Troubleshooting precast cracks

in hollow-core slabs
he following illustrations can use the information to deter- naire depicted different types of

T describe cracks that can

occur in prestressed hol-
low-core slabs during
casting, stripping, or shipment. Al-
though some cracks can and do oc-
cur under service loads, this article
covers only cracks that can occur
during fabrication and shipment.
The illustrations and accompany-
ing text can be used to identify
cracks that can originate from nu-
merous sources. Plant engineers
mine whether design or fabrication
caused cracking. Designers can
use the information to determine
the causes and consequences of
cracks and to assist in making a
judgment as to the acceptability of
the product.
The information in this article is
based on a questionnaire distrib-
uted to hollow-core slab producer
members of the Precast/Prestressed
Concrete Institute. The question-
cracks and requested respondents
to list the causes, prevention, and
effect on serviceability.
Each type of crack is given a
generic name and a brief descrip-
tion. In the first column, the causes
of the crack are described with an
explanation. The prevention is list-
ed in the second column if it is not
inherent in the cause. The last two
columns cover consequences of the
cracks and suggested methods of

Longitudinal crack at void

This type of crack occurs in either the top or bottom flange, or in both flanges at the end of the member.

Cause Prevention Effect Repair

A. Transverse shrinkage
1. Excess water in concrete
2. Rapid moisture loss
3. Heat applied too early
4. Excessive curing temperatures
5. Differential in curing tempera-
ture side to side
B. Improper handling
1. Uneven dunnage
2. Settlement of stack
C. Lack of differential compaction
D. Placement and eccentricity of
prestressing steel
1. Prestressing steel moved or
displaced during casting
2. Imbalance of prestress force
about vertical axis
3. Improper cutting sequence of
prestressing steel
E. Flange too thin due to move-
ment or misalignment of void
forms
F. Overinflation of rubber void
forms
A. Proper mix and curing Severe cracks such as a Voids may be grouted
1. Reduce water content. crack through the full solid or the crack may
2. Cover product completely and depth of the member in be epoxied. Repair may
as soon as possible (especially in an untop ped system not be required espe-
windy, hot, or dry exposure). In can affect load distribu- cially if member is used
extreme cases, spray product tion where there are in a topped system.
with mist or curing compound concentrated l oads,
before covering. openings, or transverse
3. Increase preset time before cantilevers.
curing temperature rise begins.
4. Reduce curing temperatures.
5. Check for uneven curing tem-
perature and make appropriate
corrections.
B. Proper handling
1. Use dunnage which provides
uniform bearing.
2. Use heavier dunnage at bottom
of stack to prevent settlement.
Reduce height of stack.
C. Improve vibration.
D. Proper positioning and design
of prestressing steel
1. Exercise care during casting to
prevent displacement of pre-
stressing steel.
2. Balance prestress about vertical
axis or minimize eccentricity.
3. Cut prestressing strand sym-
metrically from center to outside.
E. Co rrect an d mainta in void
form position.
F. Maintain proper inflation.
repair when required.
The report depicts hollow-core
slabs with circular voided sections.
All or most of the cracks described
apply to hollow-core slabs with
other shapes of voided sections.
As a final note, although this arti-
cle covers the typical causes, pre-
ventions, and repairs of cracks, it
cannot be expected to anticipate
every possible variation or extreme
in requirements for design and ser-
viceability.
This article is based on Fabrica-
tion and Shipment Cracks in Pre-
stressed Hollow-Core Slabs and
Double Tees, prepared by the Pre-
cast/Prestressed Concrete Insti-
tutes Committee on Quality Con-
trol Performance Criteria. For infor -
mation on troubleshooting precast
cracks in double tees, see the Oc-
tober 1995 issue of C o n c r e t e
J o u r n a l. The original report ap-
peared in the January/February
1983 issue of the PCI Journal and
is reprinted with permission.

Longitudinal crack at web

Longitudinal crack in top surface over the web. Cracks are not limited to ends of member, but can start and
stop intermittently along the length of the member.

Cause Prevention Effect Repair

A. Subsidence over void
1. Excess water in concrete
2. Bleeding rubber void forms too
soon
B. Shrinkage due to improper
curing and mix proportions
1. Excess water in concrete
2. Rapid moisture loss
3. Heat applied too early
4. Excessive curing temperatures
5. Differential in curing
A. Prevent subsidence over void. Minor cracking should If crack is severe, mem-
1. Reduce water content. have little effect: how- ber may be cut to a
2. Delay bleeding of rubber void ever, it may create narrower width or used
forms. problems with concen- in a topped system.
B. Improve curing procedures trated load distribution
and mix. in untopped systems.
1. Reduce water content.
2. Cover product completely and
as soon as possible (especially in
windy, hot, or dry exposures). In
extreme cases, spray product
with mist or curing compound
before covering.
3. Increase preset time before
curing temperature rise begins.
4. Reduce curing temperatures.
5. Check for uneven curing tem-
perature and make appropriate
corrections.

Corner cracks
These cracks are diagonal cracks starting at the end of the slab possibly extending to the edge. May be in just
the top or bottom flange, but could extend completely through the section.

Cause Prevention Effect Repair

A. Saw blade pinch es when
member cambers.
B. Sawcut not deep enough
C. Saw bla de wobble due to
excessive use
D. Uneven dunnage
E. Support blocks not providing
even distribution of load dur-
ing storage
F. Uneven handling due to pick-
up devices not being level
G. Excessive tension stress dur-
ing stripping
A. Place weight on member to Usually minimal, but Cracks may not need to
restrict camber. can reduce shear capac- be repaired depending
B. Cut completely through strands ity if w ebs are dam- on shear requirements.
and as close as possible to the aged. Evaluated similar Epoxy may be used on
bottom of the member. to opening occurring at cracks. Voids may be
the end of the member. grouted solid.
C. Proper saw maintenance
D. Provide level supports.
E. Make sure support blocks do
not transfer l oads through
flanges.
F. Use spreader beams to mini-
mize uneven handling.
G. Anne al st ran d and employ
proper cutting sequence.
 Web crack at or near the strands
These cracks are horizontal cracks in webs parallel to member length at or near the strand.
Cause
A. Excessive bursting stresses
1. Web not thick enough for
transfer of prestress force
2. Strand diameter too large for
transfer through thin webs
3. Lateral strand drift
4. Low release strength
B. Lack of concrete consolidation
around strands
C. Strand masking improperly
placed
D. Layers not bonded
E. Sawcut not deep enough or
not complete across sides
This is a crack across the member, predominantly occurring in the top, but can extend completely through the
member in severe cases.
Cause
A. Longitudinal shrinkage
1. Excess water in concrete
2. Rapid moisture loss
3. Heat applied too early
4. Excessive curing temperatures
5. Uneven heating along length of
bed
B. Contraction due to delayed de-
tensioning after uncovering
heat cured product
C. Excessive top fiber tension
1. Cantilever loading by mis-
placement of dunnage
2. Inadequate or misplaced ten-
sion reinforced in cantilevers
3. Strand pattern too low
4. Low release strength
D. Insufficient cover on trans-
verse reinforcing bar (when
required for special designs)
Prevention Effect Repair
A. Reduce bursting stresses Can reduce shear ca- Repair of this member
1. Increase web width if possible. pacity because shear to account for the
2. Provide equivalent prestress stress must be resisted strand slippage which
force with strands of smaller di- by undamaged webs. has occurred is not fea-
ameter. Evaluation must include sible; however, the
3. Check strand guides on ma- the effect of the associ- shear capacity can be
chine. ated strand slippage. improved by grouting
4. Increase release strength. voids solid, or epoxying
B. Improve consolidation around the cracks.
strands.
C. Secure masking to prevent
movement.
D. Revise production procedures
to avoid cold joints.
E. Saw completely through or
across member.
Transverse crack
Prevention Effect Repair
A. Proper mix and curing Potential shear capacity For minor cracks epoxy
1. Reduce water content. reduction if crack oc- can be effective, and
2. Cover product completely and curs at end. Can have a shear capacity can be
as soon as possible (especially in signific ant effect on increased by grouting
windy, hot, or dry exposures). In shear and moment ca- voids solid at crack.
extreme cases, spray product pacities of cantilevers. Minor cracks in the top
with mist or curing compound Reduction of moment flange at areas of posi-
before covering. of inertia in center of tive moment or in bot-
3. Increase preset time before member can cause tom flange at areas of
curing temperatures rise begins. camber differentials and negative moment may
4. Reduce curing temperatures. excessive deflections. not require any repair.
5. Check heat distribution system.
When a severe crack oc-
B. Detention as soon as strength curs in a member,
is ve rified , before pro duct cracked section should
cools be cut out and resulting
C. Reduce top fiber tension. member placed in stock.
1. Maintain proper dunnage loca-
tion.
2. Install adequate reinforcement
at proper position.
3. Check placement of strand and
consider debonding at end of
members.
4. Increase release strength to ac-
commodate top fiber tension.
D. Increase reinforcing bar cover.
 Web crack above the strands
A horizontal crack in one or more webs located above the strands. Crack widths can vary from hairline up to
1
4 inch (6.3 mm) or more in severe cases.

Cause Prevention Effect Repair

A. Excessive prestress force rela-
tive to cross section of member
B. Insufficient release strength
C. Exp an sion of rubb er v oid
forms due to increased tem-
perature
D. Bottom surfaces of member
sticking to form during strip-
ping
E. Sawcut not deep enough
F. Lifting inserts or end stirrups
misplaced
G. Mix too wet or too dry
H. Insufficient vibration
A. Re duce shear la g through Can reduce shear ca- For minimal cracks
webs. pacity because shear epoxy may be effective,
1. Increase web width or pro- stress must be resisted and shear capacity can
duce with solid voids. by undamaged webs. be increased by grout-
2. Debond strands at ends of Analysis should be con- ing voids solid.
members. servative because shear
3. Add top strands. failure is not ductile.
4. Reinforce webs.
5. Reduce prestress force if ulti-
mate strength design controls
and check service load require-
ments.
B. Increase release strength.
C. Bleed rubber void forms earlier.
D. Clean and oil form properly
or ensure a dry contact sur-
face when stack casting.
E. Cut completely through strands
and as close as possible to the
bottom of the member.
F. Place lifting inserts and stir-
rups properly.
G. Adjust water content.
H. Improve vibration.

PUBLICATION # J950970, Copyright 1995, The Aberdeen Group, All rights reserved