2. Different Types of Early-Age Crack
Researchers have provided different perspectives on classifying the types of early-age crack in hardened concrete. One approach is grouping according to crack recovering ability. Emborg and Bernander
[9] distinguished the cracking in hardened concrete to very early-age temporary or transient cracks and permanent through cracks. The transient cracks tend to close at the end of the cooling period due to compression, while the permanent through cracks do not (generally) tend to close with time. Klemczak and Knoppik-Wróbel
[10] grouped the types of crack according to the type of structure, such as massive foundation slabs and medium thick structures, because concrete performs differently accordingly to its element size and structural use.
Many researchers
[2][6][8][10][11][12][13] grouped the cracks of concrete according to the causes of cracking, such as drying shrinkage cracks and settlement cracks, while some other researchers
[14][15] have grouped the concrete cracks according to the characteristics of cracking, such as random, map, transverse, longitudinal, corner, and re-entrant cracks. , , , , and show some of these cracks, which initiated within 3 to 56 days after placing of concrete. However, the grouping of cracks according to the crack characteristics was not only limited to early-age hardened concrete, but also included hardened concrete at later ages, which is beyond the scope of the present study.
Figure 1. Early-age transverse cracks that occurred in a newly cast reinforced concrete column; these cracks occurred within three days after placing of concrete; the column was cured by wet burlap.
Figure 2. Early-age transverse crack in a concrete pavement slab which widened over time; this crack started within 56 days of concrete placement; the slab was cured using curing compound.
Figure 3. Early-age corner crack in a concrete side-walk slab; this crack appeared within 35 days after concrete placement; the concrete slab was cured by curing compound.
Figure 4. Early-age random cracks that occurred in a concrete floor slab; most of these cracks appeared within 42 days after placing of concrete; the slab was cured using thermal curing blanket.
Figure 5. Early-age map cracks that occurred in a newly cast concrete floor slab; these cracks appeared within 14 days of concrete placement; the floor slab was cured by spraying of water.
Figure 6. Restrained shrinkage cracking that occurred in a roadside concrete curb; this crack initiated within 56 days of concrete placement; the curb was cured with curing compound.
3. Causes of Early-Age Cracking
Early-age cracking occurs in concrete structures because of temperature differences and stress development during hardening of concrete. At the early-age of concrete elements or structures, when the tensile strain created from restrained thermal contraction or temperature differential surpasses the tensile strain capacity of concrete, cracking is the outcome (refer to ); the tensile strain may also be aroused from early contraction caused by autogenous shrinkage
[16]. High-strength concrete is more prone to early-age cracking due to autogenous shrinkage
[17]. Drying shrinkage hardly plays a role to cause the early-age cracking in concrete. Klemczak and Knoppik-Wróbel
[10] divided drying shrinkage into two types: external drying shrinkage and internal drying shrinkage, and this was supported by Mihashi and Leite
[8]. Holt and Leivo
[12] divided shrinkage into three types, i.e., drying, thermal, and autogenous shrinkages.
Concrete for repair purpose requires high early strength; therefore, accelerators are commonly used in the mixture to increase hydration rate. However, the increased hydration rate also causes high heat of hydration which can potentially increase autogenous deformation and subsequent cracking in concrete
[18]. Hence, the proper choice of accelerator is very important regarding the use of high-early-strength concrete in repair or overlay work. Meagher et al.
[19] studied the effect of nitrate- and chloride-based accelerators on the cracking risk in concrete at the early-age. They reported similar cracking tendencies for both accelerator types at different concentrations. However, the concrete with the chloride-based accelerator experienced higher shrinkage compared to that with the nitrate-based accelerator.
Thermal strains driven by high temperature gradients occur between the interior and surface of structural elements since concrete has poor thermal conductivity
[8][10]. The partial and fully restrained movement from the cooling or other temperature change induces tensile stress in concrete
[20][21]; because early-age concrete is generally not strong enough to resist this stress, it cracks. Holt and Leivo
[12] named this phenomenon as the thermal dilation effect.
Some researchers
[6] have different viewpoints on drying shrinkage cracking and defined drying shrinkage as a reduction in concrete volume due to moisture loss at constant temperature and relative humidity. The loss of water through evaporation results in plastic shrinkage and subsequent internal stresses
[13][22], leading to early-age map cracks on the concrete surface, as shown in . Branch et al.
[23] deduced that the presence of microsilica and the rapid drying of the concrete surface are the main reasons for plastic shrinkage in concrete elements.
Holt
[24] pointed out that the chemical shrinkage and autogenous shrinkage of concrete may contribute to its ultimate cracking risk. Chemical shrinkage is induced when the volume of hydration products becomes smaller than the original volume of reacting constituents: cement and water. It is defined as the internal volume reduction in the hydrated cement paste of concrete. In contrast, autogenous shrinkage is considered as the external volume reduction of hydrated cement paste. It happens when the hydration process consumes water and causes internal drying, resulting in a decrease in the material volume
[8][10]. At the early stage, when the concrete is still soft, autogenous shrinkage is only attributed to the chemical changes driven by cement hydration, but at a later stage (after approximately 5 h), it is mostly due to self-desiccation, which is intensified by certain mix ingredients (silica fume and superplasticizer) and low water–cement ratio
[24]. Therefore, there is a higher risk of autogenous shrinkage in high-strength and high-performance concretes.
Higher coarse aggregate content, the use of very fine and high-angularity sand, poor aggregate gradation, incompatible mineral and chemical admixtures, inadequate curing, delayed finishing, high rate of evaporation from concrete surface, and sudden temperature drop are the major causes of plastic shrinkage cracking. Plastic settlement is one of the common causes of early-age cracks in hardened concrete. The vertical settlement of solid particles and the associated vertical restraint result in differential settlements. Moreover, during the casting of concrete, bleed water moves to the surface, while solid particles settle downwards because of gravity. If the concrete is locally restrained from settling, the settlement of solid particles induces stress. When this stress exceeds the strength of freshly placed concrete, cracking will happen at the source of restraint
[25].
Increased coarse aggregate fraction, the presence of very fine sand, poor aggregate gradation, incompatible chemical admixtures, deficient curing, excessively hot conditions, inappropriate control joints, too large joint spacing, and abrupt temperature changes are the main reasons of random cracking in concrete elements
[1].
Early loading, the use of dry concrete mixture, poor aggregate gradation, the incorporation of very fine and highly angular sand, inappropriate materials combination, ineffective curing, improper design dimensions, defective joint design, differential support conditions, an excessively hot ambient environment, and rapid temperature decrease are the major reasons of longitudinal cracking in concrete elements. External loading factors such as vibration, traffic, and wind on hardening concrete should not be ignored. The external loading provides extra stress on concrete. However, the tensile strength of early-age concrete is relatively low although it increases with age
[26]. In other words, the tensile strength of concrete is very low at the initial stage, especially during the first 3 h, but becomes several times larger in the next few hours
[27]. When the tensile stress due to external loading exceeds the ultimate tensile strength of concrete, cracking occurs in concrete.
Higher content of coarse aggregate, unsuitable aggregate gradation, the use of very fine and highly angular sand, the incorporation of incompatible concrete constituents, inadequate curing, inappropriate element dimensions, deficient control joints, misplacement of dowels and/or tie bars, poor stability, extremely hot surrounding environment, and rapid temperature drop are the key causes of transverse cracking in concrete elements
[1].
Equipment or traffic loading at the early-age, inadequate curing because of late or poor coverage, excessive curling and warping stresses caused by very long dimensions, poor stability causing excessive deflection under load, and very close dowel and/or tie bars preventing joint corner relaxation are the major reasons for corner cracking in concrete elements
[1].
Skewed joints, late sawing, sawing along wind direction, and high wind are some of the reasons for pop-off cracks in concrete elements such as pavement slabs
[1]. Mismatched joints in adjacent lanes, joints matching in location but of different types, and cracking from transverse joints in previously paved adjacent lanes can cause sympathy cracks in concrete pavement
[1].
High workability, slow setting time, low viscosity, shallow placement of distribution reinforcement as well as dowel or tie bars, and large aggregate size are the major reasons for settlement cracks in concrete pavement
[1].
The increased stress due to odd shape and cracking from interior corners can cause re-entrant cracks in concrete elements
[1]. They typically originate from beam pockets, window corners, or other openings.
Issa
[14] attempted to identify the causes of the early-age cracking in concrete bridge deck through literature review and questionnaire survey throughout the United States. It was deduced that the high evaporation rate and subsequent high magnitude of shrinkage are the most common causes of cracking in concrete bridge deck. The other causes of early-age cracking identified were the use of high-slump concrete, excessive heat of hydration, inefficient curing procedures, improper sequence of concrete pouring, inadequate concrete cover, insufficient compaction, inadequate detailing of joints between new and old decks, etc.
[14]. Krauss and Rogalla
[28] also identified the deck restraint, improper curing, high early-age modulus of elasticity, creep, shrinkage, and thermal strains as the causes of cracking in concrete bridge decks.
Concrete creep is one of the major causes of the early-age cracking in concrete elements. It is defined as the result of numerous interatomic bond breaks happening at different time periods at different overstressed sites of concrete
[29]. Bažant et al.
[30] divided the creep into three types: basic creep, drying creep, and transitional thermal creep. Basic creep is strongly dependent on the age at loading and water content
[29]. Bažant et al.
[30] divided the age at loading into short-term chemical aging and long-term nonchemical aging. The effect of hydration process on the capillary pore structure in the cement paste reduces the creep compliance of concrete
[29]. This is referred to as short-term chemical aging. In long-term nonchemical aging, the cement hydration in concrete is practically stopped and the basic creep decreases while the age at loading increases
[29].
Drying creep, also referred to as Pickett effect
[31][32], occurs when concrete elements undergo deformation during drying as well as after drying. There are two major mechanisms for this form of creep—firstly, a macroscopic mechanism due to microcracking or strain-softening damage and secondly, a nanoscale mechanism due to stress-induced shrinkage
[32]. According to the macroscopic mechanism, the nonuniform moisture distribution between the external and internal layers of concrete causes shrinkage to occur in these layers at different time periods due to the loss of water from capillary pores. Consequently, a tensile stress is induced that leads to local microcracking or tensile strain-softening damage in the surface layer, resulting in nonlinear inelastic deformation (unrecoverable creep) of concrete. The second mechanism is stress-induced shrinkage due to moisture loss and temperature rise
[32]. Upon drying, a thermodynamic imbalance among the chemical potentials of various phases of pore water develops due to reduced pore vapor pressure and temperature rise
[30], resulting in tensile stresses, which are balanced by compressive stresses (micro-prestress) in the surrounding concrete and consequently concrete shrinks. This phenomenon particularly occurs in the nanostructure of concrete comprising calcium silicate hydrates, very small capillary pores, and gel pores. The breakages of bonds in the calcium silicate hydrates may happen by an increase in the magnitude of micro-prestress.
Transitional thermal creep is defined as the transient increase of creep due to changing temperature
[30]. The first mechanism is an apparent macroscopic mechanism, which is, like drying creep, owing to thermally induced microcracking. Another mechanism is the nanoscale mechanism, in which the changing temperature alters the level of micro-prestress by changing the chemical potential of nanopore water
[30].