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Non-Structural Cracks
       causes and control
Ian Gibb
Principal Materials Engineer




                               www.urs-scottwilson.com
Learning points




• Causes of cracking

• Mitigation methods

• Design / construction
  guidance




                           www.urs-scottwilson.com
Causes of cracking




                     www.urs-scottwilson.com
Some people want cracks!




                           Tate modern, London, 2007


                                   www.urs-scottwilson.com
Non-structural cracks


 Serviceability (water retaining)
         BSEN 1992-3 (cl.7.3.1)
                                         Durability
                                         BS EN 1992-1-1 (table NA.4)
Viewing distance, m




                                                                       www.urs-scottwilson.com
                                    Crack width, mm
Autogenous healing (EN1992-3)




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Non-structural cracks




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Non-structural cracks




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Non-structural cracks




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Non-structural cracks




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Non-structural cracks




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Non-structural cracks




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Non-structural cracks




                        www.urs-scottwilson.com
Causes of cracking

BEFORE HARDENING
• Early-age settlement /
  shrinkage


AFTER HARDENING
• Early thermal contraction
• Drying shrinkage
• Corrosion of reinforcement
• Sulfate attack
• Alkali-aggregate reaction


                                  www.urs-scottwilson.com
Early age
plastic settlement / shrinkage




                                 www.urs-scottwilson.com
Time to appearance

                 Hours Days   Months   Years

Plastic
Shrinkage
Plastic
Settlement
Early thermal

Drying
Shrinkage
Corrosion

Sulfate attack

Alkali-
aggregate
                                               www.urs-scottwilson.com
Plastic settlement

             Specific Gravities
             Cement:     3.2
             Aggregate: 2.5 - 3.0
             GGBS:       2.9
             Fly ash:    2.3
             Water:      1.0




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Plastic settlement




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Plastic settlement




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Plastic settlement




• Occurs in first few hours

• Restraint to movement
  causes cracking

• Cracks tend to follow
  reinforcement




                                www.urs-scottwilson.com
Secondary influences


• Slag cement – may increase bleeding
• Fly ash cement - likely to reduce bleeding
• Slow setting rates - increase potential for
  bleeding
• Depth of pour
• Ambient Temperature
• Aggregate grading


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Plastic settlement




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Plastic settlement




                     www.urs-scottwilson.com
www.urs-scottwilson.com
Prevention


• Re-vibration
• Mix design (e.g. polypropylene fibres, air, VMA)
• Increase cover to top steel




                                                     www.urs-scottwilson.com
Plastic shrinkage



           Evaporation




         Reduction in volume




              Bleeding




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Plastic shrinkage



          Evaporation




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Plastic shrinkage




                    www.urs-scottwilson.com
Plastic shrinkage




                    www.urs-scottwilson.com
Plastic shrinkage




                    www.urs-scottwilson.com
Plastic shrinkage




                    www.urs-scottwilson.com
Plastic shrinkage




                    www.urs-scottwilson.com
Plastic shrinkage




                    www.urs-scottwilson.com
Prevention


Mix Design
• air entrainment (reduces surface tension forces)

• polypropylene fibres




                                                     www.urs-scottwilson.com
Prevention


Curing
  • resin-based / silicate based (too late / too slow)
  • polythene sheet on light wooden frame




                                                         www.urs-scottwilson.com
Non-structural cracks

                 Hours Days   Months   Years

Plastic
Shrinkage
Plastic
Settlement
Early thermal

Drying
Shrinkage
Corrosion

Sulfate attack

Alkali-
aggregate
                                               www.urs-scottwilson.com
Early age
  thermal




            www.urs-scottwilson.com
www.urs-scottwilson.com
Heat of hydration

50%      Tricalcium silicate           3CaO.SiO2
25%      Dicalcium silicate            2CaO.SiO2
10%      Tricalcium aluminate          3CaO.Al2O3
10%      Tetracalcium aluminoferrite   4CaO.Al2O3.Fe2O3
5%       Gypsum                        CaSO4.2H2O




        Rate of
           heat
      evolution




                  minutes                 hours           days
                                                             www.urs-scottwilson.com
Stresses and strains due to thermal
effects



  Temperature




                                 Time
                Thermal Strain




                                        Measured

                                        Free
                                        Restrained



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Stress induced by thermal effects




   Stress               Time


                               With creep
                               Design assumption

                               No creep




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Crack formation (Internal Restraint)




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External Restraint




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External Restraint




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External Restraint




                         -
                     ting n
                 Hea sio
                    an
                 exp




                              www.urs-scottwilson.com
External Restraint




                         g-
                Co o li n io n
                         ct
                con t ra


                             int
                       s tra
                     Re




                                   www.urs-scottwilson.com
External Restraint




                     www.urs-scottwilson.com
Magnitudes of free movement


• Early age issues
   • ~130C per 100kg/m3 of cement (CEM I)
   • >500C for typical structures
   • Unrestrained early age contractions ~ 300 ε

               Cementitious     Temperature
   Cement
                 content           rise
    type
                 (kg/m3)           (0C)
   CEM I            340              31
 30% fly ash        365              20
  50% ggbs          355              21            300mm slab

  70% ggbs          410              18            Cast in summer (20oC)
                                                   19mm plywood formwork
                                                   C32/40 concrete
                                                             www.urs-scottwilson.com
Factors Influencing Heat Generation


• Section thickness
• Cement type
• Concrete mixture proportions
• Ambient & placing temperatures
• Formwork & insulation




                                           www.urs-scottwilson.com
Factors Affecting Early Thermal Cracking

• Aggregate type
  (7–14 ε / oC)
• Tensile strain capacity
  (may be less with slag and fly ash)
• External restraint
  (previous pours)
• Internal restraint
  (temp. profiles in large members)
• Stress raisers
  (changes in section)
• Reinforcement
  (controls, but does not eliminate)
                                        www.urs-scottwilson.com
Tensile Strain Capacity




                          www.urs-scottwilson.com
Example limiting temperature change




Assumes
fck C30/37
K1 = 0.65
εca = 5µε




                               20 28   35   53

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Early thermal




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Early thermal




                www.urs-scottwilson.com
CIRIA C660


Design procedure

• Temperature
  differentials

• Internal / external
  restraint

• Tensile strain capacity

• Area of reinforcement

• Crack spacing

• Crack width
                            www.urs-scottwilson.com
Drying shrinkage




   Long term
     drying shrinkage




                        www.urs-scottwilson.com
Drying shrinkage


            Water added:                  Water needed:




                           ?



• Cement = 320 kg/m3           • Cement = 320 kg/m3
• Water = 160 litres/m3        • Water = 90 litres/m3
• W/C = 0.50                   • W/C = 0.28
                                                        www.urs-scottwilson.com
Drying shrinkage




                   www.urs-scottwilson.com
Drying shrinkage

                 Hours Days   Months   Years

Plastic
Shrinkage
Plastic
Settlement
Early thermal

Drying
Shrinkage
Corrosion

Sulfate attack

Alkali-
aggregate
                                               www.urs-scottwilson.com
Drying shrinkage




                   www.urs-scottwilson.com
Drying Shrinkage




                   www.urs-scottwilson.com
Drying shrinkage




                   www.urs-scottwilson.com
How to reduce shrinkage


• Aggregate content
  (71 to 74% ~ 20%
  reduction!)

• Aggregate size
  (impacts paste volume)

• Aggregate type

• Admixtures
  (water / shrinkage reducing)

                                  www.urs-scottwilson.com
How to reduce shrinkage


• Aggregate content
  (71 to 74% ~ 20%
  reduction!)

• Aggregate size
  (impacts paste volume)

• Aggregate type

• Admixtures
  (water / shrinkage reducing)

                                    www.urs-scottwilson.com
How to reduce shrinkage

• Aggregate content
  (71 to 74% ~ 20%
  reduction!)

• Aggregate size
  (impacts paste volume)

• Aggregate type

• Admixtures
  (water / shrinkage
  reducing)

                                   www.urs-scottwilson.com
How to reduce shrinkage


• Aggregate content
  (71 to 74% ~ 20%
  reduction!)

• Aggregate size
  (impacts paste volume)

• Aggregate type

• Admixtures
  (water / shrinkage
  reducing)
                                   www.urs-scottwilson.com
How to reduce shrinkage


• Aggregate content
  (71 to 74% ~ 20%
  reduction!)

• Aggregate size                                     0.05

  (impacts paste volume)                             0.04




                                 Length change (%)
                                                     0.03

• Aggregate type                                     0.02


                                                     0.01
• Admixtures
                                                        0

  (water / shrinkage reducing)                       -0.01
                                                             0   10   20   30     40        50      60       70

                                                                                Days
                                                     -0.02


                                                                                       www.urs-scottwilson.com
Drying shrinkage


• To reduce drying shrinkage
  cracking:
  • Adequate curing
    (increases tensile strain
    capacity)

  • Reduce internal restraint
    (movement joints)

  • Crack control reinforcement




                                  www.urs-scottwilson.com
Technical Report 67


• Types of movement

• Magnitudes of movement

• Restraint (internal / surface /

  end / edge)

• Crack width calculation

• Mitigation measures
                                    www.urs-scottwilson.com
Long term
durability issue




                   www.urs-scottwilson.com
Reinforcement corrosion




                          www.urs-scottwilson.com
Reinforcement corrosion



           pH 9.0–9.5




   Phenolphthalein reaction

                              www.urs-scottwilson.com
Sulfate attack




                 www.urs-scottwilson.com
End
Thank you for your attention
        Questions?
                               www.urs-scottwilson.com

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Control of ns cracks (conc soc 070411)

  • 1. Non-Structural Cracks causes and control Ian Gibb Principal Materials Engineer www.urs-scottwilson.com
  • 2. Learning points • Causes of cracking • Mitigation methods • Design / construction guidance www.urs-scottwilson.com
  • 3. Causes of cracking www.urs-scottwilson.com
  • 4. Some people want cracks! Tate modern, London, 2007 www.urs-scottwilson.com
  • 5. Non-structural cracks Serviceability (water retaining) BSEN 1992-3 (cl.7.3.1) Durability BS EN 1992-1-1 (table NA.4) Viewing distance, m www.urs-scottwilson.com Crack width, mm
  • 6. Autogenous healing (EN1992-3) www.urs-scottwilson.com
  • 7. Non-structural cracks www.urs-scottwilson.com
  • 8. Non-structural cracks www.urs-scottwilson.com
  • 9. Non-structural cracks www.urs-scottwilson.com
  • 10. Non-structural cracks www.urs-scottwilson.com
  • 11. Non-structural cracks www.urs-scottwilson.com
  • 12. Non-structural cracks www.urs-scottwilson.com
  • 13. Non-structural cracks www.urs-scottwilson.com
  • 14. Causes of cracking BEFORE HARDENING • Early-age settlement / shrinkage AFTER HARDENING • Early thermal contraction • Drying shrinkage • Corrosion of reinforcement • Sulfate attack • Alkali-aggregate reaction www.urs-scottwilson.com
  • 15. Early age plastic settlement / shrinkage www.urs-scottwilson.com
  • 16. Time to appearance Hours Days Months Years Plastic Shrinkage Plastic Settlement Early thermal Drying Shrinkage Corrosion Sulfate attack Alkali- aggregate www.urs-scottwilson.com
  • 17. Plastic settlement Specific Gravities Cement: 3.2 Aggregate: 2.5 - 3.0 GGBS: 2.9 Fly ash: 2.3 Water: 1.0 www.urs-scottwilson.com
  • 18. Plastic settlement www.urs-scottwilson.com
  • 19. Plastic settlement www.urs-scottwilson.com
  • 20. Plastic settlement • Occurs in first few hours • Restraint to movement causes cracking • Cracks tend to follow reinforcement www.urs-scottwilson.com
  • 21. Secondary influences • Slag cement – may increase bleeding • Fly ash cement - likely to reduce bleeding • Slow setting rates - increase potential for bleeding • Depth of pour • Ambient Temperature • Aggregate grading www.urs-scottwilson.com
  • 22. Plastic settlement www.urs-scottwilson.com
  • 23. Plastic settlement www.urs-scottwilson.com
  • 25. Prevention • Re-vibration • Mix design (e.g. polypropylene fibres, air, VMA) • Increase cover to top steel www.urs-scottwilson.com
  • 26. Plastic shrinkage Evaporation Reduction in volume Bleeding www.urs-scottwilson.com
  • 27. Plastic shrinkage Evaporation www.urs-scottwilson.com
  • 28. Plastic shrinkage www.urs-scottwilson.com
  • 29. Plastic shrinkage www.urs-scottwilson.com
  • 30. Plastic shrinkage www.urs-scottwilson.com
  • 31. Plastic shrinkage www.urs-scottwilson.com
  • 32. Plastic shrinkage www.urs-scottwilson.com
  • 33. Plastic shrinkage www.urs-scottwilson.com
  • 34. Prevention Mix Design • air entrainment (reduces surface tension forces) • polypropylene fibres www.urs-scottwilson.com
  • 35. Prevention Curing • resin-based / silicate based (too late / too slow) • polythene sheet on light wooden frame www.urs-scottwilson.com
  • 36. Non-structural cracks Hours Days Months Years Plastic Shrinkage Plastic Settlement Early thermal Drying Shrinkage Corrosion Sulfate attack Alkali- aggregate www.urs-scottwilson.com
  • 37. Early age thermal www.urs-scottwilson.com
  • 39. Heat of hydration 50% Tricalcium silicate 3CaO.SiO2 25% Dicalcium silicate 2CaO.SiO2 10% Tricalcium aluminate 3CaO.Al2O3 10% Tetracalcium aluminoferrite 4CaO.Al2O3.Fe2O3 5% Gypsum CaSO4.2H2O Rate of heat evolution minutes hours days www.urs-scottwilson.com
  • 40. Stresses and strains due to thermal effects Temperature Time Thermal Strain Measured Free Restrained www.urs-scottwilson.com
  • 41. Stress induced by thermal effects Stress Time With creep Design assumption No creep www.urs-scottwilson.com
  • 42. Crack formation (Internal Restraint) www.urs-scottwilson.com
  • 43. External Restraint www.urs-scottwilson.com
  • 44. External Restraint www.urs-scottwilson.com
  • 45. External Restraint - ting n Hea sio an exp www.urs-scottwilson.com
  • 46. External Restraint g- Co o li n io n ct con t ra int s tra Re www.urs-scottwilson.com
  • 47. External Restraint www.urs-scottwilson.com
  • 48. Magnitudes of free movement • Early age issues • ~130C per 100kg/m3 of cement (CEM I) • >500C for typical structures • Unrestrained early age contractions ~ 300 ε Cementitious Temperature Cement content rise type (kg/m3) (0C) CEM I 340 31 30% fly ash 365 20 50% ggbs 355 21 300mm slab 70% ggbs 410 18 Cast in summer (20oC) 19mm plywood formwork C32/40 concrete www.urs-scottwilson.com
  • 49. Factors Influencing Heat Generation • Section thickness • Cement type • Concrete mixture proportions • Ambient & placing temperatures • Formwork & insulation www.urs-scottwilson.com
  • 50. Factors Affecting Early Thermal Cracking • Aggregate type (7–14 ε / oC) • Tensile strain capacity (may be less with slag and fly ash) • External restraint (previous pours) • Internal restraint (temp. profiles in large members) • Stress raisers (changes in section) • Reinforcement (controls, but does not eliminate) www.urs-scottwilson.com
  • 51. Tensile Strain Capacity www.urs-scottwilson.com
  • 52. Example limiting temperature change Assumes fck C30/37 K1 = 0.65 εca = 5µε 20 28 35 53 www.urs-scottwilson.com
  • 53. Early thermal www.urs-scottwilson.com
  • 54. Early thermal www.urs-scottwilson.com
  • 55. CIRIA C660 Design procedure • Temperature differentials • Internal / external restraint • Tensile strain capacity • Area of reinforcement • Crack spacing • Crack width www.urs-scottwilson.com
  • 56. Drying shrinkage Long term drying shrinkage www.urs-scottwilson.com
  • 57. Drying shrinkage Water added: Water needed: ? • Cement = 320 kg/m3 • Cement = 320 kg/m3 • Water = 160 litres/m3 • Water = 90 litres/m3 • W/C = 0.50 • W/C = 0.28 www.urs-scottwilson.com
  • 58. Drying shrinkage www.urs-scottwilson.com
  • 59. Drying shrinkage Hours Days Months Years Plastic Shrinkage Plastic Settlement Early thermal Drying Shrinkage Corrosion Sulfate attack Alkali- aggregate www.urs-scottwilson.com
  • 60. Drying shrinkage www.urs-scottwilson.com
  • 61. Drying Shrinkage www.urs-scottwilson.com
  • 62. Drying shrinkage www.urs-scottwilson.com
  • 63. How to reduce shrinkage • Aggregate content (71 to 74% ~ 20% reduction!) • Aggregate size (impacts paste volume) • Aggregate type • Admixtures (water / shrinkage reducing) www.urs-scottwilson.com
  • 64. How to reduce shrinkage • Aggregate content (71 to 74% ~ 20% reduction!) • Aggregate size (impacts paste volume) • Aggregate type • Admixtures (water / shrinkage reducing) www.urs-scottwilson.com
  • 65. How to reduce shrinkage • Aggregate content (71 to 74% ~ 20% reduction!) • Aggregate size (impacts paste volume) • Aggregate type • Admixtures (water / shrinkage reducing) www.urs-scottwilson.com
  • 66. How to reduce shrinkage • Aggregate content (71 to 74% ~ 20% reduction!) • Aggregate size (impacts paste volume) • Aggregate type • Admixtures (water / shrinkage reducing) www.urs-scottwilson.com
  • 67. How to reduce shrinkage • Aggregate content (71 to 74% ~ 20% reduction!) • Aggregate size 0.05 (impacts paste volume) 0.04 Length change (%) 0.03 • Aggregate type 0.02 0.01 • Admixtures 0 (water / shrinkage reducing) -0.01 0 10 20 30 40 50 60 70 Days -0.02 www.urs-scottwilson.com
  • 68. Drying shrinkage • To reduce drying shrinkage cracking: • Adequate curing (increases tensile strain capacity) • Reduce internal restraint (movement joints) • Crack control reinforcement www.urs-scottwilson.com
  • 69. Technical Report 67 • Types of movement • Magnitudes of movement • Restraint (internal / surface / end / edge) • Crack width calculation • Mitigation measures www.urs-scottwilson.com
  • 70. Long term durability issue www.urs-scottwilson.com
  • 71. Reinforcement corrosion www.urs-scottwilson.com
  • 72. Reinforcement corrosion pH 9.0–9.5 Phenolphthalein reaction www.urs-scottwilson.com
  • 73. Sulfate attack www.urs-scottwilson.com
  • 74. End Thank you for your attention Questions? www.urs-scottwilson.com