Early-Age Cracking in Concrete: Causes, Consequences, Remedial Measures, and Recommendations

Early-Age Cracking of Fly Ash and GGBFS Concrete Due to Shrinkage, Creep, and Thermal Effects: A Review

Supplementary cementitious materials (SCMs) are eco-friendly cementitious materials that can partially replace ordinary Portland cement (OPC). The occurrence of early-age cracking in OPC-SCM blended cement is a significant factor impacting the mechanical properties and durability of the concrete. This article presents a comprehensive review of the existing research on cracking in OPC-SCM concrete mix at early ages. To assess the effects of SCMs on the early-age cracking of concrete, the properties of blended cement-based concrete, in terms of its viscoelastic behavior, evolution of mechanical performance, and factors that affect the risk of cracking in concrete at early ages, are reviewed. The use of SCMs in OPC-SCM concrete mix can be an effective method for mitigating early-age cracking while improving the properties and durability of concrete structures. Previous research showed that the shrinkage and creep of OPC-SCM concrete mix are lower than those of conventional concrete. Moreover, the lower cement content of OPC-SCM concrete mix resulted in a better resistance to thermal cracking. Proper selection, proportioning, and implementation of SCMs in concrete can help to optimize the performance and reduce the environmental impact of OPC-SCM concrete mix.

Comparative Analysis of Engineering Carbonation Model Extensions to Account for Pre-Existing Cracks

Cracks in reinforced concrete structures can accelerate the local depassivation of reinforcement due to carbonation. Different approaches have been proposed to account for pre-existing cracks within engineering models to predict the carbonation depth. In this study, we provide a detailed comparative analysis of different extensions available for the fib carbonation model to account for cracks, viz., crack influence factor (CIF) approaches, a diffusion-based model and the crack depth adaption. The model extensions are first validated against a dataset of lab data collected from the literature and additional experiments performed as the part of this study. The CIF approaches achieved the highest accuracy for the carbonation depth prediction when compared against lab data. The diffusion-based model was inaccurate for low CO2 concentrations. The crack depth adaption provides overly conservative results. No model was found to be best performing, and large scatter was observed between predicted and experimental values. This emphasizes the need for more detailed multi-physics-based models to achieve accurate predictions. For further comparison, service life predictions were conducted for two structural scales, viz., the whole structure and the cracked area. It is concluded that the choice of model extension and the structural scale of analysis have a large influence on predicted probability of failure.

Effect of using limestone fines on the chemical shrinkage of pastes and mortars

The main aim of this study is to examine the effect of incorporating limestone fine (LF) on chemical shrinkage of pastes and mortars. For this purpose, five paste and five mortar mixes were prepared with 0, 5, 10, 15, and 20% (by weight) LF as a replacement of cement. The water-to-binder (w/b) ratio was 0.45 for all mixes. The sand-to-binder (s/b) ratio in the mortar mixes was 2. Testing included chemical shrinkage, compressive strength, density, and ultrasonic pulse velocity (UPV). Chemical shrinkage was tested each hour for the first 24 h, and thereafter each 2 days until a total period of 90 days. Furthermore, compressive strength and UPV tests were conducted at 1 day, 7, 28, and 90 days of curing. The results show that the long-term chemical shrinkage of pastes was found to increase with the increase in LF content up to 15%. Beyond this level of replacement, the chemical shrinkage started to decrease. However, the chemical shrinkage for mortars increased with the increase in LF content up to 10% LF and a decrease was observed beyond this level. It was also noticed that compressive strength for pastes and mortars attained the highest value for mixes containing 10 and 15% LF. The trend in the UPV results is somewhat similar to those of strength. Density for pastes and mortars increased up to 15% LF followed by a decrease at 20% replacement level. Correlations between the various properties were conducted. It was found that an increase in chemical shrinkage led to an increase in compressive strength.

The Effect of Harsh Environmental Conditions on Concrete Plastic Shrinkage Cracks: Case Study Saudi Arabia

Due to climate change and population expansion, concrete structures are progressively being subjected to more extreme environments. As the environment affects plastic shrinkage directly, there is a need to understand the effect of environmental changes on plastic shrinkage cracking. This paper examines the plastic shrinkage crack development parametrically at low, mid, and high drying environmental conditions, corresponding to different environments in three Saudi cities. The effects of water-cement ratios and quantities of recycled tire steel fibers (RTSF) in concrete are also investigated. The different environmental conditions for the plastic shrinkage tests were simulated in a specially designed chamber as per ASTM C1579, 2006. A digital image processing (DIP) technique was used to monitor crack initiation and development. Through the use of the crack reduction ratio (CRR), it was found that 30 kg/m³ of RTSF can control plastic shrinkage cracks at low and mid conditions. For the more extreme (high) conditions, the use of 40 kg/m³ of RTSF fiber was sufficient to completely eliminate surface plastic shrinkage cracks. This work can help develop more sustainable concrete structures in a wider set of environmental conditions and help mitigate the impact of climate change on concrete infrastructure.

The Correlation between Shrinkage and Acoustic Emission Signals in Early Age Concrete

This study analysed the processes of damage formation and development in early age unloaded concrete using the acoustic emission method (IADP). These are of great importance in the context of the durability and reliability of a structure, as they contribute to reducing its failure-free operation time. Concrete made with basalt aggregate and Portland or metallurgical cement cured under different conditions after demoulding was the test material. The obtained damage values were compared with the measured concrete shrinkage, and a shrinkage strain-acoustic emission signal (resulting from damage) correlation was found. The correlation allows easy measurement of damage level in the early period of concrete hardening, and consequently can be the basis of a non-destructive method.

Relationship between Bacterial Contribution and Self-Healing Effect of Cement-Based Materials

The civil research community has been attracted to self-healing bacterial-based concrete as a potential solution in the economy 4.0 era. This concept provides more sustainable material with a longer lifetime due to the reduction of crack appearance and the need for anthropogenic impact. Regardless of the achievements in this field, the gap in the understanding of the importance of the bacterial role in self-healing concrete remains. Therefore, understanding the bacterial life cycle in the self-healing effect of cement-based materials and selecting the most important relationship between bacterial contribution, self-healing effect, and material characteristics through the process of microbiologically (bacterially) induced carbonate precipitation is just the initial phase for potential applications in real environmental conditions. The concept of this study offers the possibility to recognize the importance of the bacterial life cycle in terms of application in extreme conditions of cement-based materials and maintaining bacterial roles during the self-healing effect.

Orthofaçade-Based Assisted Inspection Method for Buildings

Building façade assessment could be performed in a more efficient way using a multidisciplinary approach and modern technologies. This study proposes the orthofaçade-based assisted inspection method (AIM), universal and applicable to different types of façade cladding and suitable for application in the condition assessment of inaccessible building façades or high-rise and large structures of all kinds. The AIM method offers a multidisciplinary approach by combining unmanned aerial vehicle (UAV) technology, electronic tachymetry, and digital image processing techniques (photogrammetry and open-source computer vision methods). The method was verified in a case study performed on a high-rise building façade. On-site data acquisition of high-resolution images of façade and control points was conducted by UAV and tachymetry. The data were further processed in photogrammetric software in order to generate a georeferenced orthofaçade. Crack detection was performed at pixel level via computer code using the OpenCV library methods. The established diagnostic model, defined by control points, enables precise determination of crack location. Crack length, width, or area could be calculated based on the coordinates of its points, by performing simple mathematical operations. The AIM method provides automation of crack detection and precise determination of location and geometrical parameters of detected crack.

A Review of the Use of Natural Fibers in Cement Composites: Concepts, Applications and Brazilian History

The use of natural lignocellulosic fibers has become popular all over the world, as they are abundant, low-cost materials that favor a series of technological properties when used in cementitious composites. Due to its climate and geographic characteristics, Brazil has an abundant variety of natural fibers that have great potential for use in civil construction. The objective of this work is to present the main concepts about lignocellulosic fibers in cementitious composites, highlighting the innovation and advances in this topic in relation to countries such as Brazil, which has a worldwide prominence in the production of natural fibers. For this, some common characteristics of lignocellulosic fibers will be observed, such as their source, their proportion of natural polymers (biological structure of the fiber), their density and other mechanical characteristics. This information is compared with the mechanical characteristics of synthetic fibers to analyze the performance of composites reinforced with both types of fibers. Despite being inferior in tensile and flexural strength, composites made from vegetable fibers have an advantage in relation to their low density. The interface between the fiber and the composite matrix is what will define the final characteristics of the composite material. Due to this, different fibers (reinforcement materials) were analyzed in the literature in order to observe their characteristics in cementitious composites. Finally, the different surface treatments through which the fibers undergo will determine the fiber-matrix interface and the final characteristics of the cementitious composite.

Investigation of Self-Healing Mortars with and without Bagasse Ash at Pre- and Post-Crack Times

Cracks in typical mortar constructions enhance water permeability and degrade ions into the structure, resulting in decreased mortar durability and strength. In this study, mortar samples are created that self-healed their cracks by precipitating calcium carbonate into them. Bacillus subtilus bacterium (10⁻⁷, 10⁻⁹ cells/mL), calcium lactate, fine aggregate, OPC-cement, water, and bagasse ash were used to make self-healing mortar samples. Calcium lactates were prepared from discarded eggshells and lactic acid to reduce the cost of self-healing mortars, and 5% control burnt bagasse ash was also employed as an OPC-cement alternative. In the presence of moisture, the bacterial spores in mortars become active and begin to feed the nutrient (calcium lactate). The calcium carbonate precipitates and plugs the fracture. Our experimental results demonstrated that cracks in self-healing mortars containing bagasse ash were largely healed after 3 days of curing, but this did not occur in conventional mortar samples. Cracks up to 0.6 mm in self-healing mortars were filled with calcite using 10⁻⁷ and 10⁻⁹ cell/mL bacteria concentrations. Images from an optical microscope, X-ray Diffraction (XRD), and a scanning electron microscope (SEM) were used to confirm the production of calcite in fractures. Furthermore, throughout the pre- and post-crack-development stages, self-healing mortars have higher compressive strength than conventional mortars. The precipitated calcium carbonates were primed to compact the samples by filling the void spaces in hardened mortar samples. When fissures developed in hardened mortars, bacteria became active in the presence of moisture, causing calcite to precipitate and fill the cracks. The compressive strength and flexural strength of self-healing mortar samples are higher than conventional mortars before cracks develop in the samples. After the healing process of the broken mortar parts (due to cracking), self-healing mortars containing 5% bagasse ash withstand a certain load and have greater flexural strength (100 kPa) than conventional mortars (zero kPa) at 28 days of cure. Self-healing mortars absorb less water than typical mortar samples. Mortar samples containing 10⁻⁷ bacteria cells/mL exhibit greater compressive strength, flexural strength, and self-healing ability. XRD and SEM were used to analyze mortar samples with healed fractures. XRD, FTIR, and SEM images were also used to validate the produced calcium lactate. Furthermore, the durability of mortars was evaluated using DTA-TGA analysis and water absorption tests.

Preparation, Surface Characterization, and Water Resistance of Silicate and Sol-Silicate Inorganic-Organic Hybrid Dispersion Coatings for Wood

The purpose of this study was to comparatively investigate the behavior of silicate and sol-silicate coatings non-modified or modified with an organosilane on wood and on wood pre-coated with silica-mineralized primers. Adhesion strength, morphology, and water permeability and related damages were studied to evaluate the possibility of utilizing such inorganic-based coating systems for durable protection of wood without or with relatively cheap and water-borne primers. Potassium silicate and potassium methylsiliconate aqueous solutions and a colloidal silica were used for the preparation of the coatings. The white coating paints were brushed on beech wood substrates at a rate of 220 g·m-2. The coatings exhibited good coverage ability. The pull-off adhesion strength values appeared to be related to pH following a polynomial law. The adhesion strength for the silicate coatings were adequate (above 3 MPa and up to 5 MPa) for wood, whereas the values for the sol-silicates were too low for practical applications. The adhesion values were in general higher for the samples cured in a climate room (23 ± 3 °C and 75 ± 2% relative humidity) than the samples cured in the ambient atmosphere of the laboratory (23 ± 3 °C and 25 ± 5% relative humidity). The presence of microdefects (cracks, holes) was revealed in the coating layers by optical and scanning electron microscopy. The surface roughness parameters assessed by confocal scanning laser microscopy were dependent on the magnification applied for their measurement. The arithmetic average roughness Sa was between 5 µm and 10 µm at magnification 5× and between 2.5 μm and 10 µm at magnification 20×. The maximum peak-to-valley height Sz confirmed the presence of open pores emerging through the coatings. The open pores constitute free pathways for water ingress through the coatings, and could explain the high water absorption of the coatings including the methysiliconate-containing silicate coating and despite the relatively high water contact angle and low wettability exhibited by this sample. The post-application of a hydrophobizing solution containing hexadecyltrimethoxysilane and dimethyloctadecyl[3-(trimethoxysilyl)propyl]ammonium chloride considerably reduced the water permeability, while application of nanosilica-containing organic primers increased the adhesion for the coatings. Silicate coatings with adhesion great enough and resistance against water damages can be generated on wood even without a primer using low silica-to-alkali ratio binders and an organosilane additive. The sol-silicate coatings appear to be applicable only with a primer. The improvement of the paint formulations to control the formation of microcracks and open pores could be useful to reduce the liquid water permeability and increase durability. Otherwise, the application of a hydrophobizing treatment can be used for this purpose.

Feasibility and Compatibility of a Biomass Capsule System in Self-Healing Concrete

Cracking can facilitate deteriorations of concrete structures via various mechanisms by providing ingress pathways for moisture and aggressive chemicals. In contrast to conventional maintenance methods, self-healing is a promising strategy for achieving automatic crack repair without human intervention. However, in capsule-based self-healing concrete, the dilemma between capsules' survivability and crack healing efficiency is still an unfathomed challenge. In this study, the feasibility of a novel property-switchable capsule system based on a sustainable biomass component, polylactic acid, is investigated. Capsules with different geometries and dimensions were studied focusing on the compatibility with concrete, including survivability during concrete mixing, influence on mortar and concrete properties, and property evolution of the capsules. The results indicate that the developed elliptical capsules can survive regular concrete mixing with a survival ratio of 95%. In concrete containing 5 vol.% of gravel-level capsules, the compressive strength was decreased by 13.5% after 90 days, while the tensile strength was increased by 4.8%. The incorporation of 2 vol.% of sand-level capsules did not impact the mortar strength. Degradation and switchable properties triggered by the alkaline matrix of cement were observed, revealing the potential of this novel biomass capsule system in achieving both high survivability and self-healing efficiency in concrete.

Evaluating the Early-Age Crack Induction in Advanced Reinforced Concrete Pavement Using Partial Surface Saw-Cuts

The technological innovation of continuously reinforced concrete pavement (CRCP) that contains a significantly reduced amount of reinforcement and the same fundamental behavior as CRCP is called advanced reinforced concrete pavement (ARCP). This new concept of a rigid pavement structure is developed to eliminate unnecessary continuous longitudinal steel bars of CRCP by using partial length steel bars at predetermined crack locations. In Belgium, partial surface saw-cuts are used as the most effective crack induction method to eliminate the randomness in early-age crack patterns by inducing cracks at the predetermined locations of CRCP. The reinforcement layout of ARCP is designed based on the distribution of steel stress in continuous longitudinal steel bar in CRCP and the effectiveness of partial surface saw-cuts as a crack induction method. The 3D finite element (FE) model is developed to evaluate the behavior of ARCP with partial surface saw-cuts. The early-age crack characteristics in terms of crack initiation and crack propagation obtained from the FE simulation are validated with the field observations of cracking characteristics of the CRCP sections in Belgium. The finding indicates that there is fundamentally no difference in the steel stress distribution in the partial length steel bar of ARCP and continuous steel bar of CRCP. Moreover, ARCP exhibits the same cracking characteristics as CRCP even with a significantly reduced amount of continuous reinforcement.

Insight into Thermal Stress Distribution and Required Reinforcement Reducing Early-Age Cracking in Mass Foundation Slabs

The heat released during cement hydration results in temperature-induced non-uniform volume changes in concrete structures. As a consequence, tensile thermal stresses of significant values may occur. The level of these stresses can be lowered by using various technological measures during the construction process and a proper concrete mix composition. Nevertheless, the application of an appropriate reinforcement is a reliable method for controlling the width and spacing of possible cracks. The rules for calculating this reinforcement are not precisely detailed in the standards devoted to concrete structures. Additionally, the correct calculation of the reinforcement requires the identification of the tensile stress distribution in a mass slab. The presented study provides insight into stress distribution and relevant reinforcement for controlling early-age cracks of thermal origin. The existing standards and guidelines are discussed and clarified. The possible paths for calculating the reinforcement are proposed through the example of mass foundation slabs with different levels of external restraints. The results indicate a significant impact of the calculation method as well as the restraint conditions of the slab on the area of required reinforcement.

Impact of Bio-Carrier Immobilized with Marine Bacteria on Self-Healing Performance of Cement-Based Materials

The present study evaluated the self-healing efficiency and mechanical properties of mortar specimens incorporating a bio-carrier as a self-healing agent. The bio-carrier was produced by immobilizing ureolytic bacteria isolated from seawater in bottom ash, followed by surface coating with cement powder to prevent loss of nutrients during the mixing process. Five types of specimens were prepared with two methods of incorporating bacteria, and were water cured for 28 days. To investigate the healing ratio, the specimens with predefined cracks were treated by applying a wet–dry cycle in three different conditions, i.e., seawater, tap water, and air for 28 days. In addition, a compression test and a mercury intrusion porosimetry analysis of the specimens were performed to evaluate their physico-mechanical properties. The obtained results showed that the specimen incorporating the bio-carrier had higher compressive strength than the specimen incorporating vegetative cells. Furthermore, the highest healing ratio was observed in specimens incorporating the bio-carrier. This phenomenon could be ascribed by the enhanced bacterial viability by the bio-carrier.

Evaluation of the Thermal and Shrinkage Stresses in Restrained High-Performance Concrete

The early age volume deformation is the main course for the cracking of high-performance concrete (HPC). Hence, the shrinkage behavior and the restrained stress development of HPC under different restraints and curing conditions were experimentally studied in this paper. The method to separate the stress components in the total restraint stress was proposed. The total restrained stress was separated into autogenous shrinkage stress, drying shrinkage stress and thermal stress. The results showed that the developments of the free shrinkage (autogenous shrinkage and drying shrinkage) and the restrained stress were accelerated when the drying began; but the age when the drying began did not significantly influence the long-term shrinkage and restrained stress of HPC; the autogenous shrinkage stress continuously contributed to the development of the total restrained stress in HPC; the drying shrinkage stress developed very rapidly soon after the drying began; and the thermal stress was generated when the temperature dropped. The thermal stress was predominant at the early age, but the contributions of the three stresses to the total restrained stress were almost the same at the age of 56 d in this study.

Determination of Fracture Properties of Concrete Using Size and Boundary Effect Models

Tensile strength and fracture toughness are two essential material parameters for the study of concrete fracture. The experimental procedures to measure these two fracture parameters might be complicated due to their dependence on the specimen size or test method. Alternatively, based on the fracture test results only, size and boundary effect models can determine both parameters simultaneously. In this study, different versions of boundary effect models developed by Hu et al. were summarized, and a modified Hu-Guan’s boundary effect model with a more appropriate equivalent crack length definition is proposed. The proposed model can correctly combine the contributions of material strength and linear elastic fracture mechanics on the failure of concrete material with any maximum aggregate size. Another size and boundary model developed based on the local energy concept is also introduced, and its capability to predict the fracture parameters from the fracture test results of wedge-splitting and compact tension specimens is first validated. In addition, the classical Bažant’s Type 2 size effect law is transformed to its boundary effect shape with the same equivalent crack length as Koval-Gao’s size and boundary effect model. This improvement could extend the applicability of the model to infer the material parameters from the test results of different types of specimens, including the geometrically similar specimens with constant crack-length-to-height ratios and specimens with different initial crack-length-to-height ratios. The test results of different types of specimens are adopted to verify the applicability of different size and boundary effect models for the determination of fracture toughness and tensile strength of concrete material. The quality of the extrapolated fracture parameters of the different models are compared and discussed in detail, and the corresponding recommendations for predicting the fracture parameters for dam concrete are proposed.