Strength. Performance. Passion.

2013 Holcim Beton

Management Mass Pour Raft Foundation

Holcim Beton, 2013-02-13 2013 Holcim Beton

"Innovative concrete solutions, proudly delivered by people you can trust"PT. Holcim Beton

2013 Holcim Beton

Holcim BetonWhy we have to put more concern

Holcim Beton, 2013-10-06 2

Period Project Volume

(M)

Status

May 2007 Menara Bakrie 9,070 Completed

Jul 2007 Kuningan Place 6,431 Completed

Aug 2007 Kuningan Place 3,278 Completed

Sep 2007 Labuan 2 3,747 Completed

Oct 2007 Plaza Indonesia 1st 6,421 Completed

Oct 2007 Plaza Indonesia 2nd 6,755 Completed

Nov 2007 Labuan 2 5.792 Completed

Jan 2008 ST Regis 6.000 Completed

Feb 2008 ST Regis 6.000 Completed

Sep 2008 Kemang Village 6.000 Completed

Apr 2009 Kemang Village 6080 Completed

Mar 2013 Provident Park 7200 Completed

Beton Tebal dan Volumenya Besar

2013 Holcim Beton

1. Heat of Hydration and Thermal Crack (low initial temperature,

different temperature and peak temperature)

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

3. Plastic Settlement and bleeding ( low slump )

4. Cold join ( initial setting time and pouring method)

5. Pouring management plan to ensure delivery, unloading,

pouring and compacting to avoid cold join

What are focus&

Holcim Beton, 2013-10-06 3

2013 Holcim BetonHolcim Beton, 2013-02-13 4

Temperature calculation Reff. ACI 305 R 99

2013 Holcim Beton

Material Temperatur (o C)

Cement 70

Fly Ash 45

Agregate 30

Water 29

Exercise 1

Holcim Beton, 2013-02-13 5

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

Initial Temperature with ice (20 Kg) = 31.16 (o C)

Ada penambahan kenaikan suhu 2-3 o C untuk 1

jam perjalanan

2013 Holcim BetonHolcim Beton, 2013-02-13 6

Typical initial concrete temperature: 37 0C

To achieve low initial concrete around 1oC (ACI 305R-11)

can be done by lowering the temperature as follow: Cement 8 oC or

Water 4 oC or

Aggregate 2 oC

Low Initial Concrete Temperature &.

2013 Holcim Beton 7Holcim Beton, 2013-02-13

Maximum different temperature 20 oC between layer

Different Temperature

2013 Holcim BetonMass Pouring

Plastic

Styrofoam/polystyrene 2.5+2.5+5 cm

Curing Compound

Beton

50 C

Temperature

Monitoring

Monitor Temperature - Thermo Couples

2013 Holcim Beton

Estimated peak Temperature

Holcim Beton, 2013-10-06 9

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

(120 140 C Normal Concrete)

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

= 91.37o C

To prevent crack related to heat hydration, the difference of temperature per layer () should be < 20 oC. Insulator has to be installed.

Thermo couples reading on every 4 hours should started 12th hour up to 36th hour then reading on every two hours after 36th hour.

Cement content 400 KgPeak temperature (0 C) Initial cc fa constanta FA Constanta depth 2-4 m88.01 MIX 15 % FA 35.45 396 70 0.6 12

2013 Holcim Beton

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

Holcim Beton, 2013-02-13 10

2013 Holcim BetonProvidence Park

Data Trial Mix

0%

20%

40%

60%

80%

100%

120%

140%

160%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Pondok Indah

Kembangan

Rambutan

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

-10%

10%

30%

50%

70%

90%

110%

130%

150%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Pondok Indah

Kembangan

Rambutan

Perkembangan Kuat Tekan Trial Mix Fc 35 Mpa Fa 25% February 2013

2013 Holcim BetonProvidence Park

Reference Project Adiabatic Fc 35 Mpa with Flyash 20 %

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

1

2

-

F

e

b

1

3

-

F

e

b

1

4

-

F

e

b

1

5

-

F

e

b

1

6

-

F

e

b

1

7

-

F

e

b

1

8

-

F

e

b

1

9

-

F

e

b

2

0

-

F

e

b

2

1

-

F

e

b

2

2

-

F

e

b

2

3

-

F

e

b

2

4

-

F

e

b

2

5

-

F

e

b

Titik bawah

titik tengah

titik atas

t1mid-bottom

t2mid-up

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

1

2

-

F

e

b

1

3

-

F

e

b

1

4

-

F

e

b

1

5

-

F

e

b

1

6

-

F

e

b

1

7

-

F

e

b

1

8

-

F

e

b

1

9

-

F

e

b

2

0

-

F

e

b

2

1

-

F

e

b

2

2

-

F

e

b

2

3

-

F

e

b

2

4

-

F

e

b

2

5

-

F

e

b

Titik bawah

titik tengah

titik atas

t1mid-bottom

t2mid-up

Peak Temp on 71.7C on 3rd day after Pouring

Peak Temp on 75.8C on 2nd day after Pouring

2013 Holcim BetonProvidence Park

Pelaksanaan Penempatan titik pengujian suhu dengan termo couple

2013 Holcim Beton

0

20

40

60

80

100

0 5 10 15 20 25 30 35 40 45 50

C

e

l

c

i

u

s

to Hour

Point 8

Mid

Top

Bottom

Mid-Top

Mid-Bottom

0

20

40

60

80

100

0 5 10 15 20 25 30 35 40 45 50

C

e

l

c

i

u

s

to Hour

Point 9

Mid

Top

Bottom

Mid-Top

Mid-Bottom

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

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

2013 Holcim Beton

Preparing at site project

PT Holcim Beton, 2013-05-28 15

Cleaning waste concrete cuci talang truk mixer & waste sampling and

check slump test

Coordination community by project

Coordination Policy by Holcim

Supporting area for check slump test, sample and central dispatch : Tend

Chair & Table

Computer

Power and Listrik

Survey access road condition

Survey project location

Provide washout facility

Survey traffic and safety

2013 Holcim Beton

Supply Chain

PT Holcim Beton, 2013-05-28 16

NO BATCHING PLANT NUMBER

OF TRUCK

PLANT CAPACITY CYCLE

TYME

1 SITE PLANT 5 40 M3/HOURS 15 mnt

2 KUNINGAN 16 60 M3/HOURS 40 mnt

3 KAMPUNG

RAMBUTAN

21 56 M3/HOURS 45 mnt

4 PLUMPANG 25 84 M3/HOURS 60 mnt

5 KEMBANGAN 25 84 M3/HOURS 60 mnt

Batching Plant Holcim Beton

For continunos supply for mass pouring raft foundation will be

available total truck 93 units .

2013 Holcim Beton

Traffic Management

PT Holcim Beton, 2013-05-28 17

2013 Holcim Beton

Holcim Beton

PT Holcim Beton, 2013-05-28 18

Plant PlumpangPlant Plumpang

Plant Rambutan

Plant Kembangan Plant Kuningan

2013 Holcim Beton

Delivery System

PT Holcim Beton, 2013-05-28 19

Dispatching System :

Central Dispatch Center will be manage and planning concrete from our

batching plant

Track monitoring truck with GPS system

Computerized batching system with command batch

Central Dispatch on Site

Project

2013 Holcim Beton

Course Aggregate & M Sand Source

PT Holcim Beton, 2013-05-28 20

Maloko Quarry

Type : Stone Crusher

Production Capacity : 1000 m3/day

Capability : 500 m3/day

Number of trucks : 68 units

Trucks capacity : 24 m3

2013 Holcim Beton

Sand Source

PT Holcim Beton, 2013-05-28 21

Sands Quarry at Lampung

Capacity : 15000 m3

Capability to supply : 500 m3/day

2013 Holcim Beton

Suggestion Mass Pouring Raft Foundation Method

PT Holcim Beton, 2013-05-28 22

1. Pit Lift raft slab thickness : 4000 mmPouring method : Slab will divided by vertical segment with 3 layer

1st Layer maximum thickness : 900 mm

2ndLayer maximum thickness : 900 mm

3rd Layer maximum thickness : 2200 mm

2. Other massive raft slab thickness : 2500 mmPouring method : Slab will divided horizontal segment than pour by

full depth methode or layer by layer

Full depth with considering of cold join and segregation

Layer by layer with considering of cold join and unloading method

2013 Holcim Beton

Truck line up

Holcim Beton, 2013-02-13 23

2013 Holcim Beton

Traffic Management

Holcim Beton, 2013-02-13 24

Cycle time to Project

(min)

Pondok

Indah

Kemba

ngan

Rambut

an- - Plant

Loading

Time

Cycle

time to

Project

No of

Truck

Loading at plant 10 5 5 Pondok Indah 10 112 11

Check Slump 2 2 2 Kembangan 5 137 23

To Project 45 60 60 Rambutan 5 152 27

Test Slump 5 5 5 - 0 0 #DIV/0!

Queue 5 5 5 - 0 0 #DIV/0!

Unload 10 10 10 Total 62

Out of Project 5 5 5

Return 30 45 60

Total 112 137 152 0 0

1.87 2.28 2.53 - -

Loading at plant 10 5 5 0 0 No of CP 4 unit

No of Load per Hour 6 12 10 #DIV/0! #DIV/0! Capacity/CP/hour 25 m3/hour

Load Size 7 7 7 Total Capacity/hour 100 m3/hour

Rate Prod/hour

(m3/hr)42 84 70 #DIV/0! #DIV/0! Experience Factor 62%

% Contribution 80% 100% 70% 0% 0% 161.29 m3/hour

Total 34 84 49 #DIV/0! #DIV/0! 167

Production Capacity (M3) Concrete Pump Capacity

2013 Holcim Beton

Quality Control

Holcim Beton, 2013-02-13 25

1. Check temperatur

2. Slump test

3. Taking sample

Following ACI Standart for frequency

sample as below :

...

...

....

2013 Holcim Beton

Course Aggregate & M Sand Source

Holcim Beton, 2013-02-13 26

Maloko Quarry

Type : Stone Crusher

Production Capacity : 1000 m3/day

Capability : 500 m3/day

Number of trucks : 20 units

Trucks capacity : 22 m3

Distance from Project : 75 km

2013 Holcim Beton

Curing Method

PT Holcim Beton, 2013-05-28 27

1. Before pouring all area should be cover by terpaulin to prevent from rain

direct and exposure to sun

2. Right after complete finishing surface, concrete cover by plastic sheet

and 3 layer of sterofoam

3. Sterofoam will use to manage different temperature 20 C and to

accelerate time to reach steadily and stability temperature

2013 Holcim BetonMass Pouring

Conclusion

Key success of Mass Pouring is team work of main contractor,

CM, concrete supplier, concrete pump, and other related

parties

Supply continuity

To keep () < 20 oC and prevent thermal crack, monitor of

temperatur through thermo couple and period of insulator

release within time calculated.

Work safely and meeting the quality