6TH INTERNATIONAL SYMPOSIUM ON

ROLLER COMPACTED CONCRETE (RCC) DAMS

Zaragoza, 23 – 25 October 2012

ACCELERATE CURING TEST: HISTORY, DEVELOPMENT AND

APLICATIONS.

José López M. MSc

Concrete QA Lead Engineer MWHarza – Pacific Complex, Third set of Locks
Expansion Project, Panama

Ernest Schrader, PE, PhD

Schrader Consulting, Walla Walla (USA)

SUMMARY

Over the past 15 or so years, a procedure has evolved for accelerated cure of RCC
mixes so that the 1 year strength and elastic properties can be determined within
two weeks. This allows early selection of appropriate RCC mix designs with
associated realistic long term strength and elastic properties necessary for
accurate structural design.. The history, development and application of this
procedure are presented in this paper.

1. INTRODUCTION

A special method for early prediction of long term compressive and tensile
strength, with elastic properties, for Roller Compacted Concrete (RCC) and lean
conventional concrete mixes has evolved over the past 15 years. Different
commercial and “home made” equipment has been used to follow the defined
procedure of the test. This procedure has been used on many RCC dams, and it
is currently being used on a variety of large and small projects as an indispensable
way of determining key design properties and optimizing RCC mixes for probable
one year properties that can now be determined within a couple weeks.

This article will present the procedure and equipment used in different
projects around the world, including a modified version which has been developed
for conventional mass concrete. A comparison is made to results obtained at
different RCC dams between the initial trial mix program and the long term results
obtained through standard curing. Application of this method as an alternative way
for quality control testing during construction is presented. Finally, examples of
why the procedure may not have worked well in some examples are provided.
 2. SPECIAL ACCELERATE CURING TEST PROCEDURE.

A procedure was initially developed by Schrader that worked well on some

projects, but not as well at other projects that had a different type of mix, pozzolan
content, fines content, cement content, cement type, or admixture. Each time a
problem was encountered, an adjustment was made until the procedure evolved
with continued efforts primarily by Schrader, Lopez, Geikel, Montalvo and Hung
that now works well for essentially all mixes and materials. A modified version has
also been developed for conventional concrete.

Standard nominal 150 x 300 mm cylinders are used in the procedure. A

minimum of three cylinders is suggested for each mix at each age to be tested, but
two are often used for compression and one for indirect Brazilian split tension or
direct tension testing. The compression samples are often also subjected to
stress-strain testing. .

The procedure provides a reasonable, and often somewhat conservative,

indication of the long-term ultimate strength and properties of the concrete
compared to extended standard cure conditions. When the accelerated cure
procedure results in less than the 1 year strength, some practitioners have equated
it to the 180 day or other age strength, while others simply consider it to be a
conservative estimate of the 1 year strength. The accelerated cure strength will
never be more than the 1 year or ultimate long-term strength.

2.1 RCC MIX & LEAN CONCRETE.

The updated desired procedure is detailed below.

Moist cure the cylinders in a standard cure tank or moist cure room for 3 days at
21 °C (70 °F). Weaker mixes should be left un-stripped, with moisture tight
lids over the molds, in the cure room or tank. Conventional and higher
strength RCC cylinders can be stripped at one to three days depending on their
strength.

Fully submerge the cylinders in a water bath at the start of day 4. The water
bath should be covered. A special tank with a source of hot water and excellent
circulation of the heated water is needed. Alternatively, the cylinders can be
placed in a covered water bath that is then placed inside a suitably controlled
oven. Be certain that the cylinders remain totally immersed in the hot water
and the water does not evaporate.

From the start of day 4 to the start of day 5 (24 hours) raise the temperature of
the water from 21 °C to 90 °C (+2 °C,-5 °C) at a uniform rate of about 2.9 °C/hr
 (70 °F to 194 °F at a uniform rate of about 5.1 °F/hr).

Maintain 90 °C (+2 °C,-5 °C) (194 °F) for at least the next 7 days (start of day 5
until the start of day 12). A longer duration of fourteen days is desirable, but
this has not usually resulted in much additional increase in strength.

From the start of day 12 to day start of day 13 (24 hours) lower the temperature
from 90 °C to 21 °C at a uniform rate of rate of about 2.9 C/hr. (194 °F to 70 °F
at a uniform rate of about 5.1 °F/hr). This usually can be accomplished with
natural cooling.

Maintain 21 °C (70 °F) for the next 24 hours (during day 13)

At 14 days, test the samples.

Notes:

The accelerated strength will normally approximate 90%-100% of the long

term strength at 1 year.

The starting and finishing temperature can be 27 °C for tropical areas, but it
should be noted. The rate of heating and cooling should then be adjusted to
about 2.6 degrees/hr, or the length of time to achieve heating and cooling can be
reduced to about 22 hours to accommodate this change.

When time is critical, the initial cure duration can be reduced to 1 day. This
reduction is typically less critical for mixes having normal 28 day strengths in
excess of about 20 MPa (3000 psi), and more critical for lower strength mixes.
The strength result will be a more conservative estimate of the long-term ultimate
strength of the concrete.

When time is critical, it may be necessary to reduce the duration of the high
temperature cure to 6 days, or slightly less. The test will then provide a more
conservative estimate of the long-term ultimate strength of the concrete.

When time is critical, the final day of temperature stabilization at 21 °C (70 °F)
can be reduced somewhat, but it is important for the interior and exterior of the
cylinder to be at similar temperatures.

2.2 CONVENTIONAL CONCRETE.

The desired procedure, successfully used in the past, is detailed below.

Moist cure the cylinders in a standard cure tank or moist cure room for 1 day at
21 °C (70 °F).
 Fully submerge the cylinders in a water bath at the start of day 2. The water
bath should be covered. A special tank with a source of hot water and excellent
circulation of the heated water is needed. Alternatively, the cylinders can be
placed in a covered water bath that is then placed inside a suitably controlled
oven. Be certain that the cylinders remain totally immersed in the hot water
and the water does not evaporate and require additional water.

From the start of day 2 to the start of day 3 (24 hours) raise the temperature of
the water from 21 °C to 65 °C at a uniform rate of about 1.8 °C/hr (70 °F to 150
°F at a uniform rate of about 3.3 F/hr).

Maintain 65 °C (+2,-2) (150 °F) for at least the next 7 days (start of day 3 until
the start of day 10). A longer duration of fourteen days is desirable, but may
not result in much additional increase in strength.

From the start of day 10 to the start of day 11 (24 hours) lower the temperature
from 65 °C to 21 °C at a uniform rate of rate of about 1.8 °C/hr. (150 °F to 70
°F at a uniform rate of about 3.3 °F/hr).

Maintain 21 °C (70 °F) for the next 12 to 24 hours (during day 11) to assure
uniform temperature distribution within the cylinders.

Test the samples during day 11 after the 12 to 24 hour stabilization period.

Notes:

The starting and finishing temperature can be 27 °C for tropical areas, but it
should be noted. The rate of heating and cooling should then be adjusted to
about 2.6 degrees/hr, or the length of time to achieve heating and cooling can be
reduced to about 22 hours to accommodate this change.

When time is critical, the initial cure duration can be reduced to 12 hours.
This reduction is typically less critical for mixes having normal 28 day strengths in
excess of about 20 MPa (3000 psi), and more critical for lower strength mixes.
The strength result will be a more conservative estimate of the long-term ultimate
strength of the concrete.

When time is critical, it may be necessary to reduce the duration of the high
temperature cure to 6 days, or slightly less. The test will then provide a more
conservative estimate of the long-term ultimate strength of the concrete.

When time is critical, the final day of temperature stabilization at 21 °C (70 °F)
can be increased somewhat, but it is important for the interior and exterior of the
cylinder to be at similar temperatures.
 Figure 1 summarizes both procedures for RCC and CVC samples.
Fiure 1

Fig. 1

Schematic updated procedure of accelerated cure test for RCC and CVC.

The difference in procedure for RCC and mass CVC samples is primarily due
to different cement contents and internal supplemental heat that can develop
within the samples.

3. ACCELERATED CURE TEST HISTORY.

The evolution of this test has involved different initial cure times before
ramping up the temperature, rates of heating and cooling, the duration of high
temperature, different elevated temperatures and conditioning after the high
temperature cure before testing, and improvements in circulation of the hot water.

For example, the initial cure time before ramping up the temperature was
seven (7) days compared to the updated procedure now of 3 days). Rates of
heating and cooling depended from its initial standard cure tank temperature taking
in consideration if the test is done in tropical areas where the water curing
temperature is higher than in other sites where it was applicable to keep the
standard cure temperature equal to 21 °C. The duration of high temperature
initially was five (5) days against seven (7) days now being used. The rate of
temperature rise and fall is now emphasized because damage to the samples can
occur if the surface temperature changes too fats compared to the interior of the
test sample.

The history of the procedure involves various techniques and “home made”
equipment that was devised along the way. Each version or step in the evolution of
equipment had its own characteristics, advantage and disadvantages, as indicated
below:

Fig. 2

Accelerate curing tank for Angostura - Peru (1999) & Miel I-Colombia (2000) RCC
dams. Provided with four electrical heaters. Its capacity was for six (6) samples.
Initial cure time was 7 days and duration of high temperature was 5 days.

Fig. 3

Accelerate curing tank used in Mujib dam – Jordan (2001). Its capacity was for 30
samples. Initial cure time was 7 days and duration of high temperature was 5 days.

Accelerated cure tanks have had different capacities. Tanks with lower
capacity are most versatile, allowing test for individual sample set. Tanks with big
capacity can result in some samples with different initial cure time before ramping
up the water temperature.

Experience has shown that, for production operations, it is essential to have

three separate tanks. One for the 24 hour ramping up of temperature, one for
maintaining the elevated temperature for the desired time period, and one for
ramping down the temperature. If a single tank is used, only one batch of
cylinders can be cured at a time in a single tank because they all will be subject to
the same temperature rise and fall at the same time.

Fig. 4

Heater with automatically control used in Burnett dam – Australia (2004-2005).

Initial cure time was 7 days and duration of high temperature was 5 days.

Fig. 5

Accelerate curing tank used in Pinalito dam – Dominican Republic (2006). Its
capacity was for 36 samples in two levels. Initial cure time was 7 days and duration
of high temperature was 5 days. Hot water steam was supplied during test.
 Fig. 6

Accelerate curing test using PVC barrels 50 gallons capacity used in Dong Nai 3 &
Dong Nai 4 dams – Vietnam (2006-2009). Its capacity was for 3 samples. Initial
cure time was 7 days and duration of high temperature was 5 days. See the heater
placed in the bottom of plastic barrel cure tanks used.

Fig.7

Accelerate cure tank used during development of trial RCC mixes in El Realito
RCC dam – Mexico (2010). Heater of water was done using a gas source with an
automatic control and monitoring of heat applied.
 Fig. 8

Commercial accelerated curing tank from Iris, used for Wyaralong Dam – Australia
(2009-2011) in its mix program and quality control. Its capacity was for 20 samples.
Initial cure time was 3 days and duration of high temperature was 7 days.

One of the most important characteristics of this test is to have available a

proper pump which allow a excellent circulation of hot water, including between the
samples and under the samples, which should be separated from each other and
supported in a rack with water circulating under them. Characteristics of this pump
could have 0.5 HP of power, monophasic and a range from 10 to 30 l/sec.

The number and type of water heaters depends on the size of the cure tank
and the high temperature target to reach during the test. As an example, the cure
tank used in Miel I RCC dam had four water heaters each one with 1500 watts of
capacity. For Dong Nai 3 and Dong Nai 4 RCC dam, only one water heater was
used and no pump was used during the execution of the test (See figure 6).

A pyrometer with capacity for temperature reading capacity between -30 °C

to 1,000 °C jointly with thermocouples type J at different locations inside the cure
tank was used at Miel I (See figure 2).

An automatic panel for control rates of heating and cooling of water

temperature, jointly with start & off button and four unipolar thermomagnetic
switches 20 amp was used in Angostura dam during execution of its trial RCC mix
program.

An internal water bronze condenser placed below the hermetic top cover
provided with pipes 3/16” was used in both Angostura and Miel I projects, in order
to continuously convert the steam generated during the execution of the test to
water, preventing the generation of pressure on the inner side of the tank.

Equipment is now commercially available to do the test, for example form Iris
in Australian (Brisbane), with automatic controllers and software for monitoring the
test (See Figure 8 & 9). This AC tank has among other the following
characteristics:

The Iris-AC Tanks were custom designed specifically for high temperature
testing by delivering performance and accuracy throughout the whole
process. To reach the higher testing temperatures the skin is fully
insulated and sealed to minimize losses.
A mesh of internal piping, an internal side mounted pump gives a constant
and even circulation throughout the tank.
The tanks are made from stainless steel which allows the testers to use
specific chemicals which can clean any scale build-up and can withstand
any issues caused from any chemicals leaching from within the concrete.
The tanks use 3 dispersed elements. If 1 element fails due to any reason
the tanks have enough power to continue running and holding
temperature. This feature can save days’ worth of work, these can be often
lost when elements fail and temperatures fall out of spec. For long test
 methods which run for numerous weeks the 2 elements will keep running
and until the test is finished and the water can be drained to make the
repairs.
If the tests require controlled ramp down 2 methods can be used. A heat
exchanger module can be installed on the side of the tank and can add
cooling when a solenoid is triggered by the temperature controller. The
Wyaralong models have a cooled compressed air capillary system through
the bottom of the tank. When the tank is in a ramp down sequence the
solenoid is turned on and cold air bubbles through the tank. If water and
specimens drop temperature too quickly the controller will balance the rate
by pulsing the elements. This combination is highly accurate.
The tanks were supplied with a temperature logger which recorded
readings independent to the reading of the temperature controller. This
allows multiple points for recording to make sure circulation and
temperature dispersion is being achieved.
Software was used to monitor the temperature logger which allowed the
lab technicians to run reports with great ease.
The panel temperature controller was programmed with specific
proportional integral derivative settings tested and mapped specifically for
90°C tests.
Elements are mounted underneath a mesh to allow both circulation and
segregation from and around the samples.
The IRIS-AC Tanks are generally made to have the internal dimensions of
750 x 750 x 600 mm. This allows the units to sit with the controller on a
pallet, making it easy to ship around when labs move throughout projects.

Fig. 9

Automatic controller equipment for monitoring the accelerated cure test.

Other possibilities for execution of accelerate cure test using tubs and ovens
readily available at labs had been used, using the procedure previously indicated
for putting the samples in sealed tubs of water that are then placed in a large oven.
 4. ACCELERATED CURE TEST APPLICATION.

The procedure has been used on many RCC dams during different stages of
their development (design and construction), and it is currently being used on a
variety of large and small projects as an indispensable way of determining key
design properties and optimizing RCC mixes based on one year properties
determined within a couple weeks. It is especially useful in this regard when
standard cure earlier age compressive samples may have lower strengths, but
the accelerated cure test shows that adequate strength will be achieved in the long
term. Applications of accelerated cure tests in different RCC dam projects are
shown in figures 10 to 17.

Fig. 10

Compressive strength vs. Age for Angostura RCC dam (551,000 m3 & 102 m
high). Standard cure vs. Accelerate cure. RCC mixes: VAR-VAR-4.9/5.0 (4.7).
Alluvial aggregate (mainly Argillite) as aggregate. Design stage.

Fig. 11

Compressive strength vs. Age for Miel I RCC dam (1’700,000 m3 & 192 m high) –
Verification RCC trial mixes. Standard cure vs. Accelerate cure. RCC mixes:
VAR-0-4.9/5.1(6.9). Neis and Cuarcite as aggregate. Additional test were done
with different RCC moistures and aggregate source.
 In 2004-2005 an earlier version of the accelerated cure procedure was used
effectively at Burnett (Paradise) dam in Australia with “Home Made” equipment. It
allowed early selection of the required minimal cement content (no commercial
pozzolan) in two weeks time. The resulting accelerated cure strengths were
conservatively 81% of the average 1 year standard cure strength for compression
and 82% for split tensile strength. A different way to view the data is that it resulted
in the approximate 56 to 90 day standard cure strength. This is for data during the
first production RCC period of 5 June through 30 September 2004. Accelerated
cure for the remainder of the project, after an adjustment was made in the mix,
resulted in 78% of the standard cure 1 year strength for compression, which still
was the approximate 56 to 90 day standard cure strength (See Figure 12).

Fig.12

Burnett Dam (400,000 m3 & 50 m high), Lean Mix: 65 kg Cement, Basalt Aggregate
Fines, No Fly Ash. Average of All Compressive and Split TensileTests for first
Production RCC with 4.9% Moisture, 5 June - 30 September 2004.

At Burnett (Paradise) dam, as well as other projects, the modulus of elasticity

as percentage of the compressive strength was similar for standard cure and
accelerated cure samples. This applies to the modulus at 25%, 50%, 75%, and
100% of ultimate load, indicating that the entire stress-strain curve is similar for
both methods of cure

Fig. 13

Comparison of strength for different gradations and aggregate types, with

pozzolan. Dong Nai 3 RCC dam – Vietnam (1’100,000 m3 & 105 m high). Trial
RCC mix design stage & Compressive strength vs. date to different ages, including
accelerate cure test to 14 days. Construction stage.

DIAMER BASHA - THOR

Compression Vs Type of Pozz/Filler at 127 kg
50
48 85+0+4.8 (4.7X) VB=10 NOTHING ADDED Large Markers Are
46 Accelerated Cure
85+127+4.9 (4.7X) VB=10 GINI ADDED
44
42 85+127+5.0 (4.7X) VB=? ASH ADDED
40
85+127+4.8 (4.7X) VB=11 SLAG ADDED
Compressive Strength (MPa) 38
36 85+127+4.9 (4.7X) VB=10 CEMENT ADDED
34
32 For strength, Adding Slag is Much
30 Better than Adding Cement.
28 Adding Ash Loses Effectiveness at At
High Percentages
26
24
22
20
18
16
14
12
10
8
6
4
2
0
1 10 100 1000
Age (Days)

Fig. 14

Effect of adding different type of pozzolan or filler on compressive strength.

Compressive strength for early and long term with standard cure and accelerated
cure. Diamer Basha RCC dam (17’000,000 m3 & 276 m high). RCC mixes:
85+127+4.9(4.7%). Trial RCC mix design stage.

Fig. 15

Wyaralong Dam trial mixes with 85 kg cement and 85 kg fly ash or 85 kg milled
aggregate fines, using poor quality sandstone aggregates in the RCC.
 Fig. 16.

Susu Dam trial mixes ranging from 55 kg/m3 cement+100 kg/m3 fly ash to 95
kg/m3 cement+120 kg/m3 fly ash. Standard cure results through 90 days plus
accelerated cure shown at 365 days.

Fig. 17

GERDP Dam trial mixes. Various mixes with Messebo cement and no
pozzolan. With results through 14 days for standard cure, the continued
strength gains with time, and the ultimate 1 year strengths, have been
realistically determined by use of the accelerated cure (AC) test.

5. REASONS IDENTIFIED AS CAUSES THAT EXPLAIN THE

MALFUNCTION OF THE TEST.

Examples of “trouble shooting” that has identified reasons why the procedure may
not have worked well in some examples are indicated below:

An excessive rate of temperature rise or cooling that causes the exterior

of the cylinder to expand or contract too fast compared to the interior as
a result of temperature differentials..
Poor hot water circulation, resulting in non-uniform temperature
distribution in the tank. This includes around each cylinder (which
cannot occur properly if the cylinders are in contact with each other), and
under the cylinders. If the cylinders are not on an elevated rack with
water circulating under them, the bottom will be insulted.
Power outages that interrupt water circulation and allow the water to
drop below the desired temperature.
Loss of water due to evaporation or leakage during the test.
 A heating element being inside the chamber and too close to some
cylinders. This can result in “hot spots.”
Software or automated controllers re-setting themselves back to time
“zero” and re-starting the heating or cooling cycle..
The interior of the cylinder developing destructive steam or vapor
pressure if the temperature within the cylinder exceeds 100 C degrees.
This can happen of the temperature controllers are not adequate or
there is a hot spot in the tank. It also can occur if the cylinder has high
heat cement and/or high cement content that generates internal heat in
addition to the heat from the hot water. This is the main reason for
lower cure tank temperatures for conventional concrete samples with
higher cement contents.

6. SUMMARY.

Experience and continuous improvement of equipment and procedures at different

RCC projects around the world with different aggregates, cement types, pozzolan
types, gradations and admixtures, has demonstrated the current general reliability
of the special accelerated cure test. It can be used effectively to approximate one
year strengths and elastic properties within two weeks.