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IS 457:1957 is the Indian Standard (BIS) for general construction of plain and reinforced concrete for dams and other massive structures. This code provides specific guidelines for the construction of mass concrete structures, primarily dams. It focuses heavily on managing the heat of hydration, temperature control, the use of exceptionally large aggregates (up to 150mm), and construction joint detailing to prevent thermal cracking in massive concrete pours.
Code of Practice for General Construction of Plain and Reinforced Concrete for Dams and Other Massive Structures
Overview
Status
Current
Usage level
Specialized
Domain
Water Resources — Cement, Concrete, Aggregates and RCC
! Temperature control is the most critical aspect of mass concrete. Pre-cooling of aggregates or substituting mixing water with flaked ice is often mandatory.
! Embedded cooling pipes (post-cooling) may be required in very massive pours to circulate cold water and extract hydration heat.
! Rapid surface cooling of mass concrete must be avoided to prevent steep thermal gradients and cracking. Insulation during curing may be necessary.
ACI 207.1R-05American Concrete Institute (ACI), USA
HighWithdrawn
Guide to Mass Concrete
Directly addresses materials, mix proportioning, properties, and thermal control for mass concrete structures.
EM 1110-2-2000U.S. Army Corps of Engineers (USACE), USA
HighCurrent
Standard Practice for Concrete for Civil Works Structures
Provides comprehensive standards for concrete used in dams, locks, powerhouses, and other massive civil structures.
ACI 301-20American Concrete Institute (ACI), USA
MediumCurrent
Specifications for Structural Concrete
General concrete specification that includes a dedicated section (Section 8) for mass concrete requirements.
CIRIA C766Construction Industry Research and Information Association (CIRIA), UK
MediumCurrent
Control of cracking in early-age concrete
Focuses specifically on the key challenge of thermal crack control, a central theme of IS 457.
Key Differences
≠IS 457:1957 is based on empirical methods and lacks quantitative limits for thermal control, whereas modern codes like ACI 207.1R mandate detailed thermal analysis and specify maximum temperature differentials.
≠The Indian standard has little to no mention of chemical admixtures. Modern equivalents extensively detail the use of water-reducers, retarders, superplasticizers, and air-entraining agents to control heat, workability, and durability.
≠IS 457 focuses on Portland cement types. Modern standards heavily emphasize the use of Supplementary Cementitious Materials (SCMs) like fly ash and ground granulated blast-furnace slag (GGBS) to reduce heat of hydration and improve durability.
≠IS 457 uses outdated concrete grade designations (e.g., M150) based on specified proportions, while current international standards use performance-based specifications based on compressive strength (e.g., MPa or psi) and other durability criteria.
Key Similarities
≈All standards recognize that managing the heat of hydration to prevent thermal cracking is the primary objective in the design and construction of mass concrete.
≈Both IS 457 and modern codes recommend the use of the largest practical maximum size of coarse aggregate to reduce water and cement demand, thereby lowering heat generation and shrinkage.
≈The fundamental construction practice of placing concrete in managed lifts or blocks to control heat dissipation is a core principle shared by IS 457 and its international counterparts.
≈An emphasis on robust, well-braced formwork capable of withstanding high pressures from deep pours and the need for extended and thorough curing are common to both the old Indian standard and current international guides.
Parameter Comparison
Parameter
IS Value
International
Source
Typical Lift Height
Generally limited to about 1.5 m.
Typically 1.5 m to 2.3 m, but must be justified by thermal analysis.
ACI 207.1R-05
Maximum Size of Coarse Aggregate
Up to 150 mm, or even 200 mm in special cases.
Commonly 75 mm to 150 mm.
EM 1110-2-2000
Maximum Allowable Temperature Differential
Not specified numerically; qualitative guidance to avoid cracking.
Often limited to 20°C (35°F) between the core and the surface.
ACI 207.1R-05
Minimum Curing Period
Not less than 21 days for dams.
Minimum 14 days, often 21-28 days or longer depending on SCMs and exposure.
USACE EM 1110-2-2000
Recommended Slump
As low as possible, not exceeding 25 to 50 mm.
Typically 25 to 75 mm (without water reducer).
ACI 207.1R-05
Fly Ash Content (as % of cementitious material)
Not mentioned; use of pozzolana is suggested but not quantified.
Typically 25% to 50% for Class F fly ash; can be up to 70% in some applications.
EM 1110-2-2000
⚠ Verify details from original standards before use
Key Values4
Quick Reference Values
maximum aggregate size150 mm (for mass concrete interior)
minimum curing period14 days
slump mass concrete25 mm to 50 mm
max placement temperatureTypically restricted to limit peak hydration temperature (often 15°C to 20°C placement)
What is the primary difference between IS 457 and IS 456?+
IS 457 specifically deals with mass concrete (like dams) where heat of hydration and thermal cracking are primary design constraints, whereas IS 456 is for general building concrete.
What is the maximum aggregate size permitted for mass concrete?+
Aggregates up to 150 mm are typically permitted in the interior of mass concrete to reduce the cementitious content, thereby lowering the heat of hydration.
How is temperature controlled during placement?+
Through pre-cooling of raw materials (chilled water, ice flakes, shaded aggregates), post-cooling using embedded pipe systems, and lifting height restrictions.