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Thermal Cracks in Concrete Structure—The Basic Issues to Be Understood

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DOI: 10.1007/978-981-16-0945-9_19

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Thermal Cracks in Concrete
Structure—The Basic Issues
to Be Understood

Trong Chuc Nguyen , Anh Kiet Bui, and Quoc Long Hoang

1 Introduction

Thermal cracks occur in concrete structures caused by the temperature difference

between locations in the structure exceeding the allowable limit. The cooler portion
at the concrete block surface contacting with air ambient cools down quickly and
tends to contract more than that at the warmer portion inside the mass concrete
block. Thermal cracks occur when the restraint resulting in tensile stresses exceeds
the tensile strength of concrete [1–3]. It is noted that thermal cracks not only occur
on mass concrete structures but also others, such as pavements, concrete structures
working in high-temperature environments, etc.
To find out the reason why thermal cracks appear, the following reasons need to
be distinguished.
The cement hydration process: the chemical reaction between cement and
water accompanies an exothermic process [4, 5]. The heat dissipation rate of cement
decreases with time. For small and thin structures, the amount of heat generated
during hydration is quickly diffused into the air and cracks do not occur at an early
age. However, for the mass concrete structures, the amount of internal hydration
heat of the concrete block increases and decreases slowly due to the low thermal
conductivity of concrete, while the concrete zone nearby the surface cools down
quickly and exposes directly to the air ambient. This leads to the contraction of the
surface elements of the concrete block, but they are limited by the internal
expansion of the concrete block. Therefore, uneven contraction, expansion between

T. C. Nguyen
Q. L. Hoang
Institute of Special Construction Engineering, Le Quy Don Technical University,
Hanoi, Vietnam
A. K. Bui (&)
Faculty of Civil Engineering, Ho Chi Minh City Open University,
Ho Chi Minh City, Vietnam
e-mail: [email protected]

© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2021 229
T. Q. Bui et al. (eds.), Structural Health Monitoring and Engineering Structures,
Lecture Notes in Civil Engineering 148,
https://doi.org/10.1007/978-981-16-0945-9_19
230 T. C. Nguyen et al.

elements in concrete blocks causes the formation of thermal cracks. In most cases in
construction, thermal cracks in mass concrete structures often occur at an early age
[6–9].
Effect of ambient temperature and solar radiation: when the elements of the
concrete block are exposed to a hot (or cold) ambient temperature, it leads to a
thermal contraction (or expansion) changing the volume of concrete blocks.
Thermal cracks may occur if the volume change is restraint [10–12].

2 Materials and Methods

2.1 Object of Study

Mass concrete: there are several different definitions of mass concrete based on the
standard of each country. However, the main factor for determining a mass concrete
block structure is depended on its minimum size. According to ACI 301, mass
concrete structures include mat foundations, dams, and other concrete structures
with a width or depth exceeding 4 feet (1.3 m) [13]. Besides, the ratio of surface
area to volume of concrete blocks is also given by many documents to define mass
concrete [14]. Besides, structures that are small in size but use large amounts of
cement or high-heat cement should also take measures to prevent the formation of
thermal cracks at an early age.
The main concern with mass concrete is the thermal gradient formed as dis-
cussed above. From the above reason, thermal cracks on the surface of concrete
blocks are formed at an early age (due to hydration of cement) and later (due to
changes in ambient temperature).
Other concrete structures: thermal cracks can occur not only for mass concrete
structures but also for structures, such as pavement, concrete slabs working in
high-temperature environments, etc.
For cement concrete pavement with a large surface area, it receives heat directly
from the sun and the heat is transmitted downward and heats up. The temperature of
cement concrete pavement is transmitted to the environment by convection form
(the surface). Part of the heat is transferred to the ground through the bottom of the
cement concrete pavement. The heat transfer from the sun to the surface of cement
concrete pavement is described as Fig. 1 [15].
Especially, during the exploitation process, the cement concrete pavements are
affected by the variation of environmental temperature. Thus, the change of ambient
temperature leads to the temperature difference between the surface and the bottom
of the cement concrete pavement. As a result, the temperature difference in the
cement concrete pavement causes contraction and expansion.
The deformation process of cement concrete pavement is prevented from
moving laterally due to friction between the concrete slab and its foundation.
Therefore, thermal stresses are formed on cement concrete pavement [16].
Thermal Cracks in Concrete Structure … 231

Fig. 1 Cement concrete

pavement is affected by
environmental
temperature [15]

2.2 How to Recognize Thermal Cracking?

Thermal cracks are caused by temperature differences exceeding permissible val-

ues. Thereafter they appear randomly on the surface of the concrete block. Thermal
cracks due to temperature effects usually appear within a few days after removing
the formwork.
Cracks related to temperature changes impact the surface of cement concrete
pavement often like cracks due to shrinkage. These cracks usually occur perpen-
dicular to the longest axis of the concrete slab. This type of cracking occurs any
time after the concrete is poured but usually occurs in the first summer or winter of
the first year.

2.3 Several Criteria Are Used to Evaluate Thermal Cracks

To control crack formation, it is necessary to control the maximum temperature

difference in concrete structures. Usually, the permissible temperature difference is
taken as 20 °C and does not depend on the construction area and the type of
concrete.
In Vietnam, according to TCVN 305.2004 “Mass concrete—code of practice of
construction and acceptance”, two factors should be controlled to prevent cracking
in mass concrete structures. First, the temperature difference (DT) between the
center of the mass concrete and its surface should be less than 20 °C. The second,
module of temperature gradient (MT) should be less than 50 °C/m.
232 T. C. Nguyen et al.

According to the CIRIA C600 standard (Great Britain) points out that the
maximum temperature difference between the inner zone of the mass concrete and
its outer surface DTmax is determined by the Eq. (1).

3:7e
DTmax ¼ ð1Þ
a

where e—ultimate tensile strength of early age concrete; a—is the coefficient of
thermal expansion of concrete.
In Japan, the assessment of the formation of cracks in concrete mass can be made
using the cracking index, defined as described in Eq. (2).

f t ð sÞ
Icr ¼ ð2Þ
fsp ðsÞ

where Icr is the index of thermal cracking; ft(s)—tensile strength, corresponding to

the age of concrete s; fsp(s)—is the maximum temperature stress caused by the
cement hydration process per day s.
The cracking can be estimated by Thermal Cracking Index as presented in
Table 1.

2.4 A Method to Solve the Temperature Problem

in the Concrete Structures

To solve the thermal problems including temperature field and thermal stress in
mass concrete structures, the finite element simulation has been used as an opti-
mized option.
The numerical solution of the problem is based on the solution of the differential
equation of the theory of thermal conductivity [14, 15].
     
@ @T @ @T @ @T @T
kx þ ky þ kz þ qv ¼ qc ð3Þ
@x @x @y @y @z @z @s

where kx, ky, and kz—coefficient of heat diffusion of the material in the directions of
the axis X, Y, and Z in the Cartesian coordinate system, respectively, m2/s; qv—

Table 1 Cracking index criteria for controlling thermal crack formation [25]
Crack control criteria Thermal crack index (Icr)
The prevention of cracks Icr  1.5
Possibility of limited cracks 1.2  Icr  1.5
Limiting the occurrence of dangerous cracks 0.7  Icr  1.2
Thermal Cracks in Concrete Structure … 233

internal heat source due to cement hydration (W/m3); c—specific heat of concrete,
kJ/kg.°C; q—density of concrete, kg/m3; T—temperature, (°C); s—time, (day).
When solving the temperature regime, the following boundary condition as
shown in Eq. (4) is used.

@T @T @T

kx n x þ k y n y þ k z n z þ q v þ h T s  Tf ¼ 0 ð4Þ
@x @y @z

where nx, ny, and nz—vector normal to X, Y, and Z direction of heat transfer,
respectively; Ts and Tf —nodal temperature at the boundary points and air tem-
perature, respectively; h—convection coefficient.

3 Results and Discussion

3.1 How to Minimize Thermal Cracks?

3.1.1 Massive Concrete Structures

To minimize thermal crack development in mass concrete structures, it is important

to know which characteristic parameters affect the appearance of thermal cracks.
These are the maximum temperature and temperature difference in mass concrete
blocks. Therefore, the determining maximum temperature in concrete blocks is
necessary to provide appropriate measures to control thermal cracks. Besides, the
reduction of the temperature difference between the inner zone and the concrete
zone at the surface of the concrete block contacting the air ambient should also be
considered. Previous studies indicated that the allowable temperature difference
should not exceed 20 °C [17, 18]. In rare cases, cracks may occur when the tem-
perature difference is lower or higher than the allowable value. The determination of
the maximum temperature and temperature difference in mass concrete block can be
measured by using Finite Element simulation or using thermal sensors inserted
inside the concrete block.
Minimizing crack formation is recommended by designers and contractors. The
main factors causing the formation of thermal cracks should be considered, such as
the initial temperature of the concrete mixture, cement content, cement type, the
time of concreting, curing conditions, etc. [19].
A few measures to minimize cracking formation for mass concrete.
Using cement replacement materials to reduce hydration heat source in mass
concrete structures.
According to Tang et al. [20], the results showed that the replacement of cement
by class F of natural pozzolan (PU) significantly reduces the maximum temperature
in mass concrete structures. Maximum temperatures at the center of concrete blocks
with a composition using 100% cement and with a composition using 20% PU
234 T. C. Nguyen et al.

replacing cement are 65.76 and 52.44 °C after 48 h of hardening, respectively. The
results of the temperature distribution in concrete blocks are shown in Fig. 2.
Hence, it is necessary to optimize the composition of the concrete mixture by
using cement replacement materials, such as fly ash, slag, or using low-heat cement.
Using chemical admixtures to delay the moment the temperature reaches its
maximum value in mass concrete block.
Lower the initial temperature of the concrete mixture: the initial temperature of
the concrete mixture greatly affects the maximum temperature value in mass con-
crete blocks. To reduce the initial temperature of the concrete mixture, there are
many measures, such as: reducing the temperature of the aggregate of concrete
mixture, using ice instead of a part of water, using liquid nitrogen to cool down the
concrete mixture. When using measures to reduce the initial temperature of the
concrete mixture, it is necessary to calculate in detail the economic feasibility of
the given measures [21–24].
According to the principle of conserving the heat before and after mixing the
concrete mixture, the temperature of the concrete mixture after mixing is deter-
mined by the formula (5) [25].

0:2ðma Ta þ mc Tc Þ þ mw Tw
Tmix ¼ ð5Þ
0:2ðma þ mc Þ þ mw

where ma, mc, and mw—mass (kg/m3) of aggregate, cement, and water, respec-
tively; Ta, Tc, and Tw,—temperature (°C) of aggregate, cement, and water,
respectively; specific heat capacity of aggregate (or cement) and water approximate
0.2 kJ/kg.°C and 1.0 kJ/kg.°C, respectively.
Guidelines for controlling cracked concrete mass 2016 [24] indicates that: to
decrease 1 °C of concrete mixture, it normally needs to reduce the temperature of
cement, aggregate, and water corresponding to 8 °C, 2 °C, and 4 °C, respectively.

(a) with a composition of 100% (b) with a composition of 20% PU replacing

cement cement

Fig. 2 Distribution of temperature in concrete blocks after 48 h of concrete hardening [20]

Thermal Cracks in Concrete Structure … 235

When a part of ice water is used to replace concrete mixing water, the tem-
perature reduction of the concrete mixture compared to when not using ice water is
determined by the formula (6) [25].

mice f79:6 þ ðTw  0Þg

DTmix ¼ Ef ð6Þ
0:2ðma þ mc Þ þ mw

where mice—weight of ice water, kg/m3; Ef—cooling effect, varying in a range of

(0.7–0.8).
Besides, lowering the temperature of the aggregates in the concrete mixture, the
method of using liquid nitrogen can be used to reduce the temperature at casting the
concrete. This method is applied by injecting liquid nitrogen directly into the con-
crete mixture during mixing.
Selection of the moment of placing concrete is important to control the maximum
temperature in the concrete block. In particular, placing concrete at night or in the
early morning has many advantages, such as: minimize the risk of heavy traffic
congestion to the construction site, reduce solar radiation during construction.
Using cooling systems: one of the most effective ways to prevent cracking is to
use a cooling pipe system. This method has been used for mass concrete structures,
such as dams, foundations, piers bridges, etc. The first cooling pipe system was
used in the construction of the Hoover Dam (USA). The same procedure was
applied for other projects, i.e., Xiang Hong Dian Dam (China), Bureyskaya
hydroelectric plant (Russia), Seo-He Bridge (South Korea), Tuyen Quang Dam
(Vietnam) [26–30].
Besides, the cooling pipes method can adjust the maximum temperature in
concrete blocks by changing the working time of cooling pipes, water temperature.
This method allows to reduce the maximum temperature in mass concrete to the
appropriate value.
According to [6], it is quite effective to use the cooling pipe system to control the
formation of thermal cracks in the mass concrete structures. Also, the study eval-
uated the effect of cooling water temperature on the maximum temperature in mass
concrete structures as shown in Fig. 3. It can be seen that when using a cooling pipe
system with cooling water temperature Tw = 25 °C, the temperature in the center of
the concrete block significantly decreases 15.71% when compared to the case
without using a cooling pipe system.
However, when the cooling water temperature changes from 25 to 10 °C, the
maximum temperature at the center of the concrete block only decreases from 60.01
to 55.4 °C (4.61 °C). It can be concluded that the maximum temperature of the
concrete block is not significantly dependent on the temperature of the cooling pipe.
Use surface insulation: the main purpose of this method is to reduce the tem-
perature difference between the inner zone and the surface of the concrete block.
The surface insulation layer can be used during construction in both winter season
(preventing rapid cooling of concrete block surface) and summer season conditions
(reducing the warming of concrete block surface). Currently, there are many types
of surface insulation, i.e. polyethylene, polystyrene foam, water or sand layer,
236 T. C. Nguyen et al.

Fig. 3 The temperature at the center of the concrete block changes over time [6]

burlap [30–33]. The change in insulation thickness affects the maximum temper-
ature and the temperature difference between the center and the surface of the
concrete block [32].
The results showed that it can reduce the risk of cracking occurring when the
temperature difference between the center and surface of the concrete block is
16.65 °C with using an insulation thickness of 1 cm while the temperature differ-
ence is 26.31 °C in the case without using insulation (Fig. 4).

a)Without using insulation b) With using 1 cm thickness of

polystyrene insulation

Fig. 4 Temperature variation in the center and surface of the concrete block [33]
Thermal Cracks in Concrete Structure … 237

Fig. 5 Temperature distribution in the concrete block: case 1 (a); case 2 (b) [34]

Reduce the thickness of the concrete casting block: the thickness of the concrete
casting block greatly affects the maximum temperature in mass concrete structures.
As indicated in Aniskin et al. [34], the thickness of the concrete casting affects
the maximum temperature of the concrete block. Two concreting cases: (a) case
1—using the layer thickness of 2 m; (b) case 2—using the layer thickness of 4 m
were presented. The temperature distribution in concrete blocks in two cases above
are shown in Fig. 5. As can be seen, the maximum temperature in the concrete
block in case 1 is 36.66 °C while that in case 2 is 39.70 °C. Hence, pouring with a
smaller thickness of concrete block can reduce the maximum temperature in the
concrete block.

3.1.2 Other Concrete Structures

To prevent the formation of cracks in cement concrete pavement structures under

the effect of environmental temperature changes, it is needed to determine the
temperature difference between the surface and the bottom of the cement concrete
pavement. Based on that basis, a proper design of the length-thickness and
width-thickness ratios of cement concrete pavement can be made.

3.2 How to Repair Thermal Cracks?

To repair the cracks on concrete structures should be consulted by experts and

designers to avoid damage later on. For cement concrete pavement, it may be
repaired by using compatible materials or demolition of the cracked and dumped
area replaced by new cement concrete. For the mass concrete, the repair process
depends on the crack width, the crack depth, and the later operation. If the crack
width is small, it does not affect the strength and workability of the structure. In
contrast, if the crack width is large, spraying epoxy, as a suitable option, is nec-
essary to be used.
238 T. C. Nguyen et al.

4 Conclusions

1. From the above discussions, the mechanism of thermal crack formation in

concrete structures in general needs to be understood. At last, the research
directions are proposed to control the formation of cracks for each type of
structure.
2. To control and prevent the formation of thermal cracks, some alternatives based
on the type of structure are proposed:
For large concrete structures: these factors affecting the temperature distribution
and stress field, such as cement content, type of cement, the initial temperature of
the concrete mixture when pouring, etc., should be optimized.
For cement concrete pavement, the thickness and dimensions of the concrete
slab are carefully determined.

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