Open Access

ARTICLE

Hydration Heat Analysis and Crack Control of Composite Box Girders with Corrugated Steel Webs in Prefabrication

Xuefeng Wang^1,2, Haiqing Cao^1,2, Ke Jiao^3,*, Aoxiang Li^1,2, Zhongwei Li^1,2

1 China Construction Sixth Engineering Bureau Co., Ltd., Tianjin, 300000, China
2 China Construction Bridge Co., Ltd., Chongqing, 400000, China
3 School of Water Conservancy and Transporation, Zhengzhou Unversity, Zhengzhou, 450001, China

* Corresponding Author: Ke Jiao. Email:

(This article belongs to the Special Issue: Sensing Data Based Structural Health Monitoring in Engineering)

Structural Durability & Health Monitoring 2025, 19(4), 985-1010. https://doi.org/10.32604/sdhm.2025.061554

Received 27 November 2024; Accepted 13 February 2025; Issue published 30 June 2025

Abstract

This study examines the temperature field distribution characteristics and temperature effects during the prefabrication of composite box girders with corrugated steel webs (CBGCSWs), aiming to provide practical recommendations for controlling temperature-induced cracking and technical guidance for concrete mix proportions and placement processes. Based on field measurement data, a three-dimensional finite element model was developed to simulate the temperature effects at critical locations during the prefabrication phase. By varying the concrete mix proportions, initial casting temperature, and ambient temperature, the study elucidates the variation patterns of the temperature field during precast placement. The results show that the temperature rise caused by hydration heat increases with higher cement and fly ash content, whereas reducing cement and using minimal fly ash effectively lower the hydration temperature. However, the influence of fly ash on prestress losses should be carefully evaluated during the design phase. Higher initial casting temperatures accelerate hydration rates, leading to a rapid temperature rise. Significant differences between the initial casting and ambient temperatures result in larger residual temperature stresses. Based on concrete mix proportions, curing conditions, and ambient temperatures, three recommended casting temperature ranges were identified: 5°C–10°C, 10°C–25°C, and 25°C–30°C. Variations in the average ambient temperature affect the peak temperature of the hydration reaction and indirectly influence the final temperature distribution of the concrete structure. Optimizing the demolding time and applying geotextiles and water curing effectively reduces the peak temperature, maximum internal-to-surface temperature gradients, and surface tensile stresses, thereby mitigating the risk of temperature-induced cracking.

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Keywords

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