Experimental and finite element investigations on hydration heat and early cracks in massive concrete piers

The concrete hydration heat and different construction methods directly affects the early crack resistance of massive concrete structures and may lead to concrete cracks. In this work, the hydration heat test and finite element simulation were conducted to investigate the early cracking resistance and the main influencing factors of the massive concrete bridge pier. The size of the bridge pier was 8 m (length) × 4 m (width) × 22.5 m (height), and the pier was poured in two layers (8.5 m/14 m) with an interval of 37 hours. The internal temperature of the pier was tested 16 days after the concrete pouring using pre-buried temperature sensors, and the crack expansion on the surface of the pier was continuously observed during the test period. The test obtained a maximum concrete temperature of 64.25 °C after 100 hours after the concrete pouring, and 3 cracks were found on the surface of the pier. The pier simulation model is established according to the actual situation in the test, The maximum temperature inside the bridge pier obtained from the simulation is 61.73℃, and the temperature field development pattern and the crack expansion on the pier surface were basically consistent with the test, which confirmed the reliability of the simulation method. Besides, the simulation process found that the maximum main tensile stress on the surface of the bridge pier was 2.77 MPa, which was mainly distributed near the interface of the 2 layers, indicating that the layered pouring scheme adopted in the test was improper. The effect of layered casting schemes on the early cracking resistance of massive concrete has rarely been discussed, and further simulations revealed that: the maximum main tensile stress can be reduced by gradually improving the number of layers, layer height and interval between each layer. By changing the original layered pouring scheme to 3 layers with an interval of 3 days between each layer, the maximum principal tensile stress is reduced to 1.50 MPa, and early cracking of the bridge pier can be avoided. This work provides a general numerical analysis method with high accuracy, parameterization and quantification for early crack control of massive concrete structures in a multi-factor complex environment.