“After water, concrete is the most widely used substance on Earth. If the cement industry were a country, it would be the third largest carbon dioxide emitter in the world with up to 2.8bn tonnes, surpassed only by China and the US,” says The Guardian. As we head into the fall season, many jobs in construction continue to require concrete work. Pouring concrete during the cooler months presents unique challenges, but with the right approach, we can have a successful outcome. Timing, preparation, and technique all play important roles in making sure concrete cures properly and remains durable throughout the colder months. In this blog, we’ll cover some strategies to help us pour concrete effectively in fall at Kilgore Companies, so that every project remains on track, no matter the drop in temperatures.
Preparing the Site
Proper site preparation is always important, but as fall temperatures begin to dip, it becomes even more important. Before we pour any concrete, it’s important to clear the site of debris, leaves, and moisture. Fall weather tends to bring unpredictable rain, and any excess moisture can interfere with the bonding process. By making sure the site is dry, level, and free from any organic material, we create a foundation that sets us up for success.
We should also take into account the surrounding environment, making sure the area around the site is stable and protected. Fall winds can pick up and bring additional debris, so safeguarding the area can prevent unnecessary disruptions. Having windbreaks, tarps, or other protective measures in place helps us maintain control over the pour, keeping the concrete clean and the worksite safe.
Timing the Pour for Cooler Weather
Timing becomes a significant factor in fall concrete work. As temperatures fluctuate throughout the day, it’s best to plan pours for when the weather is most stable. In early fall, midday typically offers the warmest and most consistent conditions. By aiming to pour during this window, we give the concrete the best chance to set correctly.
The goal is to avoid pouring when the temperature is too low, as this can cause the concrete to freeze before it has a chance to cure. Fall mornings and evenings often bring colder temperatures, so we should always keep an eye on the forecast and adjust our schedule to prevent any issues related to freezing. In some cases, using accelerants can help speed up the curing process, but we should only use these solutions when necessary and with caution to avoid compromising the concrete’s strength.
Managing Water-Cement Ratios
One of the factors in successful concrete pours, especially in the fall, is managing the water-cement ratio. Cooler temperatures require us to be mindful of how much water we mix into the concrete. Too much water can weaken the final product, while too little can cause issues with setting and curing.
In fall weather, moisture in the air can also affect the mix. We may need to adjust the water content slightly based on humidity and temperature. A good practice is to always keep the mix as dry as possible while still maintaining workability. This balance is key to creating durable, long-lasting concrete, especially when dealing with unpredictable fall conditions.
Use of Curing Blankets and Other Insulation
After the concrete is poured, the curing process begins. In cooler weather, this process can slow down, which can affect the overall strength and integrity of the concrete. To combat this, we can use curing blankets or insulated covers to help retain heat and protect the concrete from the cold.
Curing blankets come in various thicknesses and materials, but the goal is the same: to provide a consistent, warm environment that promotes proper curing. It’s important to cover the concrete as soon as it is set to have minimal heat loss. In some cases, additional insulation, like straw or foam, can be used underneath or around the formwork to further protect the concrete from freezing temperatures. By maintaining a stable curing environment, we help the concrete reach its full strength without being compromised by the cold.
Consideration of Concrete Additives
Fall can bring challenging conditions that might require us to modify our approach to have quality concrete. Additives, such as air-entraining agents or water reducers, can be valuable tools to improve the durability of the concrete and protect it from cold weather conditions.
Air-entraining agents introduce tiny air bubbles into the concrete, allowing it to expand and contract without cracking as temperatures fluctuate. These additives are particularly useful in fall when early cold snaps can occur. Water reducers can be used to decrease the amount of water in the mix while maintaining workability, ensuring a stronger end product.
When using any additive, we must carefully follow the manufacturer’s instructions to ensure that the chemical reactions align with the fall conditions we’re working in. The right additive can make all the difference.
Protecting the Concrete After Pouring
Once the concrete is poured and cured, the work isn’t over. The fall season can bring temperature swings that impact the freshly set concrete. To protect it, we need to take a few extra steps. Curing blankets, as mentioned earlier, help maintain warmth during the initial set, but additional measures can be helpful in the days following the pour. “Concrete sealer is a protective barrier that gives longevity to concrete and makes cleaning easy. If your concrete is new, you’ll need to let it cure; wait at least one month before applying sealer. Before you apply it, check the weather,” says Lowes.
Working with Reinforcement and Formwork
In fall, the temperature doesn’t just affect the concrete—it can also impact the formwork and reinforcement. Cold temperatures can cause metal reinforcements to contract, which may lead to cracks or stress in the finished concrete. That’s why it’s important to make sure that any reinforcement is properly placed and secured before pouring the concrete.
Additionally, formwork should be sturdy and well-insulated. If the formwork isn’t insulated properly, it can draw heat away from the concrete, slowing down the curing process. We can use insulated forms or add insulation to the formwork to help maintain consistent temperatures throughout the curing phase.
Keeping Safety in Mind
Jobs in construction come with safety risks, and pouring concrete in the fall adds a few extra considerations. Slippery surfaces due to wet leaves or frost, unexpected gusts of wind, and cold temperatures that can numb extremities all pose risks to workers.
Monitoring Long-Term Performance
The work doesn’t end once the concrete is poured and cured. We should keep an eye on the long-term performance of the concrete, especially as winter approaches. Fall pours are susceptible to freeze-thaw cycles, which can cause cracking if not properly managed.
Sealing the concrete before winter sets in can help protect it from moisture and freezing temperatures. By applying a high-quality sealer, we can create a barrier that prevents water from penetrating the surface and causing freeze-thaw damage. Regular maintenance checks throughout the winter make sure that the concrete remains in good condition and performs well for years to come. Concrete pouring in the fall requires careful planning and execution, but with the right techniques, we can ensure success. From site preparation to curing and long-term protection, every step plays a role in the durability and quality of the final product. As professionals in the construction industry, we know how important it is to adapt our methods to the season. With these strategies, we can confidently tackle concrete pours throughout the fall, keeping our projects on schedule and maintaining the high standards that define jobs in construction. To find more information about Kilgore Companies, check out our website.