Pouring Concrete in the Cold: How REDCOM Built a Strong Foundation in Freezing Temperatures
Shark River Road Warehouse - Tinton Falls, New Jersey
In a perfect world, construction sites would exist in a controlled environment, free from weather-related obstacles. In reality, builders must contend with nature’s unpredictability, including extreme cold.
REDCOM’s ongoing project in Tinton Falls, NJ, a 130,000 sq. ft warehouse with 60 car parking spaces and 44 oversized parking spaces, was no exception. Designed to accommodate up to 8 tenants with 8,400 sq. ft. of office space, this site required a strong concrete foundation for long-term durability.
Like any other aspect of a project, concrete has traits and quirks around which you must plan. So, what happens when you try to pour concrete in sub-freezing temperatures? The result can be a weakened foundation that compromises structural integrity. Here’s how REDCOM dealt with this obstacle in Tinton Falls while staying efficient and within budget.
Let’s start from the beginning: What is Concrete?
Concrete is a composite material composed of cement, coarse aggregates (e.g., crushed stones and gravel), fine aggregates (e.g., sand and silt), and water. Although “cement” and “concrete” are often used interchangeably, cement is just one ingredient in the mix.
When these materials are combined with water, the hydration process (commonly called “curing”) begins, causing the mixture to harden and strengthen.
At temperatures below 40° Fahrenheit, the initial curing process slows down significantly, sometimes stopping altogether. If concrete fails to harden properly, hidden flaws can develop, making buildings more susceptible to future damage.
Common Methods to Pour Concrete in Cold Temperatures
Crews mitigate issues caused by extreme cold on site in several ways. Some opt to use heated concrete mixtures to create an ideal temperature to cure. Others utilize chemical accelerators that help speed up the curing process. These two methods could also be combined depending on the project’s specific needs. The downside of these methods, however, is that they present a significant stake in the project budget.
REDCOM's Approach
Rather than opting solely for expensive heating solutions, REDCOM developed a creative and cost-effective strategy to keep the concrete at the proper temperature before pouring.
Pre-heating the Ground
About an hour before pouring, REDCOM’s team utilized the excavator on-site to run its arm along the trench where the concrete would be poured. The friction between the steel excavator bucket and the ground generated enough heat to warm the ground naturally, much like rubbing your hands together on a cold night.
Insulating with Blankets & Optimizing the Mix
After pre-heating, the crew covered the trench with insulation blankets to trap the warmth and maintain a stable ground temperature.
REDCOM also incorporated heated water and chemical accelerants into the mix to further ensure proper curing.
Every project presents unique obstacles, and overcoming extreme cold in Tinton Falls is just one example of how REDCOM addresses these challenges. Our experienced team can view challenges from a new perspective, sometimes finding that the most practical solutions are the ones right in front of us.