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<p>The construction of Yanji Yangtze River Bridge main pylons, employing C60 concrete with wall thicknesses up to 4.25&#xa0;m, presented formidable challenges in controlling thermal cracking. This study presents an integrated methodology for mitigating early-age cracking in thick-walled high-strength mass concrete (HSMC) bridge pylons through the synergistic combination of advanced material design and multi-physics simulation. A novel crack-resistant concrete was developed by incorporating 8% of a temperature-regulating and shrinkage-compensating anti-cracking agent, which reduced the early-age temperature rise rate by 37% and exhibited superior deformation characteristics under simulated thermal histories. Laboratory tests revealed 446 µε greater expansion during the temperature rise stage and a 0.63 µε/℃ reduction in shrinkage rate during temperature drop, while maintaining 215 µε effective expansion after 14 days. A sophisticated multi-physics coupling model accounting for hydration-temperature-humidity-restraint interactions was employed to quantitatively assess cracking risk and optimize construction parameters. The integrated strategy, implementing crack-resistant concrete with optimized techniques (placing temperature ≤ 28&#xa0;°C, cooling pipes, and formwork retention ≥ 5 days), consistently maintained cracking risk coefficients below the critical threshold of 0.7. Field implementation achieved maximum core temperatures below 75&#xa0;°C, core-surface differentials below 25&#xa0;°C, and preserved residual expansion of 164.3-241.1 µε up to 12 days, resulting in zero harmful cracking. This research establishes a validated technical framework for crack-resistant construction of similar HSMC structures.</p>

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Integrating Crack-Resistant Concrete with Multi-Physics Simulation for Early-Age Cracking Risk Mitigation in HSMC Bridge Pylons

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • Beixing Li,
  • Dong Xu,
  • Hui Huang,
  • Yuxin Guo

摘要

The construction of Yanji Yangtze River Bridge main pylons, employing C60 concrete with wall thicknesses up to 4.25 m, presented formidable challenges in controlling thermal cracking. This study presents an integrated methodology for mitigating early-age cracking in thick-walled high-strength mass concrete (HSMC) bridge pylons through the synergistic combination of advanced material design and multi-physics simulation. A novel crack-resistant concrete was developed by incorporating 8% of a temperature-regulating and shrinkage-compensating anti-cracking agent, which reduced the early-age temperature rise rate by 37% and exhibited superior deformation characteristics under simulated thermal histories. Laboratory tests revealed 446 µε greater expansion during the temperature rise stage and a 0.63 µε/℃ reduction in shrinkage rate during temperature drop, while maintaining 215 µε effective expansion after 14 days. A sophisticated multi-physics coupling model accounting for hydration-temperature-humidity-restraint interactions was employed to quantitatively assess cracking risk and optimize construction parameters. The integrated strategy, implementing crack-resistant concrete with optimized techniques (placing temperature ≤ 28 °C, cooling pipes, and formwork retention ≥ 5 days), consistently maintained cracking risk coefficients below the critical threshold of 0.7. Field implementation achieved maximum core temperatures below 75 °C, core-surface differentials below 25 °C, and preserved residual expansion of 164.3-241.1 µε up to 12 days, resulting in zero harmful cracking. This research establishes a validated technical framework for crack-resistant construction of similar HSMC structures.