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Early-age cracking in mass concrete structures resulting from thermal stress is a well-documented phenomenon that impacts their functionality, durability, and integrity. The primary cause of these cracks is the uneven temperature rise within the structure due to the exothermic nature of cement hydration. Assessing the likelihood of cracking involves comparing the tensile strength or strain capacity of the concrete with the stresses or strains experienced by the structure. Challenges in evaluating the risk of thermal cracking in mass concrete structures stem from various material and technological factors that influence the magnitude and progression of hydration heat-induced temperature and thermal stress. These complexities can be addressed through numerical analysis, particularly finite element analysis (FEA), which offers comprehensive modeling of early-age effects by considering all pertinent material and technological variables. However, employing FEA poses challenges such as the requirement for numerous input parameters, which may be challenging to define, and the need for specialized software not commonly available to structural engineers. Consequently, the necessity for such advanced modeling, which demands significant time investment, may not always be warranted and should be initially assessed through simpler methods. This is primarily because the definition of massive structures—those susceptible to adverse effects such as cracking due to temperature rise from hydration heat—is not precise. To address these challenges, the authors propose a three-step method for evaluating structures in this regard. The first step involves a simplified method for the classification of massive structures. The second step entails estimating hardening temperatures and levels of thermal stress using straightforward analytical techniques. The third step, reserved for structures identified as having a potential risk of early thermal cracks, involves numerical modeling. The outlined procedure is illustrated with an example application, demonstrating its practicality in analyzing a massive concrete wall constructed on the foundation. [ABSTRACT FROM AUTHOR]

Mass concrete is widely used in large-scale projects, including metro upper cover structures, water conservancy dams, and heavy equipment foundations, among others, necessitating the process of health monitoring in mass concrete construction. The development of reliable and simple strength-monitoring methods for mass concrete is challenging because the inner temperature of mass concrete is high and changes a lot. This study proposes a strength-monitoring approach for mass concrete using barium titanate–bismuth ferrite/polyvinylidene fluoride (BT–BFO/PVDF) nanocomposite piezoelectric sensors, wherein the new sensors are embedded as actuators and sensors in mass concrete. The stress wave generated by the BT–BFO/PVDF piezoelectric sensors is used to monitor the specimen's strength for 28 days. The piezoelectric voltage received by the sensors in mass concrete is analyzed. The experimental results indicate that the signal received by the BT–BFO/PVDF sensors is not easily affected by the internal temperature of mass concrete compared with that of the traditional PVDF piezoelectric sensors. The signal parameters sensitive to concrete strength variation and the change trend of concrete strength are closely related to the piezoelectric voltage. Therefore, the proposed approach using BT–BFO/PVDF nanocomposite piezoelectric sensors is efficient (error < 10%) in mass concrete monitoring. Moreover, the monitoring results do not need temperature compensation. The physical meaning of the obtained strength prediction formula is proposed. An experimental system based on PVDF dynamic strain-sensing characteristics is established. [ABSTRACT FROM AUTHOR]

In engineering practice, similar surface insulation measures are typically applied to different parts of mass concrete surfaces. However, this can lead to cracking at the edges of the concrete surface or the wastage of insulation materials. In comparison to flat surfaces, the edges of mass concrete structures dissipate heat more rapidly, leading to more pronounced stress concentration phenomena. Therefore, reinforced insulation measures are necessary. To reduce energy consumption and enhance overall insulation effectiveness, it is essential to study the specific insulation requirements of both the flat surfaces and edges of concrete separately and implement targeted surface insulation measures. Taking the bridge abutment planned for pouring in Nanjing City as the research object, this study established a finite element model to explore the effects of different ambient temperatures and different surface heat dissipation coefficients on the early-age temperature and stress fields of different parts of the abutment's surface. Based on simulation results, reasonable heat dissipation coefficients that meet the requirements for crack prevention on both the structure's plane and edges under different ambient temperatures were obtained. The results indicate that under the same conditions, the reasonable heat dissipation coefficient at the edges was smaller than that on the flat surfaces, indicating the need for stronger insulation measures at the edges. Finally, mathematical models correlating ambient temperature with reasonable heat dissipation coefficients for the structure's plane and edges at these temperatures were established, with high data correlation and determination coefficients (R2) of 0.95 and 0.92. The mathematical models were validated, and the results from finite element calculations were found to be consistent with those from the mathematical models, validating the accuracy of the mathematical models. The conclusions drawn can provide references for the insulation of similar engineering concrete planes and edges. [ABSTRACT FROM AUTHOR]

Hydration heat of early-age sidewalls can cause cracks owing to thermal stress, reducing the durability of underground space structures. The heat can be removed by the flowing water in the cooling pipe system. However, the cooling pipe may cause thermal stress due to the temperature gradient in the region adjacent to the cooling pipe, resulting in concrete cracking. To minimize the temperature peak of sidewalls and cracking risks in the region adjacent to the cooling pipe, the crack-distribution characteristics, temperature, and strain evolution of an early-age sidewall with a cooling pipe system are analyzed by concrete temperature and strain tests. Furthermore, a model that accounts for the early-age behavior of concrete and cooling-pipe effects is developed and solved. Finally, the effects of cooling-pipe parameters and ambient temperature on the sidewall's temperature field and cracking risk are analyzed. The results indicate that the cracks emerge in the first two weeks after concrete pouring; most are vertical, and a few oblique cracks emerge in the wall corner. The tensile stress in the region adjacent to the cooling pipe gradually decreases along the flow direction. Reducing the water temperature and increasing the flow rate reduces the sidewall's temperature peak and cooling rate. However, they increase the cracking risk in the region adjacent to the cooling pipe. When the flow rate exceeds 0.6 m3/h, further increasing the flow rate does not significantly affect the temperature field. Reducing the distance between cooling pipes reduces the temperature peak, cooling rate, and cracking risk in the region adjacent to the cooling pipe. In high-temperature environments, the cracking risk in the region adjacent to the cooling pipe increases significantly. [ABSTRACT FROM AUTHOR]

Using limestone powder (LP), the by-product of manufactured sand, to replace part of fly ash (FA) or manufactured sand could not only turn waste into treasure and decrease the price of concrete, but could also enhance the performance of concrete and reduce environmental pollution. However, the impact of various LP incorporation methods on the performance of mass concrete was inconsistent. In this paper, the effects of LP on the workability, compressive strength, constrained expansion rate, hydration temperature and impermeability of mass concrete were studied by replacing FA or manufactured sand alone and replacing FA and manufactured sand simultaneously. The results showed that the impact of LP on the performance of mass concrete was equal when it replaced FA alone and FA and manufactured sand at the same time. When the replacement amount was 20%, the workability, expansibility and early strength of concrete were improved, but the later strength and impermeability were slightly reduced. The workability, compressive strength, expansibility and impermeability of mass concrete were improved when manufactured sand was replaced alone, and the optimal dosage was 10%. The LP, moreover, reduced the hydration temperature peak of concrete in three kinds of mixing methods, but the temperature peak appeared earlier. At lower dosages, LP optimized pore structure and promoted the early hydration of cement through filler effects and nucleation effects. When LP replaced manufactured sand, the microstructure of concrete was more dense, so the replacement of manufactured sand had a better effect on the improvement of concrete properties. A reference value for the use of LP in mass concrete is provided in this study. [ABSTRACT FROM AUTHOR]

This study provides the results of an experiment on the possibility of using high-volume ground granulated blast furnace slag (HVGGBFS)-based concrete as mass concrete. In addition to the control concrete, the total weight of the binder was 75% ground granulated blast furnace slag (GGBFS) and 25% ordinary Portland cement (OPC). For the aggregates, both natural and recycled aggregates were used. Three specimens with dimensions of 800 mm × 800 mm × 800 mm were prepared to simulate mass concrete. The workability, temperature aging and strength of the mass concrete were tested. The test results showed that utilizing HVGGBFS concrete as mass concrete can significantly reduce the heat of hydration due to the low heat of hydration of GGBFS, while the heat of hydration of GGBFS and recycled aggregate combination is 11.2% higher than normal concrete, with a slump that is 31.3% lower than that of plain concrete. The results also showed that the use of recycled aggregates in HVGGBFS concrete can significantly reduce workability. However, the compressive strength is higher than when natural aggregates are used due to the alkali activation effect caused by the recycled aggregates. The compressive strength at 7 and 28 days increased by 33.7% and 16.3%, respectively. [ABSTRACT FROM AUTHOR]

A judgment method of the final setting time of mass concrete based on strain monitoring and the selection criterion of the starting point of effective deformation are proposed, and the safety of the concrete structure is evaluated based on this. Firstly, the strain monitoring theory of mass concrete is analyzed to clarify the temperature effect component and monitoring mechanism of an early strain of concrete. Then, taking the mass concrete plate of an engineering project as the research object combined with the mechanical analysis, the early strain monitoring data are segmented, and the relationship between the strain response and the temperature in different stages is fitted based on robust regression, so as to explore the correlation between strain and temperature in each stage and better explain the setting process of the concrete structure. Finally, taking the final setting time as the starting point of the effective strain, the safety of the concrete structure is further evaluated. The results show that there is a clear linear relationship between the strain response and temperature, and a high negative correlation between strain and temperature after the final setting. The time point when the frequency modulus corresponding to the strain enters a steady change and decreases with the increase of temperature is taken as the final setting time, which conforms to the concrete condensation mechanism and the temperature effect of early strain monitoring. [ABSTRACT FROM AUTHOR]

Temperature control is the primary concern during the design and construction process of mass concrete structures. As the concrete production has an enormous negative environmental impact, the development of green mass concretes will eventually become as important as the thermal characteristics. Therefore, this paper investigates the use of Electric Arc Furnace (EAF) steel slag aggregate for the partial replacement of the natural aggregate in the production of mass concrete. The impact of EAF steel aggregate on mass concrete workability, strength, and thermal behaviour was analysed. In addition, a cradle-to-gate LCA study was conducted to evaluate the environmental footprint and sustainability potential of the tested mass concrete mixtures. The study results suggest that the use of EAF steel slag aggregate in combination with a low-heat cement with a high content of blast furnace slag can significantly lower the temperature, reduce the environmental impact, and increase the sustainability potential of mass concrete, while at the same time providing sufficient workability and compressive strength. The study results indicate that EAF steel slag can be upcycled into an aggregate for the production of green mass concrete mixtures. [ABSTRACT FROM AUTHOR]

This paper presents a solution strategy, based on a parallel Genetic Algorithm (GA), to optimize the construction of massive concrete structures. The optimization process aims at minimizing the construction cost, considering the following design variables: the concrete mixes, the placing temperature, the height of the lifts, and the time intervals between placing the lifts. The cracking tendency is taken into account by a penalty scheme imposed to the fitness function of the GA. A thermo-chemo-mechanical model is used to calculate the transient fields of hydration, temperature, stress, strain, and cracking tendency. This model is implemented in a finite element code that is, in turn, parallelized. To demonstrate the efficiency of the proposed methodology, the simulation of the construction of a structure similar to the real thick foundation of an industrial building is presented. It shows that the optimization procedure here presented is feasible and is ready to be used in real engineering applications. [ABSTRACT FROM AUTHOR]

In long-lasting mass concrete structures the desired material properties of the concrete mix to realize a durable concrete and a concrete surface without cracks conflict with each other. The requirement of concrete with high durability leads to high thermal energy release and therefore, as another consequence, to high crack risk. Crack reduction is achieved by use of concrete with low hydration energy, which on the other hand leads to a decrease in concrete durability. Besides from optimized base materials and concrete technology, a gradient material distribution in the cross-section could reduce the problem since durable concrete is needed near the surface and the requirement of low-hydration energy is located in the center of the member. A simplified model is used to investigate the possible effect of a gradient concrete material distribution in mass concrete structures on crack reduction. The results of the analysis show that gradient concrete might contribute to lowering the constraint stresses and therefore the crack risk during concrete hardening. [ABSTRACT FROM AUTHOR]

This paper summarizes an engineering experience of solving the problem of thermal cracking in mass concrete by using a large project, Zhongguancun No.1 (Beijing, China), as an example. A new method is presented for controlling temperature cracks in the mass concrete of a foundation. The method involves controlled cycles of water circulating between the surface of mass concrete foundation and the atmospheric environment. The temperature gradient between the surface and the core of the mass concrete is controlled at a relatively stable state. Water collected from the well-points used for dewatering and from rainfall is used as the source for circulating water. Mass concrete of a foundation slab is experimentally investigated through field temperature monitoring. Numerical analyses are performed by developing a finite element model of the foundation with and without water circulation. The calculation parameters are proposed based on the experiment, and finite element analysis software MIDAS/CIVIL is used to calculate the 3D temperature field of the mass concrete during the entire process of heat of hydration. The numerical results are in good agreement with the measured results. The proposed method provides an alternative practical basis for preventing thermal cracks in mass concrete. [ABSTRACT FROM AUTHOR]

Acoustic emission (AE) is capable of monitoring the cracking activities inside materials. In this study, embedded sensors were employed to monitor the AE behavior of early age concrete. Type 1-3 cement-based piezoelectric composites, which had lower mechanical quality factor and acoustic impedance, were fabricated and used to make sensors. Sensors made of the composites illustrated broadband frequency response. In a laboratory, the cracking of early age concrete was monitored to recognize different hydration stages. The sensors were also embedded in a mass concrete foundation to localize the temperature gradient cracks. [ABSTRACT FROM AUTHOR]

For a long time, temperature control and crack prevention of mass concrete is a difficult job in engineering. For temperature control and crack prevention, the most effective and common-used method is to embed cooling pipe in mass concrete. At present, there still exists some challenges in the precise simulation of pipe cooling in mass concrete, which is a complex heat-flow coupling problem. Numerical simulation is faced with the problem of over-simplification and inaccuracy. In this study, precise simulation of heat-flow coupling of pipe cooling in mass concrete is carried out based on finite element software COMSOL Multiphysics 5.4. Simulation results are comprehensively verified with results from theoretical solutions and equivalent algorithms, which prove the correctness and feasibility of precise simulation. Compared with an equivalent algorithm, precise simulation of pipe cooling in mass concrete can characterize the sharp temperature gradient around cooling pipe and the temperature rise of cooling water along pipeline more realistically. In addition, the cooling effects and local temperature gradient under different water flow (0.60 m3/h, 1.20 m3/h, and 1.80 m3/h) and water temperature (5 °C, 10 °C, and 15 °C) are comprehensively studied and related engineering suggestions are given. [ABSTRACT FROM AUTHOR]

Prediction of hydration temperature and induced stresses in mass foundation slabs, due to the hydration effects is a difficult task. The complexity of this issue is compounded by transient and non-linear thermo-mechanical phenomena as well by a significant number of contributing technological and material factors that affect the early-age volume changes. This is a probable reason for the limited number of simple analytical methods allowing for the estimation of these effects. This work presents a new proposal in the discussed field. The submitted analytical method for determining the hydration temperature rise, its differentials at a cross-section and induced thermal stresses in mass concrete foundation slabs considers the majority of important technological and material factors, such as the initial temperature of the concrete, the ambient temperature, the thermal properties of the concrete and the heat exchange conditions on the slab surfaces. In stress analysis, both self-balanced and restraint stresses are calculated. Finally, the method is validated in FE analysis conducted for the slabs with various heights and made of different types of cements, as well as by the thermal measurements from the construction site. Due to the limited number of methods allowing for the analytical estimation of the early age thermo-mechanical effects in slabs, this new proposal can be useful in the assessment of these effects. [ABSTRACT FROM AUTHOR]

Mass concrete has been commonly known for its thermal stresses which arise due to the entrapment of hydration temperature susceptible to thermal cracking. The utilization of mineral additives is a promising and widely adopted technique to mitigate such effects. This paper presents the thermal, physico-chemical, mechanical, and morphological behaviour of mass concrete with blends of bentonite (BT) and fly ash (FA). Apart from the rise in temperature due to hydration, the compressive strength, ultrasonic pulse velocity (UPV), differential thermal analysis (DTA), thermo-gravimetric analysis (TGA), X-ray diffraction (XRD) analysis, and microstructure were studied. The results of this study revealed that the substitution of BT and FA significantly improved the compressive strength and development rate of UPV in the mass concrete samples. The FA concrete (FC) specimen presented the lowest temperature during the peak hours compared to all other concrete mixes studied in this research. Bentonite concrete (BC) was also found to be more effective in controlling the escalation of temperature in mass concrete. Scan electron microscopy (SEM) micrographs presented partially reacted FA particles in a mix. XRD and DTA analysis indicated that the concentration of calcium hydroxide (CH) declined by substituting FA and BT, specifically in ternary blends, which was due to the dilution effect and consumption of CH through the pozzolanic reaction. [ABSTRACT FROM AUTHOR]

The current work presents the complex investigation of the influence of cement and aggregate type on the thermo-mechanical behavior of mass concrete. Six types of cement with different amounts of non-clinker constituents and four types of aggregates are used in experimental tests. Particular attention was given to the low clinker cements with high amounts of siliceous fly ash and ground blast furnace slag. The experimental research covered the determination of thermal, mechanical, and rheological properties of early age concrete with different constituents. Experimental results have been used both to validate the numerical model and analysis of exemplary foundation slab. The results confirm the importance of the concrete mix composition and it has been shown that the early-age volume deformation and possible cracking is the result of the concerted action of thermal and mechanical properties of concrete. The obtained results indicate granite as the best aggregate for mass concrete. Considering the type of cement, much better behaviour of mass concrete has been noted for cements with fly ash and composite cements containing both fly ash and slags than cements only with slag. [ABSTRACT FROM AUTHOR]

Mass concrete has been commonly known for its thermal stresses which arise due to the entrapment of hydration temperature susceptible to thermal cracking. The utilization of mineral additives is a promising and widely adopted technique to mitigate such effects. This paper presents the thermal, physico-chemical, mechanical, and morphological behaviour of mass concrete with blends of bentonite (BT) and fly ash (FA). Apart from the rise in temperature due to hydration, the compressive strength, ultrasonic pulse velocity (UPV), differential thermal analysis (DTA), thermo-gravimetric analysis (TGA), X-ray diffraction (XRD) analysis, and microstructure were studied. The results of this study revealed that the substitution of BT and FA significantly improved the compressive strength and development rate of UPV in the mass concrete samples. The FA concrete (FC) specimen presented the lowest temperature during the peak hours compared to all other concrete mixes studied in this research. Bentonite concrete (BC) was also found to be more effective in controlling the escalation of temperature in mass concrete. Scan electron microscopy (SEM) micrographs presented partially reacted FA particles in a mix. XRD and DTA analysis indicated that the concentration of calcium hydroxide (CH) declined by substituting FA and BT, specifically in ternary blends, which was due to the dilution effect and consumption of CH through the pozzolanic reaction.

Acoustic emission (AE) is capable of monitoring the cracking activities inside materials. In this study, embedded sensors were employed to monitor the AE behavior of early age concrete. Type 1-3 cement-based piezoelectric composites, which had lower mechanical quality factor and acoustic impedance, were fabricated and used to make sensors. Sensors made of the composites illustrated broadband frequency response. In a laboratory, the cracking of early age concrete was monitored to recognize different hydration stages. The sensors were also embedded in a mass concrete foundation to localize the temperature gradient cracks.