Types and features of using heating mats for heating concrete

In order to ensure proper curing and strength, concrete must be heated during cold weather. The use of heating mats is one practical way to handle this situation. Because of the constant warmth these mats provide, even in cold weather, the concrete can set properly.

There are several varieties of heating mats, and each is made to meet a particular need during the curing of concrete. Certain mats are electric, meaning they are simple to set up and consistently distribute heat. Others are hydronic, maintaining the necessary temperature with heated water. Both varieties work to keep the concrete from freezing and guarantee that it develops the required strength.

Heating mat use is especially advantageous for projects in areas with severe winters. These mats assist in preventing delays and guarantee that construction schedules remain on schedule by preserving the ideal curing temperature. They are a versatile tool in concrete construction because they are simple to use and can be adjusted to fit various project sizes and shapes.

Heating mats can also be used to maintain the temperature of existing concrete during repairs, in addition to being used for new concrete pours. They are a priceless tool for contractors who want to produce excellent work in any weather because of their adaptability and efficiency.

What are heating mats

Heating mats are unique blanket-like devices that help the concrete mixture solidify at the temperature necessary for adequate hydration.

The goods are made up of multiple layers:

• IR heating layer (made of polymeric materials);
• heat-insulating layer, which is filled with air;
• several layers of special heat-reflecting material;
• moisture-resistant layer (made of PVC);

Furthermore, the apparatus is equipped with unique bimetallic thermostats that shut off at +70 °C and restart at +60 °C, respectively, in accordance with the specified temperature threshold.

Electricity (220 V), delivered to the heating mat via a power cable, is typically used for infrared heating of poured concrete.

The products fall into two categories: isothermal and thermoelectric, depending on the underlying operating principle.

Isothermal awnings

The most basic multilayer products made of polyester, tarpaulin, or other materials are called isothermal type devices. The awning’s exterior is coated with a moisture-resistant substance, and its interior contains a 1.5 cm-thick layer of synthetic padding.

The products are easily fixed on the concrete surface because they are equipped with metal eyelets, which are metal rings installed in the web.

The primary benefits of awnings are:

• light weight (no more than 1100 g/m2);
• low cost (from 250 rubles per 1 m2);
• large selection of sizes;
• additional protection of the concrete base from rain and wind.

It is important to keep in mind, though, that these polyester padding products are similar to a household thermos in that they only slow down the cooling process rather than raising the temperature.

Using more functional products is advised for better and more efficient heating.

Electromats

The design of Thermoelectric Construction Mat (TEMS) is also quite basic. But unlike synthetic winterizers, it operates on the "warm floor" theory. These kinds of products have graphite heating elements built into their designs, which heats the concrete.

With TEMS, freshly poured concrete can be heated to a maximum temperature of +70 °C and kept there for a few days.

An infrared radiation is produced when the polymer layer is voltaged, and this radiation progressively starts to reach a depth of 60 cm in the concrete. Heat loss is reduced because of the air gap and reflective material.

When discussing the benefits of using thermoelectric mats to heat concrete, the following points are important to note:

• the ability to heat the solution even in difficult weather conditions;
• easy to use;
• heating that is carried out over the entire concrete surface, thereby eliminating the risk of cracking the monolith due to temperature changes;
• the possibility of multiple use of products;
• the ability to use mats simultaneously with other heating means (for example, mineral wool or other lightweight insulation can be laid on top of the heating mat);
• low energy consumption (from 0.3 to 0.6 kW / m 2 ).

However, there are some subtleties to using TEMS that must be considered in order to ensure efficient heating.

Features of the use of electromics

First and foremost, one must consider that these devices are limited to operating temperatures between -40 and +45 °C. Let me say this: a high heat threshold like this does not surprise you. The truth is that hot weather necessitates accelerating the mixture’s set strength because too much moisture evaporates from the mass at higher temperatures and during the lengthy solidification process. In these circumstances, the mixture will gain 70% of its strength after 20 hours if a thermomatic device is used.

Furthermore, it is imperative to comply with the subsequent guidelines when using mats:

1. Laying out mats, make sure that there is no overheating. To do this, put them very tightly (preferably overlapping) to each other.
2. If you need to heat a vertical surface or column, then the mat can be tied to it using straps or clamps.
3. Make sure that the TEMS fits tightly to the concrete mass.
4. If you put mats on a curve surface or plan to transport them, then you can bend the products only along the lines that are indicated on the devices. Otherwise, you can damage the heating elements.
5. If the temperature begins to exceed +70 ° C, and thermostats do not work, turn off the mats from the network manually.
6. Upon completion of heating, disconnect the mats from the power grid and wait for them to complete cooling. You can shoot mats only after they are the concrete surface itself equal in temperature with environmental indicators.
7. Keep in mind that you can’t walk on mats or throw heavy or sharp objects on them.

Verify that the seller of the mats has a TEMS patent before purchasing. Even at a very tempting price, you shouldn’t purchase such products if the necessary documentation was not given to you.

TEMS cost and choice

A brand-new heating mat designed to heat concrete with a standard size of 1.2 x 3.2 m will set you back between 9,500 and 10,500 rubles today. Everything relies on whether the buyer contacts middlemen or buys the device straight from the supplier.

You can order an awning if you need it in a specific size, but the cost per square meter will be roughly 2400 rubles in this scenario.

Renting a TEMS makes sense if you only need it for a single use. In this instance, the total cost of enjoyment will not exceed 250 rubles per day (per mat).

It is important to consider multiple models when discussing the top product brands.

TEM-450

TEM heating mats are the most widely used product among builders today. When it comes to heating soil and concrete, these are some of the best heaters available. The Heat Plus APN410 brand of 450 W frost-resistant, high-power infrared film is used in TEM products. The film has a minimum operating temperature of -60 °C in the environment. With a good density of 650 g/m2, the PVC layer satisfies all GOST 29151-91 requirements.

TEM-450 mats are used to simultaneously heat concrete in two ways:

• contact (concrete begins to heat from contact with the surface of the mat);
• With the help of IR rays.

Each square meter of such a device costs 2500 rubles.

Flexihitis

This brand sells its products in rolls as well as regular mat form. These TEMS can have capacities ranging from 300 to 500 W/m 2. In this instance, the products’ outer layer of moisture protection satisfies IPX7 requirements. A typical rectangular product with dimensions of 1.2 x 2.7 m weighs no more than 2.5 kg/m^2.

Flexihitis operate at a lower temperature (between -40 and +40 °C) than the TEM-450, but experts observe that they are highly reliable and continue to function without fail.

Products cost 2200 rubles per square meter.

Type of Heating Mat	Features and Uses
Electric Heating Mats	Provide consistent heat, ideal for small to medium concrete projects, easy to install and control temperature.
Hydronic Heating Mats	Use heated water, suitable for large-scale projects, offer uniform heat distribution, more complex installation.

In order to guarantee that concrete cures properly in cold weather, heating mats are a necessary tool. They help to maintain the proper temperature for concrete to set and harden by providing steady, dependable heat. This avoids common problems like uneven curing and cracking, which can weaken the concrete’s structural integrity.

There are various kinds of heating mats that are available, and each is made to fit particular requirements and circumstances. Electric heating mats are simple to use and can be spread out over a wide area rapidly. For bigger projects where consistent heat distribution is essential, hydronic heating mats—which make use of heated water—are perfect. The choice between the two depends on the specific needs of the project as well as the surrounding circumstances. Both offer clear advantages.

Heating mat use is simple, but it needs to be planned and observed carefully. To maintain ideal curing conditions, it is imperative to make sure the mats are put correctly and that the temperature is checked frequently. In cold climates, heating mats can greatly improve the strength and quality of concrete when installed properly.

All things considered, heating mats are a wise purchase for any concrete-related building project in the winter. They offer comfort in knowing that the concrete will properly cure and reach its peak strength. Contractors can enhance project outcomes and increase the longevity of their concrete structures by knowing the various kinds of heating mats and how to use them efficiently.

An efficient way to make sure concrete cures properly in cold weather is to use heating mats. These mats offer steady, regulated heat that keeps things from freezing and speeds up the curing process. They are energy-efficient, simple to install, and suitable for a range of concrete tasks, from modest fixes to substantial pours. Contractors can work in colder climates without sacrificing the strength and durability of the concrete by using heating mats; therefore, they are an indispensable tool for construction in difficult climates.

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