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How did Burj Khalifa engineers pour concrete to a height of 600 meters without losing its properties?
📌 The problem: How do you pour concrete to a height of 600 meters without losing its properties?
The Burj Khalifa is 828 meters tall.
But the concrete had to be poured to the 156th floor (approximately 605 meters)... and this was the project's first implementation challenge.
The problem here was:
🔻Concrete dries quickly in Dubai's high temperatures.
🔻Ordinary concrete pumps can't reach sufficient pressure to pump it upwards.
🔻Any delay in pumping = separation of concrete components (granular segregation).
🛠️ The genius solution they came up with:
🔸 Special concrete mix (Concrete Mix Design):
They used High Performance Concrete (HPC) concrete.
🔸Compressive strength: C80 – C100.
The cement content was relatively reduced, and additives such as:
Superplasticizers (to increase workability without excess water)
Retarders (to delay setting)
Silica Fume (to increase strength and reduce segregation)
🔸Concrete temperature control:
Pouring was always done at night (between 1 a.m. and 5 a.m.)
🔸Crushed ice was used instead of mixing water.
🔸Internal coolers were installed in the mixers. (Chillers)
🔸They recorded the temperature of the mixture at each point to ensure it did not exceed the permissible limit (32°C).
🔸The most powerful concrete pumps in the world at the time:
German pumps were used:
Putzmeister BSA 14000 SHP-D
Pumping concrete at a pressure of up to 200 bars
Pumping capacity of up to 165 m³/hour
Concrete traveled along 150 mm diameter steel lines for a vertical distance of more than half a kilometer!
🧠 A brilliant implementation detail:
Engineers were responsible for monitoring the concrete's arrival time to the site. If any shipment was delayed beyond the permissible time (approximately 90 minutes), it was immediately rejected.
Compressive strength of 100 N/mm²
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