Mass Pour District 8_referensi_03032015
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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
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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
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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
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2013 Holcim BetonHolcim Beton, 2013-02-13 4
Temperature calculation Reff. ACI 305 R 99
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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
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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 &.
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2013 Holcim Beton 7Holcim Beton, 2013-02-13
Maximum different temperature 20 oC between layer
Different Temperature
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2013 Holcim BetonMass Pouring
Plastic
Styrofoam/polystyrene 2.5+2.5+5 cm
Curing Compound
Beton
50 C
Temperature
Monitoring
Monitor Temperature - Thermo Couples
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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
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2013 Holcim Beton
Mix Design (low cementitious material, low w/c ratio, initial setting time)
Holcim Beton, 2013-02-13 10
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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
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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
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e
b
1
3
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e
b
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b
1
8
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F
e
b
1
9
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F
e
b
2
0
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F
e
b
2
1
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b
2
2
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F
e
b
2
3
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F
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b
2
4
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F
e
b
2
5
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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
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F
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1
3
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F
e
b
1
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F
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1
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1
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0
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1
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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
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2013 Holcim BetonProvidence Park
Pelaksanaan Penempatan titik pengujian suhu dengan termo couple
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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
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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
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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 .
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2013 Holcim Beton
Traffic Management
PT Holcim Beton, 2013-05-28 17
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2013 Holcim Beton
Holcim Beton
PT Holcim Beton, 2013-05-28 18
Plant PlumpangPlant Plumpang
Plant Rambutan
Plant Kembangan Plant Kuningan
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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
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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
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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
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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
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2013 Holcim Beton
Truck line up
Holcim Beton, 2013-02-13 23
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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
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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 :
...
...
....
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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
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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
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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