Simulation of Hardening of the MahanaKhon Tower Mat Foundation

Abstract: Cement hydration is the result of a series of simultaneous chemical reactions occurring during the production of concrete. An excessive amount of heat is generated, which consequently may give rise to thermal stresses and cause early age cracks in concrete that may affect its structural integrity, and load bearing capacity. Incorporating fly ash into the concrete mixture has shown to be an efficient method to reduce the temperatures developed during early age hydration, especially for massive concrete structures. Fly ash does additionally affect the concrete's development of compressive strength, tensile strength and Young's modulus. The MahanaKhon tower's mat foundation is divided into 14 layers, with fly ash incorporated in the concrete mix. A finite element model was developed of the mat foundation with COMSOL Multiphysics to simulate the developed temperatures and thermal stresses during curing. The simulations were carried out as parametric studies with different strain reference temperatures. The simulated temperatures were compared with existing temperature measurements that were conducted in three different elevations in each concrete layer. The result of the temperature analyses showed that the measured temperatures were generally larger than the simulated ones, which may have been the result of the numerical model's heat conductivity and convective heat transfer coeffcient not reflecting the actual case. Furthermore, the numerical model did not take into account the effects of solar radiation, which would most likely have increased the temperature of the concrete. The maximum simulated temperatures were mostly found in the center level of the concrete, followed by the lower level, and the lowest at the top. It was also observed that the maximum temperatures in some of the mat foundation layers could exceed 70 °C, which is generally considered high since the risk of delayed ettringite formation may arise. The large temperature is partially a result of not using cooling methods, such as cooling pipes, but also due to the high initial and ambient temperatures. The result of the thermal stress analyses showed that no tensile stresses arose when the strain reference temperature, Tref, was specified to 30 °C, corresponding to the mean ambient temperature. This is due to the concrete temperature not falling below Tref, and the concrete will therefore be in expansion and only be subject to compressive stresses. Increasing Tref to 50 °C, which was considered a reasonable estimation, resulted in developed tensile stresses in all mat foundation layers, where the majority of the mat foundation layers showed a risk of superficial surface cracks. The maximum tensile stresses were found at the final time of the simulations, which was expected, since the temperatures were at their lowest as a result of removing the curing insulation. Finally, setting Tref to 70 °C, corresponding to the maximum temperature during hardening, increased the induced tensile stresses considerably, due to the large temperature gradient between Tref and the concrete temperature. The maximum stresses were, as expected, located at the top level and caused by internal restraint. The second largest tensile stresses were found in the center level, also subject to internal restraint. The lowest tensile stresses were located in the lower level, subject to external restraint.