipong et al., 2002) Cement content of concrete is the next factor in heat

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generation. As cement is the main source of heat generation during the hydration process,
larger portion of cement leads to larger amount of heat generated.

Another factor that affects the thermal behavior of concrete is cement fineness. The cement
fineness affects the rate of heat generation more than the total generated heat (Price, 1982).
Greater fineness increases the surface available for hydration, causing more rapid generation
of heat. This causes an increase in rate of heat liberation at early ages, but may not influence
the total amount of heat generated in several weeks.

Placing temperature of concrete is another effective element on the maximum temperature

of concrete. A higher initial temperature results in higher maximum temperature. The inner
part of a mass concrete element is in a semi-adiabatic condition, which means heat exchange
with the outer environment is very difficult. Therefore the initial heat entraps and the heat of
hydration adds to the initial temperature. Placing temperature also affects the rate of
adiabatic temperature rise of concrete.

2.3 Measuring temperature rise in concrete

A large amount of heat is generated during the hydration process of cementitious material in
mass concrete elements. A great portion of generated heat that is trapped in the center of
mass concrete element escapes very slowly because concrete has a low conductivity. This
situation leads to a temperature difference between center and outer part of the mass concrete
element. Temperature difference is a cause for tensile strains, which in turn is a source for
tensile stress. Tensile stress forms cracks in concrete structure. These cracks are called
thermal cracks. Various test methods such as the heat solution method, adiabatic calorimeter
method, and semi-adiabatic calorimeter method are available to measure the heat of
hydration and the resulting temperature rise of concrete.

2.4 Adiabatic temperature measurement

One of the most popular methods to predict the mass concrete peak temperature
rise is using adiabatic temperature rise curves. These curves have been developed for
concrete with different cement types and placing temperature. The measurement method

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consists of introducing into the calorimeter a sample of fresh concrete just after the mixing
and measuring the temperature of the specimen.

Figure 2.1: Adiabatic test apparatus

Adiabatic calorimeters rely on the principle that, at any time during the test, the temperature
of the sample surroundings must be equal to the temperature of the concrete. This condition
requires that additional heat be supplied from outside. This has a computer-controlled
environmental chamber maintain air temperature inside the chamber within ±0.2 °C of the
preset value. To maintain and monitor in such a precision needs sophisticated modern
equipment and the cost of the test is high. So as an alternative Semi adiabatic test and heat
lose compensation has introduced in literature.

2.5 Semi adiabatic temperature rise

Several different versions of semi-adiabatic curing tests have been developed. In general,
due to heat loss, that is, heat dissipation from the concrete specimen to the surroundings, the
measured temperature rise is lower than the adiabatic temperature rise by an error dependent
on the specimen size and the effectiveness of the heat insulation provided. With similar heat
insulation provided, the error is larger for a smaller specimen size and smaller for a larger
specimen size, while for the same specimen size, the error is larger with less heat insulation
provided and smaller with better heat insulation provided. Consequently, the measured
temperature rise by a semi-adiabatic curing test is highly dependent on the test setup.

The test setup for the semi-adiabatic curing test is quite simple. It consists only of an
insulated mold, several thermocouples for measuring the temperature of the concrete and the
ambient temperature, and a data logger for recording the temperature readings. The

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temperature readings were taken at 5-minute intervals and recorded for data analysis after
the curing test was completed.

Figure 2.2: Test setup for semi-adiabatic curing tests

Wooden mold provided with both internal and external heat insulation internal insulation -
the 400 mm concrete cube specimen being cast as the phenolic polymer has lower heat
capacity and heat conductivity than the plywood, this arrangement would minimize the
amount of heat absorbed by the mold. The temperature of the specimen measured using
thermocouples at four locations. Centre of mass, centre of one face, mid-point of an edge
and one corner.

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 Figure 2.3: Thermocouples arrangement of the sample

Four additional thermocouples were attached to the centres of three side faces and the top
face of the external shell respectively to measure the ambient temperature

2.5 Heat loss compensation

The test method with heat loss compensation was cross-verified by adiabatic curing tests of
a large number of concrete mixes to be highly accurate (Ng et al.,2008) Its reliability has
been confirmed by numerous successful applications (Ng et al., 2009a; Kwan et al., 2011a,
2011b, 2012)

The conceptual basis and mathematical derivations of heat loss compensation are presented
in this section. Specimen of volume V, Volumetric mean temperature of the concrete TV,
the placing temperature TP, Adiabatic temperature rise be TG. The measured temperature
rise (TV – TP) is lower than the adiabatic temperature rise TG by an amount proportional to
the heat loss HL and ψ is the volumetric specific heat capacity of concrete,

TV – TP = T G – H L
Vψ
Re arranging,
TG = T V – T P + H L
Vψ

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Applying the Fourier Law to the heat conduction through the insulating materials, the rate
of heat loss,

∂HL = k(TS – TA)

∂t
k overall thermal conductivity of the insulating materials. According to Morabito and
Barberis (1993), for adiabatic curing test, l may be determined after completion of the test
by setting the temperature of the surrounding medium at an arbitrary low level to deliberately
allow cooling of the concrete specimen and measuring the corresponding rate of temperature
drop with time. TS surface mean temperature of the concrete, TA ambient temperature, t is
the time after placing of the concrete, the heat loss HL
𝑡
HL = 0
k ( TS – TA )dt

Substituting the above formulae for the heat loss, the adiabatic temperature rise TG

k 𝑡
TG = T V – TP + k ( TS – TA )dt
Vψ 0
TG = (TV – TP) + k ∑ (TS – TA) Δti
Vψ
Since the temperature difference varies quite slowly with time, a constant time interval of
five minutes was found to yield accurate results. Substituting the above formulae for the heat
loss, the adiabatic temperature rise TG

TG = (TV – TP) + k ∑ (TS – TA) Δti

Vψ
Since heat loss is a characteristic of the test set-up, can determined from the temperature
difference (TS – TA) and the corresponding rate of drop of TV with t when there is no further
heat generation from the concrete.

𝜕Tv k
= (Ts − TA )
𝜕t Vψ

Theoretically, the volumetric mean temperature TV and surface mean temperature TS,
1 ⬚
TV = 𝑣
T(x, y,z) dV
𝑉

1 ⬚
TA = T(x, y,z) dA
𝐴 𝐴

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Temperature profile within the concrete volume approximated by a quartic polynomial
curve,
T(x, y, z) = 𝑤 1 +𝑤 2 (𝑥 4 +𝑦 4 +𝑧 4 ) +𝑤 3 (𝑥 4 𝑦 4 +𝑦 4 𝑧 4 +𝑥 4 𝑧 4 ) +𝑤 2 (𝑥 4 𝑦 4 𝑧 4 )

By substituting Tm, Tf, Te, and Tc;

64 48 12 1
TV = Tm + Tf + Te + Tc
125 125 125 125
16 8 1
TA = Tf + Te + Tc
25 25 25

Using the below equations, the adiabatic temperature rise at any time t can be determined
from the semi-adiabatic curing test results.

TG = (TV – TP) + k ∑ (TS – TA) Δti

Vψ
64 48 12 1
TV = Tm + Tf + Te + Tc
125 125 125 125
16 8 1
TA = Tf + Te + Tc
25 25 25

At a sufficiently long time after placing of the concrete, there should be no further heat
generation from the concrete and TG would become fairly constant. Based on experimental
findings, this happens at about 120 hours after placing of concrete.

Figure 2.4: Temperature Rise Curve with heat lose compensation

Using the above equations, the adiabatic temperature rise at any time it can be determined
from the semi-adiabatic curing test results. It is noteworthy that the size of concrete specimen

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may be increased so as to reduce the heat dissipation per concrete volume to the
surroundings, and hence to decrease the reliance on heat loss compensation. Nevertheless,
as the heat dissipation is inevitable, heat loss compensation should always be applied.

2.6 FE Model

The analyses of heat of hydration in a general 3D space, is proposed in this section. The
thermal behavior is carried out by using a 3D finite element approach. The theoretical model
presented above is accounted into the commercial FE code Midas/FEA (Midas-IT-User-
Manual, 2010) with the aim to investigate the hydration and heat transfer of the considered
concrete samples.
MIDAS calculates changes in nodal temperatures with time due to conduction, convection
and heat source in the process of cement hydration.

In Midas FEA Training Series HA-1. Heat of Hydration – Cooling Pipes has clearly given
the steps how to analyze heat of hydration in a concrete block.

Figure 2.5: Midas HA-1. Heat of Hydration – Cooling Pipes tutorial

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 CHAPTER 3

MATERIALS AND METHODS

3.1 Methodology

As a matter of principle, the mechanical behavior of concrete can be predicted by modeling

in detail the complex phenomena arising from the hydration reaction which develops during
the setting and hardening phases and results in the heat flow often responsible of premature
cracking (van Breugel, 1991)

Methodology used in this research is,

• Develop adiabatic curves
• Development of FEM model
• Validation FEM model
• Experiments on industry used concrete mixtures
• Composition of Set of guideline

Under 1st phase of this research, Up to validation of FEM model has done. The primary
objective of the current study is to extend the Madupushpa’s method for concrete
temperature development with semi-adiabatic experiments to finite element model analysis.
The potential of the predictor is verified with an experimental investigation comprising a
concrete block cast in two stages.

3.2 Develop adiabatic curves

In Madupushpa’s method, the measured temperature from the experiment and calculation
done to get the adiabatic temperature rise is mentioned in the Appendix 1. Following figure
shows the resulting semi-adiabatic temperature behavior and the adiabatic temperature
profile predicted with the heat loss compensation method. The maximum semi-adiabatic
temperature rise is 33℃ and the maximum adiabatic temperature rise is 53.5℃. The

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compressive strength of the cubes at 28-days is 46.9 MPa.

60

50

40

30

20

10

0
0 20 40 60 80 100 120 140 160

Adiabatic Temperature Rise Semi Adiabatic Temperature Rise

Figure 3.1: Adiabatic Temperature Rise and Semi Adiabatic Temperature Rise

3.3 Experimental data in to modeling

For the verification of the prediction model, a 1000 mm × 7000 mm × 350 mm concrete
specimen is cast with a 12 mm plywood formwork in to a concrete floor. After 18 hours, the
formwork is removed and a second block having 1000 mm × 350 mm × 350 mm dimensions
is cast on the first block, see Figure 3. The concrete mix proportions selected for a grade 35
concrete are so that: OPC- 493 kg/m3 , Fine aggregate- 652 kg/m3 , Coarse aggregate- 992
kg/m3 and water- 212 kg/m3 . For the two segments of cast, three thermocouples are fixed
at the locations shown in Figure 3. All the temperature measurements are detected for 140
hours at 30 min. intervals via a data logger. Simultaneously, a semi-adiabatic calorimeter
test is conducted for a sample obtained from the same concrete mix. The semi-adiabatic
specimen is cast in a 200 mm × 200 mm × 200 mm size regiform box which was placed in
another large outer regiform box, and regiform balls were filled between as an insulation
material. The test is carried on the entire 140-hour period and two-point temperature
measurements along with the ambient temperature are acquired using the data logger. The
final heat loss characteristic value (𝜆) is computed to be 0.023 by averaging estimated heat
loss during 120 to 140 hours.

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Figure 3.2: Temperature measuring points of 1st step and 2nd step concrete elements done
for the experiment

Modeling of this was done through MIDAS only for the 1st stage. The base,1st stage
concrete was modeled as 3D elements and meshed.

Figure 3.3: FE Model in Midas

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 CHAPTER 4

RESULTS AND DISCUSSIONS

4.1 Results

Midas model was developed to the specifications in the Madupushpa et al,2017 and
validated comparing the results gained from the experimental model described.

Temperature
60

50

40
Temperature [°C]

30

20

10

0
0 20 40 60 80 100 120 140 160
Time(hr)

Predicted Temperature Rise Actual Temperature Rise

Figure 4.1: Predicted Temperature Vs Actual Temperature Rise

Figure 4.1 shows a comparison between the predicted and measured temperature variation
of the centre node (A). The comparison is almost similar for the first ten hours, thereafter a
deviation is noticed.

Peak temperature in actual 55 °C occurred at 13.5h whereas Peak Temperature in model 47

°C occurred at 12.5h. The deviation of the predicted maximum temperature is 14.5% from

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the experimental value. Almost throughout the descending branch, the predicted temperature
profile is observed to be over the measured profile.

4.2 Discussion

Temperature profile has captured by Numerical prediction model of the concrete mass to a
good level of accuracy. The correlation between the predictions and measurements is
impressive particularly in the ascending branch. Since the ascending branch is more critical
towards thermal cracking, it is a good attribute of the predictor. The potential of the predictor
towards segmental concrete casting situations also sounds good. The discrepancies observed
could be due to inaccuracies in the thermal parameters used, disregarding of radiation heat
loss, shortcomings associated with the semi-adiabatic to adiabatic temperature conversion
etc. Further investigation into these areas are matters for future work.

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 WORK SCHEDULE
Description July August September October November December January February March

Literature Survey

Adiabatic Heat of hydration curve

FE Model Development

FE Model Validation through literature

Report Writing

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22
 REFERENCES

Journal articles

Ballim, Y., 2004. A numerical model and associated calorimeter for predicting temperature
profiles in mass concrete. Cement & Concrete Composites, Issue 26, pp. 695-703.

Ballim, Y. & Graham, P., 2003. A maturity approach to the rate of heat evolution in concrete.
Magazine of Concrete Research, June, Issue 55, pp. 249-256

Kyle, A. R. et al., 2006. Evaluation of temperature prediction methods for mass concrete
members. ACI Materials Journal, September-October, 103(5), pp. 357-365.

Ng, P., Ng, I. & Kwan, A., 2008. Heat loss compensation in semi-adiabatic curing test of
concrete. ACI Materials Journal, January-February, 105(1), pp. 52-61.

Ng, I.Y.T., Ng, P.L., Kwan, A.K.H., Effects of Cement and Water Contents on Adiabatic
Temperature Rise of Concrete. ACI Materials Journal. Volume 106, No 1, pp42-49. (2009a).

Ng, P.L., Ng, I.Y.T., Kwan, A.K.H., Adiabatic Temperature Rise of Incompletely
Hydrated Cement Concrete. Key Engineering Materials. Volume 400-402,
pp157-162. (2009b).

Ng, P.L., Ng, I.Y.T., Fung, W.W.S., Chen, J.J., Kwan, A.K.H., Adiabatic Temperature Rise
of Pulverised Fuel Ash (PFA) Concrete. Advanced Materials Research. Volume 168-170,
pp570-577. (2011a).

Ng, P.L., Fung, W.W.S., Chen, J.J., Kwan, A.K.H., Adiabatic Temperature Rise of
Condensed Silica Fume (CSF) Concrete. Advanced Materials Research. Volume
261-263, pp788-795. (2011b).

Madupushpa, K.D., Kahatapitiya, N.K.S.S., Yapa, H.D., Numerical Prediction of Concrete

Temperature. ACEPS-2017, pp347-354.

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Wasala, W. T., 2014. Prediction of heat development in concrete using semi adiabatic
temperature measurements, MEng Thesis,University of Peradeniya.

Books or a report

Midas FEA User Manual - Analysis and Algorithm.

Adiabatic Temperature Rise of Mass Concrete in Florida, Abdol R. Chini and Arash Parha.
Report Submitted to Florida Department of Transportation (Contract No. BD 529)

Others

Midas FEA Training Series, HA-1. Heat of Hydration – Cooling Pipes.

(http://en.midasuser.com/training/tutorial_read.asp?idx=336&pg=1&so=&sort=&bid=6&n
Cat=&nCat2=128&bType=&totCount=32)

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