Effective Thermal Management in Precast Concrete

BCRC-Effective-Thermal-Management

Effective Thermal Management in Precast Concrete for Major Infrastructure Projects

The Victoria Park-Canning Level Crossing Removal (LXR) Project is part of the Metronet infrastructure initiative. The project is Perth’s first major elevated rail designed to improve public transport safety, create new and versatile public spaces for the community, and reduce traffic congestion.

When complete, the Victoria Park-Canning Level Crossing Removal Project will feature five new, modern elevated stations, further enhancing connectivity and reducing travel disruptions across Perth. This milestone marks a significant step toward a more efficient and accessible public transport network for the city.

Thermal Management Challenges

BCRC tackled one of the biggest challenges in the precast concrete industry: managing heat during curing. With over 790 precast elements, including piers, Roofs, L-beams, and headstocks, manufactured for the project, implementing effective thermal management strategies was essential to maintaining structural integrity and meeting the tight schedule.

In precast concrete projects, heat of hydration, which is released during cement curing, can lead to thermal cracking and Delayed Ettringite Formation (DEF) if left unchecked. This project encountered added complexity due to the varied geometries and thicknesses of the elements, posing specific challenges:

1. High Binder Content Mixes:

These mixes were essential to achieve the rapid strength gains required but also significantly increased the internal heat, complicating temperature control.

2. Complex Geometries:

The varying thicknesses across different sections of the precast elements led to uneven heat distribution, making it difficult to ensure uniform cooling.

3. Accelerated Curing Requirements:

The project’s ambitious timeline necessitated fast curing, which amplified thermal control issues.

4. Maturity Considerations:

Different parts of each element cured at different rates, demanding close monitoring to avoid defects and inconsistencies.

Developing an Effective Thermal Control Plan

To overcome these challenges, the project team devised a comprehensive thermal control plan incorporating several key strategies:

FEM-Based Thermal Modelling:

This advanced modelling provided detailed insights into heat flow patterns, identifying hotspots and enabling targeted cooling interventions.

Cooling Pipe System:

Embedded cooling pipes were strategically placed to dissipate heat in critical areas. Adjusting the pipes’ size, spacing, and flow rates allowed for consistent cooling across the elements.

Optimized Steam Curing:

The team carefully adjusted the steam curing process to align with the natural heat of hydration, promoting uniform maturation.

Real-Time Monitoring and Validation: Thermocouples embedded in the elements facilitated continuous temperature monitoring. This real-time data allowed for dynamic adjustments to the cooling system, ensuring effective thermal management.

Results and Key Takeaways

The thermal management strategies implemented on this project resulted in several notable outcomes:

Minimal Cracking: Almost no significant thermal cracking was observed in the precast elements, demonstrating the effectiveness of the cooling and monitoring systems.

Accelerated Construction: The ability to strip formwork in hours rather than weeks greatly streamlined the construction process.

Specification Compliance: Temperature differentials were kept below the project’s stringent limits (70°C peak temperature and 20°C differential), confirming the project’s success in thermal management.

BCRC Effective Thermal Management
BCRC Effective Thermal Management
BCRC Effective Thermal Management

Key Takeaways for Future Projects

This case study offers important insights into the significance of effective thermal management in complex precast concrete projects:

1. FEM Modelling is Essential: Multi-dimensional thermal analysis allows for accurate predictions of peak temperatures and temperature gradients, particularly in complex structures.

2. Cooling Systems Are Crucial: A well-designed cooling system is indispensable for managing internal heat and preventing thermal cracking.

3. Continuous Temperature Monitoring: Real-time data enables immediate adjustments, ensuring consistent thermal control throughout the curing process.

4. Early Expert Engagement: Engaging thermal management experts early in the design phase can help pre-empt potential issues and streamline project execution.

This project underscores the critical role of robust thermal management in successfully executing large-scale infrastructure initiatives.

METRONET Victoria Park-Canning Level Crossing Removal Project Flyover - October

BCRC In Western Australia

western-australia-BCRC-Mining

Maximise the Life of Your Asset with BCRC

Founded in 2005, BCRC is a technical leader in durability design, structural inspection and repair consulting.

With operations nationally and substantial expertise in Western Australia, our services span the following industries:

Civil Infrastructure, Resources and Mining, Power and Energy, Oil and Gas, Water and Waste-Water, Bridges,  Marine Infrastructure, Tunnels, Buildings and Facilities.

BCRC specialists understand the unique challenges asset owners face and what it takes to design and build infrastructure that exceeds its expected operational life with minimal maintenance requirements.

Our multidisciplinary consultants have experience in all materials and applications. Whether it’s concrete, timber, steel, brickwork, corrosion-protective coatings or waterproofing, we offer a range of services to prevent deterioration over the lifetime of a project and help mitigate potential cost overruns due to unforeseen repairs or upgrades.

The BCRC team offers durability design and remedial design, durability plans review, structural investigations, non-destructive and destructive testing, materials selection, corrosion assessments, cathodic protection, repair specification, service life modelling, remedial project management, expert witness and dispute resolution services.

You can reach out to us for any advice on durability.

Contact: Egor Volkov  perth@bcrc.com.au    949-951 Wellington Street West Perth, WA 6005

SOME BCRC WESTERN AUSTRALIA PROJECTS

Hamersley Iron
Paddington Gold Mine
Lion Ore Plant
Fortescue Metals Group (FMG)  Expansion Project
Ravensthorpe Mine
Boddington Gold Mine
Tropicana Gold Mine
Karara Iron Ore 
Dampier Bulk Liquids Berth
Busselton Wharf Aquarium
Narrows Rail Bridge Perth
Kalgoorlie Reservoir
Perth Metro Tunnel
Welligton Street Underground Station
Esplanade Underground Station
Jervoise Bay Wharves
Esperance Port Access Corridor
Esperance Rail Tunnel
Shenton Avenue Interchange, Perth
Merriden Bypass
Twilight Bridge, Esperance
Mt Henry Bridge Duplication, Perth
Orong Road Interchange, Perth
Causeway Bridge, Perth
John Street Bridge, Esperance
Perth Law Courts
Fremantle Port Wharf Deck
Karrinyup Shopping Centre
Leonora Crane Shed
Harbour Town Perth
Cape Lambert Power Station
Cockburn (Coogee Beach) Life-Saving Club
Ocean Keys Shopping Centre (Clarkson)
Century City, Perth
AMP Building, Perth
Parmelia House Perth
ANZ Bank Perth
Carillon City, Perth
Frank Papworth

Frank Papworth – Durability Consultancy

Frank Papworth is a globally recognised Civil Engineer and Concrete Durability Consultant with over 35 years of experience in the industry. His contributions to concrete durability, inspection, and repair have established him as a leading figure in the field, earning him key leadership roles and prestigious awards.

He has Chaired CIA’s durability committee, Chaired fib COM8 on durability, and Won the Malhotra durability prize.

Egor-Volkov-BCRC

Egor Volkov – Senior Engineer

Egor’s experience in assessing steel, reinforced concrete, and timber structures, especially for transport, marine, and local government clients, is a valuable skill that further enhances BCRC WA’s expertise.

His experience in remedial design specification and project management enhances our ability to support clients who are committed to extending the service life of their assets.

Herman-Jong

Herman Jong – Durability Consultant

Herman has over 30 years of experience in construction materials technology in Australia and internationally. Herman has over 10 years of professional engineering experience in Australian inspection and assessment consulting in the building, transport, water, mining and marine infrastructure sectors.

Herman has strong technical consulting skills and in-depth knowledge of structure condition and durability assessments of reinforced concrete/steel structures.

Adam-Papworth

Adam Papworth – NDT Technician

Adam has over fifteen years of non‐destructive testing experience in the field and laboratory.

Adam is experienced in assessing the in‐situ condition of reinforced concrete for both new and existing structures.

Adam is experienced in state‐of‐the‐art techniques to monitor corrosion in reinforced concrete structures and material testing, including non‐destructive techniques.

BCRC Western Australia -Perth

Contact Egor Volkov

perth@bcrc.com.au

At BCRC, you can access a dedicated technical expert aligned with your durability design, remedial management, and construction project requirements.

Whether it’s the design of new structures, the inspection and restoration of older ones, or resolving disputes that may arise, the BCRC team are available to assist at every stage.