Bluescope Steel Thermal Modelling

CQT Services was engaged to provide specialist concrete thermal modelling and durability support for Project Prime at Port Kembla Steelworks, a major industrial and infrastructure project for BlueScope Australia and New Zealand.

The project involved significant mass concrete elements, including pile caps, plinths and large beams up to approximately 3 metres deep by 2 metres wide. Due to the size and geometry of these elements, concrete temperature rise from cement hydration presented a key technical risk. Thermal modelling was undertaken to assess peak hydration temperatures and temperature differentials, with a focus on managing the risk of Delayed Ettringite Formation, unplanned cracking and long-term durability impacts.

Where modelling indicated that project thermal limits may be exceeded, CQT worked through a range of practical thermal control strategies. This included the development and review of concrete mix designs incorporating high proportions of supplementary cementitious materials to reduce heat generation while maintaining long-term strength performance. CQT also assessed optimal concrete placement temperatures, recommended suitable placement timing to take advantage of cooler periods, and provided advice on insulation systems such as thermal blankets, sealed air spaces and other methods to control temperature differentials.

For larger concrete beams, CQT provided technical input into internal cooling pipe systems, including cooling arrangement, manifold configuration and flow requirements. CQT also worked with the broader project and structural engineering team to optimise pour sequencing and provide inputs to help control thermal strain within the concrete elements.

Through this work, CQT helped identify the thermal controls required to support constructability, durability and compliance with project requirements. The advice assisted the project team in managing early-age concrete temperature risks while supporting efficient construction and long-term performance of the concrete elements.