Research on Crack Control of Mass

Concrete Structure
Sameer Kadam, Navneet Kallapalli
Department of civil engineering,
Saraswati college of engineering, Kharghar.
[email protected]
[email protected]

Abstract— With the development of economy in our country,

I. INTRODUCTION
the scale of construction has become more and more
complicated. This cause the problem of mass concrete cracks Many concrete structures in the construction of the project
in industrial and civil buildings increasingly prominent and and the use of engineering in varying degrees, different
become a fairly common problem. The problem of mass forms of cracks, which is a fairly common phenomenon.
cracks in mass concrete is very complex and involves all It is a long plagued technical problems of construction
aspects related to the engineering structure. The control of workers. The microscopic study of the strength of
temperature cracks in mass concrete foundation is related to
concrete and the experience provided by a large number
geotechnical, structural, building materials, construction,
environment and other multi-disciplinary. The hydrothermal
of engineering practices have shown that the cracks in the
heat released by the mass concrete in the hardening process structure are unavoidable. The cracks are a kind of
which produces a large temperature change, and the acceptable material, such as the requirement of anti will
resulting of temperature stress is the main factor leading to pay a huge economic cost; scientific requirements should
the occurrence of cracks in the concrete, thus affecting the be to control the extent of its tolerance within the
integrity of the structure, water resistance and durability, allowable range. These aspects of the prediction,
and become structural hidden dangers. Therefore, the mass prevention, and treatment of cracks, collectively referred
concrete in the construction must consider the crack control. to as 'building cracks control', this aspect of scientific
The reason and control measures of the temperature cracks research work is important for practical significance,
of mass concrete are analyzed and summarized. According to
technical and economic significance, a large volume of
the specific situation, these measures are applied to the
concrete large-scale basic engineering construction, and the
concrete structure cracks are mainly due to deformation.
material selection, mixing ratio, admixture, construction For the definition of mass concrete, the American
arrangement and pouring process, conservation and other Concrete Society has had the requirement that 'any large
aspects to take a strict control measures. At the same time the volume of concrete in situ, which is large by volume,
basic position of the internal and external temperature
must be required to take measures to solve the problem
difference was monitored. The temperature control measures
and monitoring results taken for the basic engineering
of hydration heat and consequent volume deformation,
provide a reference for the construction of similar projects limit the cracking to reduce the crack. '[1] Japan Institute
and provide the basis for further theoretical research. The of Architectural standards is defined as:' the minimum
design of multi-storey buildings currently growing in both size of the structural section of more than 800mm, while
height and size. To compensate for these growths, it is hydration heat caused by the maximum temperature of
necessary to design a larger and deeper foundation. This concrete and the difference between the outside
causes more mass concrete use in the foundation temperature is expected to exceed 25 ℃ of concrete, for
construction. Mass concrete has a special characteristic than the mass of concrete. '[2] China's engineering sector that
ordinary concrete. Mass concrete can produce very high when the concrete structure section size is greater than
hydration heat because of the very large casting volume. If
1m, it is called large volume of concrete. [3] The
not well controlled, this heat of hydration can cause cracks in
the concrete. Several methods can be used to control the heat
literature pointed out: in the industrial and civil building
of hydration that occurs, such as the use of ice as a part of structure, the general cast-in-place continuous wall
batch water, the use of water flow in embedded pipe, structure, underground structures, and equipment base is
additives such as fly ash and others. The combination of using easily caused by the temperature shrinkage stress caused
ice as part of the batch water and water flow in embedded by the structure, commonly known as 'mass concrete
pipe to control the heat of hydration was used in this study. structure.'
After this method was applied in mass concrete casting,
concrete temperature checking conducted for several days. From the definition of mass concrete from above
Temperature checks indicate that the method has been mention, mass concrete is larger in geometric
successfully managed to keep the heat of hydration that dimensions, taking into account the volume change and
occurs in the concrete remains below the safe limit. fracture problems caused by cement hydration heat.

Keywords— mass concrete; crack control; hydration heat; There are four main points to consider in designing a
temperature stress; cooling; mass concrete. The first is the availability of concrete,
concrete mixer truck and concrete pump in sufficient
quantities. This is to keep the concrete pouring not
stopped due to lack of supply, resulting in a cold joint on can lessen the heat-generating potential of the
the concrete. The second is a good mix design, so that concrete;
the initial temperature of the concrete can be pushed as
• Precooling, where cooling of ingredients achieves
low as possible. The third is the cooling and insulation
a lower concrete temperature as placed in the structure;
planning of the system, to keep the temperature
difference in the concrete within the boundary. The • Post cooling, where removing heat from the
fourth is the temperature evaluation that occurs on the concrete with embedded cooling coils limits the
concrete after the concrete casting. temperature rise in the structure; and
India is a developing country, which is currently • Construction management, where efforts are made
focusing on infrastructure development. Hundreds of to protect the structure from excessive temperature
buildings, seaports and toll roads built by the differentials by knowledgeable employment of
government in the last 4 years. This development concrete handling, construction scheduling, and
resulted in the growing demand for concrete and the construction procedures.
development of concrete technology in India. To carry
Typical construction practices used to control temperature
out the construction of the building effectively and
changes within concrete structures include according to
efficiently, foundation design using mass concrete as a
ACI.207-4R.1993 [2] are:
pile cap are widely used in India. Implementation of this
method would require a good and comprehensive design. • Cooling batch water
Where all aspects of preparation, implementation and
evaluation shall be conducted in accordance with the • Replacing a portion of the batch water with ice
standards of applicable regulations. • Shading aggregates in storage
The planning and construction of mass concrete • Shading aggregate conveyors
foundations is a complex thing, because many factors
and many parties involved. For this reason, this research • Spraying aggregate stockpiles for evaporative
paper is expected to provide guidance on the cooling effect
construction phase of mass concrete foundation. In this
• Immersion of coarse aggregates
research, the case study is a multilevel building in
Surabaya, India. In this research paper, will be explained • Vacuum evaporation of coarse aggregate moisture
about the methods of planning, implementation and
evaluation used in the construction of mass concrete • Nitrogen injection into the mix
foundations. • Using light-colored mixing and hauling equipment
II. LITERATURE REVIEW
• Placing at night
The mass concrete was first used in the construction of • Prompt application of curing water
the dam in America in early 1930. At that time many dam
was built with a large wall thickness, so it takes concrete • Post-cooling with embedded cooling pipes
with a very large volume. In the mass concrete
construction, there is a lot of damage in the form of cracks • Controlled surface cooling
on the wall of dam that has been completed. From the • Avoiding thermal shock at form removal
results of the current study, it was recorded that high
temperature rise due to cement hydration, correlated • Protecting exposed edges and comers from
directly with the level of crack that occurred. To do excessive heat loss
special research about mass concrete, ACI Committee
207, Mass Concrete, was organized in1930 for the In the design of reinforced concrete elements, there is a
purpose of gathering information about the significant temperature change to be considered is the difference
properties of mass concrete in dams and factors which between concrete peak temperatures achieved during
influence these properties (ACI,1996) [1]. initial hydration (usually within the first week) and the
minimum temperature of the concrete. An increase in
To ensure that the results of mass concrete work properly, initial hydration temperature can produce stress on the
control of the concrete temperature must be performed. concrete. At this early age, the modulus of elasticity of
According to ACI 207.1R-96 [1], there are four element the concrete is small, so the pressure caused by the
to consider in mass concrete construction, are: temperature rise is not significant. The level of heat
generated from the concrete depends on the amount of
• Cementitious material content control, where the cement and pozzolan volume (if any), the composition
choice of type and amount of cementitious materials and the fineness of the cement. The hydration
temperature is influenced alternately by the amount of IV. RESEARCH STATUS
heat lost or obtained as regulated by the size of the
member and the exposure conditions (ACI,1995) [3]. A. Domestic situation

One of the most widely used pozzolan material, as China has do more research on the cracking of
cementitious material in concrete mix is fly ash. With concrete, and in the construction project, there are
the use of fly ash as a cementitious material, the use of some achievements in cracking of concrete under the
cement in the concrete mixture can be reduced, so that action of load. With the large-scale capital
the hydration temperature of the concrete can also be construction, the new problems brought by the
reduced. For use in concrete, ASTM C618 specifies the application of commercial concrete, the study of
requirements for Class F and Class C fly ashes and concrete cracking under non - load is mainly focused
Class N for raw or calcined natural pozzolans. on the causes and control measures of cracking.
According to “ACI Concrete Terminology,” fly ash is Professor Huang Tiyuan [4] from the concrete material
“the finely divided residue that results from the itself analysis of the reasons for the early concrete
combustion of ground or powdered coal and that is cracking and the construction unit in order to improve
transported by flue gases from the combustion zone to the transition period to pursue the early strength of
the particle removal systems” (ACI, 2008) [4]. The use cement and cement manufacturers in order to meet the
of fly ash as a cement replacement material in the needs of the market is also the pursuit of early strength,
concrete mixture has a maximum limit. For fly ash and even 'super early strong.' While the early
Class F recommended percentage is 15 - 25% of the performance of early strength concrete is relatively
weight of cementitious material. As for Class C fly insufficient. A lot of cement 3 days strength has exceeded
ash, the recommended percentage is 20-35% of a lot of national standards, too high early strength prone
cementitious material (ACI,1993) [5]. to early cracks. At the same time, early strength is easy
In general, there is a limit of temperature in the mass to cause deterioration of concrete performance.
concrete to prevent heat, crack the concrete and
B. International Situation
maintain the durability of the concrete. The maximum
permissible temperature limit on concrete is usually From the international norms and some of the major
taken at 70 ° C. While the temperature difference projects of the actual design shows that the deformation
between the center and the maximum concrete surface of the building structure caused by the cracks caused by
is 20 ° C. However, in many cases, the temperature the objective existence of two types of schools:
limit is determined by each project (Soo Geun, 2010)
[6]. The first class, the design specification is very flexible, there
are no clear provisions of the calculation of cracks, the
III. APLLICATION OF MASS design method left to the designer free to deal with. The
CONCRETING IN ENGINEERING installation of the expansion joints and settlement joints,
there is no strict rules, basically set by experience, there
In the water conservancy project, mass concrete is
are many projects without leaving the expansion joints,
mainly used for the pouring of concrete dams, such as
leaving no settlement joints, basically take the 'crack on
the pouring of concrete in the Three Gorges Dam, and
the block, block on the row' of the actual treatment
its concrete pouring scale has attracted much attention.
means. Some of the relevant cracks are calculated only as
In bridge engineering, large volume concrete pouring
a reference and not as a requirement.
is mainly used for piers. Industrial and civil building
structure, large equipment foundation, high-rise The second class, the design specifications are clearly
building box foundation floor, raft foundation floor, defined, there are formulas for the calculation of the load
continuous wall and underground tunnel are large cracks and have a strict allowable width limit. There is no
volume concrete structure. With the strengthening of calculation of the cracks caused by deformation, as long
economic strength, China's high-rise buildings in large as the specification at a certain distance to leave an
numbers, the scale of the project is expanding, the expansion joints, the load difference is large, leaving the
structure is also increasingly complex, large-scale sagging that the problem no longer exists, that is, leaving
industrial and civil buildings in some of the basis of its the seam is not broken design principles.
size of several thousand m3 or more common, and
some High-rise civil construction of the raft-based The impact of temperature on the deformation of
concrete volume of some is more than 10,000 m3, the concrete structures, countries have the corresponding
thickness is 2 - 4m, the length is more than 100m. For provisions. For the pouring temperature of a large
example, Shanghai Jinmao building large volume volume of concrete, the United States does not exceed 32
concrete raft foundation, the thickness is 4m, and the C; while, for Japan Civil Engineering Society
total concrete volume is 13500 m3. construction specifications do not exceed 30 C and the
Japanese Institute of Architects regulations do not exceed of heat per gram of ordinary Portland cement up to 500J.
35 C The former Soviet Union stipulates that the Due to the large thickness of the mass concrete, the
temperature of the concrete from the mixing station is not hydration heat is not easily distributed in the structure, so
more than 30 to 35 ° C when the pouring surface it will cause the concrete structure inside the rapid
coefficient is greater than 3; the original West standard warming. In the water conservancy project is generally 15
stipulates that the temperature of the fresh concrete - 25 ℃ [7]. While the construction project is generally 20
unloading shall not exceed 30 C. In China, 'hydraulic - 30 ℃, or even higher. Experiments show that cement
concrete structure construction and acceptance of norms' hydration heat in 1 to 3 days to release the most heat,
(SDJ207-82) provides: large volume of concrete pouring about 50% of the total heat, concrete pouring after 3 to 5
temperature should not exceed 28 C; and in the 'high-rise days, the highest temperature inside the concrete.
building concrete structure technical regulations' (JGJ3- The architectural structure of concrete strength grade is
2002) only provides: 'The basis of large volume of increasing, but there is many structures inappropriate
concrete continuous pouring, should be measured by the selection of the high strength level.
temperature difference', but no specific control value.
B. Impact of internal and external constraints
V. CAUSE ANALYSIS AND
PREDICTION OF CRACKS IN MASS All kinds of concrete structure in the deformation
CONCRETE changes must be subject to certain constraints, thus
A. Types of cracks hindering its free deformation, hinder the deformation of
the factors known as the constraints. Constraints are
In previous study[6], it is pointed out that concrete cracks divided into inner and outer constraints.
can be divided into 'microcracks' and 'macroscopic 1). Outer Constraints
cracks' according to the different crack width of concrete. The deformation of an object is hindered by other
objects, and the deformation of a structure is hindered by
1) Microscopic Cracks: another structure. The interdependence between the
Since the 1960s, through the modern experimental structure and the structure, between objects and objects is
equipment of concrete (such as various solid microscopes, called 'outer constraint'. Because of the different
X-ray equipment, etc.), can be confirmed in the concrete conditions of the various building structures, there are
structure has not yet bear the existence of the invisible different degrees of constraints between the structures.
micro-cracks. Its width is below 0.05 mm. Microcracks According to the size of the constraint degree, the outer
are mainly composed of adhesive cracks, cement stone constraints are divided into three kinds which are
cracks, and aggregate cracks. unconstrained (free body), elastic constraints and full
constraints (embedded solids).
2) Macroscopic Cracks: 2) Inner Constraints
An object or a component itself between the various
Cracks in the concrete with a width of not less than particles of the role of mutual restraint, known as the
0.05 mm are visible cracks, also known as macroscopic 'internal constraints.' There may be different temperatures
cracks. The macroscopic fracture is the result of the and shrinkage deformations along the cross-section of a
continuous expansion of microscopic fractures. member, causing internal confinement stresses between
VI. ANALYSIS OF CRACKS IN MASS successive points of the continuum. The cracks in the
CONCRETE structure, non- penetrating surface cracks accounted for
60% to 70%. The reason for its cracking is mainly due to
The temperature cracks in the mass concrete construction the deformation caused by the self-restraint stress. When
phase are the result of the development of internal the mass of concrete is greater than or equal to 500mm, it
contradictions. Concrete stress and strain due to internal may be due to the uneven cooling of hydration heat and
and external temperature difference, on the other hand, the uneven shrinkage caused by significant self-restraint
external constraints of the structure and the constraints of stress, resulting in surface cracking.
the concrete particles is to prevent this strain, once the
temperature stress can withstand the ultimate tensile C. The impact of external temperature changes
strength of concrete, will produce different degrees of the
cracks. During the construction phase of Mass Concrete
Structures, changes in outside air temperatures have a
A. Effect of hydration heat significant impact on the prevention of massive concrete
cracking. As the higher the ambient temperature, the
The cement produces a lot of heat during the hydration higher the pouring temperature of the concrete; and if the
reaction. This is the main source of heat for mass concrete outside temperature decreases, but also increase the rate
internal temperature rise. The test proved that the amount of concrete cooling, especially the temperature drop, will
greatly increase the outer concrete and internal concrete
temperature gradient, which will lead to transition of the General Work Requirements
temperature stress, easy to make large volume of concrete Mass Concrete Volume : 2710 m3
cracks. • Cement : 667.5 tons
The internal temperature of the concrete is composed of • Sand : 2273.6 tons
the adiabatic temperature rise of the hydration heat, the • Stone : 3005.3 tons
temperature of the pouring temperature and the heat • Fly Ash : 203.25 tons
dissipation temperature of the structure, and the Implementation time : 72 hours Number of
temperature stress is caused by the temperature Ready-mix Company used 2
deformation which caused by the temperature difference. Ready-mix capacity (Company 1) : 1810 m3
At the same time, under high- temperature conditions, a
Ready-mix capacity (Company 2) : 900 m3
large volume of concrete due to the thickness of large,
Target speed of 1 batching plant : 30 m3 / hour
difficult to heat.
Number of "Concrete Pump" : 4 units + 2 units
stand by Truck Mixer
VII. CONTROL MEASURES FOR MASS
CONCRETE CRACKS • Ready-Mix Company 1 : 25 Units
• Ready-Mix Company 2 : 25 Units
Practical experience shows that the cracks in the existing
mass concrete structures are mostly caused by Mass Concrete Pouring Plan
temperature cracks. To prevent the occurrence of Ready-Mix Company 1
temperature cracks is a large volume of concrete research Total pouring targeted is 1810 m3 in 72 Hours
important issue, China since the 1960s began to study, Number of Concrete Pump (CP) use : 2 Concrete
has accumulated a lot of successful experience. Pump Casting speed per Mixer Truck (MT) 7.5 m3 : 30
Engineering measures commonly used to prevent minutes Number of Mixer Truck use : 25 Truck
concrete cracks are: the use of low-heat cement Cycle time of 1 Mixer Truck : 30 minutes
varieties;the concrete structure of a reasonable sub-sub- (Concrete pour to CP) + 20 minutes (cleaning) + 90
block; to meet the strength and other performance minutes (Trip to batching plan) + 90 minutes (Process in
requirements under the premise of minimizing the amount batching plan) + 90 minutes (Travel back to project
of cement; to select the appropriate aggregate; embedded location) = 320 minutes
water pipes, water cooling, reducing the concrete out of Number of Mixer Truck Trip : 241 trip
the machine temperature and pouring temperature; use of Ready-Mix Company 2
surface protection, control of the concrete out of the Total pouring targeted is 900 m3 in 72 Hours
temperature and pouring temperature; Thermal insulation Number of Concrete Pump (CP) use : 2 Concrete
measures to reduce the temperature difference between Pump
inside and outside; to take measures to prevent a large Casting speed per Mixer Truck (MT) 7.5 m3 : 30 minutes
volume of concrete cracks. Number of Mixer Truck use : 25 Truck
Cycle time of 1 Mixer Truck : 30 minutes
A. Study Area (Concrete pour to CP) + 20 minutes (cleaning) + 90
minutes (Trip to batching plan) + 90 minutes (Process in
This study will be conducted on building construction in batching plan) + 90 minutes (Travel back to project
Surabaya, Indonesia. Mass concrete reviewed in this location) = 320 minutes
study is the foundation of the building, with a thickness of Number of Mixer Truck Trip : 120 trip
1.5 to 2 m. The dimensions of the foundation are 70 x 40
m as shown in FIG. 1. B. Mixed design with a mixture of fly ash and cold
water (Precooling)

Use mix design with the following mixture so that the

initial temperature of the concrete can be lowered. Mix
design for fc‟30:

Water Cement Ratio : 0.43

Cement : 250 kg
Fly Ash : 75 kg (30%)
Sand : 839 kg
Gravel : 1109 kg
Water : 150 kg
FIG. 1 FOUNDATION OF BUILDING Water temperature (used ice water) : 7 'C
 Slump : 10 ± 2 cm embedded pipe layout can be seen in Fig.4. The pipe
Admixture : Type D: 0.72 kg, Type F : 4.1 kg used is a 1.5 '' diameter black steel pipe and 1.5 mm
Calculated fresh concrete temperature : 30 ° C thickness. The arrangement of pipes is divided into 3
Calculated peak concrete temperature : 65.7 ° C zones, where each zone has different concrete thickness
and pipe configuration. Their respective water pumps
C. Surface Insulation (Post Cooling) service the pipelines of each zone, having their own
inlets and outlets. The arrangement of pumps and tanks
Surface insulation is performed as soon as the concrete that drain water in each zone can be seen in Fig.5.
surface hardened (1.5 hours of concrete pour time). Surface
insulation is done by covering the surface area of concrete
with a layer of plastic, 2 cm Styrofoam and wet sand with a
thickness of 20 cm. Surface insulation is performed for 14
days, or after concrete temperature difference < 20 ° C. After
surface insulation is removed, proceed with curing using
water or wetted cloth.

Wet Sand

Styrofoam

Plastic Sheet

Concrete

Fig. 4 Embedded pipe installation layout plan

Fig. 2 Diagrammatic representation of cross section of surface
insulation

Fig. 5(A) Embedded pipe system at site

Fig. 3 Surface insulation at site

D. Installation of Pipe Cooling System (Post Cooling)

Pipe cooling is done by flowing cold water into the

iron pipe has been installed within the concrete. Pipe
cooling is done until the concrete temperature drops to
at least 15 ° C from the peak concrete temperature. The
 VIII. CONCRETE TEMPERATURE
MONITORING

To ensure the temperature difference in concrete <20

'C, the temperature in the concrete must be controlled
with thermocouple installed in the concrete.
Thermocouple is installed on 3 layer thickness and 6
point, so the amount of thermocouple is 18 pieces.
Thermocouple measurements are performed every two
hours for the first 24 hours, and every 3 hours for the
next 24 hours. Measurements are made for 5 days, or
Fig. 5(B) Embedded pipe system at site when the concrete has reached a constant temperature.
Installation of thermocouple mounted on top, middle
and bottom position of concrete thickness.
The inlet of this pipe cooling system comes from a Thermocouple is mounted on a PVC pipe bound to the
tank with a capacity of 2 m3. The water at this reservoir reinforcing steel. The outer end of the thermocouple
will be pumped with a High Pressure Pump to the 5 probe is labeled according to position in the concrete and
inlets available. This inlet tube will be equipped with a wrapped in plastic to avoid getting wet. The outer end of
temperature gauge thermometer. The water in this inlet the probe will be connected to the digital thermometer
tank will be cooled with ice cubes. Water from 5 outlets for temperature readings. The measurement of outer air
will be accommodated at a 0.5 m3 capacity tank. Water temperature and temperature in inlet and outlet tanks is
entering at the reservoir will be measured in done simultaneously with thermocouple measurements.
temperature. It will then be flowed back to the inlet tank
for recirculation.

E. Installation of Closed Tents

The installation of a cover tent aims to prevent

raindrops at the time of casting. In addition, the
installation of tents cover also aims to prevent the heat
of sunlight, so that the concrete temperature can be
reduced. Closing Tents can be assembled by themselves
using pipes and tarpaulins, or rent a cover tent with a
6x6 m module.

Fig. 8 Thermocouple for measurement of temperature

Fig. 6 Layout of installation of closed tents

 on the Repair of Concrete Crack by Shotcrete Technique,
International Journal of Civil Engineering and Technology, 9(5),
2018, pp. 611 – 617.
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[J]. Concrete, 2000,7: 3 - 5.
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[15] Li Jiye, Liu Fuchen. Construction quality problems and prevention
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From the temperature, measurements that have been China Construction Industry Press, 1997. 136-137.
made can be concluded as follows:
• From the temperature measurement, it shows
that the increase of concrete temperature occurring in
the mass concrete foundation is still below the
maximum temperature limit (maximum measurement
temperature 68 'C <Maximum Temperature limit of
70'C).
• The measurement results show that the highest
and lowest temperature difference on this mass concrete
foundation, below the permissible temperature
difference (Maximum temperature difference
measurement 13 'C <Maximum Temperature limit of 20
° C).
• Maximum Temperature occurs at approximately
60 hours (3 days) after the casting and began to decrease
the temperature after the 5th day.
• All systems that have been planned to control the
temperature of the concrete can function properly and
with satisfactory results.

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