Crack Free Concrete Formulation Methods
Concrete cracking remains a persistent challenge in construction, with microcracks developing as early as the first 24 hours of curing. Field data shows that even high-performance concrete can develop cracks ranging from 50 micrometers to several millimeters wide, significantly impacting structural durability and leading to maintenance costs that can exceed 30% of initial construction budgets.
The fundamental challenge lies in balancing concrete's mechanical strength requirements with its inherent tendency to develop shrinkage-induced stresses during curing and service life.
This page brings together solutions from recent research—including nano-silica modified formulations, tire-derived rubber granule composites, basalt fiber reinforcement systems, and innovative curing control methods. These and other approaches focus on practical implementation strategies that can be scaled to commercial construction while maintaining workability and cost-effectiveness.
1. Concrete Composition with Specific Limestone Aggregate and Multi-Agent Additive System
丽水交投建筑工业化制造有限公司, 2025
Crack-proof and impermeable concrete comprising a combination of cement, aggregate, expansion agent, anti-cracking agent, waterproofing agent, water-reducing agent, and admixtures. The concrete contains a specific limestone aggregate with particle size range of 7-30mm, and is formulated with a proprietary combination of expansion agent, anti-cracking agent, and waterproofing agent to achieve superior mechanical properties and impermeability. The admixtures enhance crack resistance and durability through cross-linking and modification of natural fibers, while the diatomaceous earth provides enhanced durability through pore structure modification.
2. Cementitious Composite with Tire-Derived Rubber Granules and Polymeric Fibers for Enhanced Tensile Strength and Crack Control
THE REGENTS OF THE UNIVERSITY OF MICHIGAN, GEORGIA TECH RESEARCH CORP, 2024
Engineered cementitious composite that achieves ultra-high tensile strength and extremely narrow crack widths through the incorporation of tire-derived rubber granules. The composite combines Portland cement binder, tire-derived rubber granular component, calcined clay component, limestone, water, superplasticizer, and polymeric fibers. The tire-derived rubber granules, which are processed to enhance their mechanical properties, are incorporated into the cementitious matrix to achieve the desired tensile strain capacity of 3% and crack width of less than 50 micrometers.
3. Concrete Additive with Polymer Emulsion Matrix and Controlled Polymerization Components
SICHUAN SHENGJI HONGBO BUILDING MAT CO LTD, SICHUAN SHENGJI HONGBO BUILDING MATERIAL CO LTD, 2024
Concrete anti-cracking and anti-seepage agent that improves durability without compromising workability. The agent comprises a polymer emulsion matrix with monomer and comonomer components, which undergoes controlled polymerization through initiator decomposition. The emulsion system is stabilized with emulsifier, stabilizer, and preservative, while pH control ensures optimal performance. The agent's unique composition balances workability with enhanced durability, making it suitable for concrete applications requiring both strength and resistance to water ingress.
4. Concrete Formulation with Nano-Silica Fume and Sepiolite for Enhanced Durability and Impermeability
KIZILSU KIRGHIZ AUTONOMOUS PREFECTURE SHUNXIN COMMERCIAL CONCRETE CO LTD, 2024
A new concrete formulation for enhanced durability and impermeability, particularly addressing the challenges of crack resistance and water management in high-performance concrete applications. The formulation combines a controlled cement mix with specialized additives to prevent cracking and improve water resistance, while incorporating innovative components like nano-silica fume and sepiolite to enhance mechanical properties. The formulation achieves superior performance through its precise balance of cement, aggregate, and additives, enabling high-performance concrete with improved durability and water management characteristics.
5. Concrete Mixing Device with Rotating Shaft and Radial Rod Assembly
TONGXIANG YADU CONCRETE CO LTD, 2024
A novel concrete production method for preventing cracking through a unique mixing and stirring device. The device comprises a mixing barrel, a cover body with a rotating mixing assembly, and a shaft with a mixing rod. The mixing assembly features a motor at its top, a shaft connected to the motor output, and multiple rods arranged along the shaft. This design enables precise control over the mixing process, with the shaft providing a rotating mixing action while the rods provide additional mixing and distribution capabilities.
6. Concrete Composition with Modified Basalt Fibers and Silane-Nano-SiO2 Solution Integration
BEIJING TIEKE BUILDING TECH CO LTD, 2024
High-performance concrete with enhanced crack resistance and improved mechanical properties, achieved through a novel preparation method that incorporates modified basalt fibers into cement-based materials. The method involves hydrolyzing a silane coupling agent to produce an alkane coupling agent solution, which is then mixed with nano-SiO2 to create a modified solution. This solution is then incorporated into cement-based mixtures, where it combines with the modified basalt fibers to improve the concrete's mechanical strength, water retention, and cohesion. The modified solution enhances the fiber's compatibility with cement matrix, reduces bleeding, and significantly improves the concrete's shrinkage behavior, resulting in a high-performance concrete with superior crack resistance.
7. Concrete Composition with Crushed Sharp-Edged Aggregate and Fiber Reinforcement
KEZHOU SHUNXIN COMMERCIAL CONCRETE CO LTD, 2024
A crack-resistant concrete that incorporates a unique combination of cement, aggregate, and reinforcement to prevent cracking. The concrete comprises cement, water, coarse aggregate, and fine aggregate, with specific proportions of each component. The aggregate is crushed into blocks with sharp edges, while the cement is prepared by fusing water with the cement particles. The aggregate blocks are then stored separately for later use. The concrete formulation includes a viscous additive, fiber reinforcement, and a water-reducing agent, which work together to enhance the concrete's durability.
8. Concrete Composition with Reduced Cement-to-Aggregate Ratio, Nano-Silica Admixture, and Controlled Curing for Crack Resistance
BEIJING CARS CONSTRUCTION TECHNOLOGY CO LTD, 2024
Crack-resistant concrete for plateau construction, featuring improved durability through enhanced material preparation and application. The concrete formulation combines a reduced cement-to-aggregate ratio with specialized admixtures and nano-silica mortar emulsion, resulting in improved slump, reduced shrinkage, and enhanced thermal resistance. The preparation method incorporates controlled water reduction and controlled curing strategies to optimize concrete properties in the plateau environment. This approach enables reliable structural integrity in high-radiation conditions while minimizing early cracking.
9. Concrete Composition with Basalt Nanoparticles Prepared via Multi-Stage Treatment Process
THE UNIV OF JORDAN, 2023
Concrete composition with enhanced mechanical properties achieved through the incorporation of high-performance basalt nanoparticles. The composition comprises cement, water, basalt fine sand, basalt aggregates, one or more admixtures, and specifically engineered basalt nanoparticles. The basalt nanoparticles are prepared through a multi-stage treatment process that includes mechanical grinding, thermal treatment, and separation. The resulting composition exhibits significantly improved mechanical strength compared to conventional concrete formulations.
10. Alumina-Coated Colloidal Silica Nanoparticles with Controlled Size Distribution for Cementitious Compositions
INTELLIGENT CONCRETE LLC, 2023
Alumina-modified colloidal silica nanoparticles that mitigate Alkali Silica Reaction (ASR) in cementitious compositions, and methods of using the nanoparticles to produce improved cementitious compositions. The nanoparticles have diameters of about 3 nm to about 100 nm, with a coating of at least 0.03% alumina, and are present in an aqueous solution. The nanoparticles are effective in reducing ASR in concrete by controlling the hydration reactions of cement, and enhance the compressive and flexural strength of formed cementitious articles.
11. Concrete Matrix with Basalt Fibers Featuring Controlled Length Distribution for Enhanced Crack Resistance
HUNAN CITY UNIVERSITY, 2022
Anti-cracking concrete with enhanced durability through the strategic incorporation of basalt fibers. The concrete matrix is combined with 0.05% basalt fibers, which provide superior crack resistance compared to conventional fibers. The fiber length is carefully controlled to optimize crack reduction while maintaining sufficient tensile strength. The fiber length gradually increases as the concrete reaches its optimal strength, leading to a gradual reduction in crack formation. This controlled fiber length distribution enables the concrete to exhibit superior crack resistance without compromising its mechanical properties.
12. Concrete Composition with Multi-Component Mix Incorporating Fly Ash, Steel Slag, Phosphorus Slag, and Specialized Admixtures
Shaanxi University of Science and Technology, SHAANXI UNIVERSITY OF SCIENCE & TECHNOLOGY, 2022
High-performance concrete for critical infrastructure applications that combines exceptional durability, impermeability, and toughness. The concrete achieves these properties through a multi-component approach involving fly ash, steel slag, phosphorus slag, secondary hydration, and specific additives. The preparation involves precise mixing of these components with specialized admixtures, including ultra-fine silicon and boron nitride powders, graphene oxide, and dispersion activators, to create a uniform and dense structure. The resulting concrete exhibits exceptional resistance to cracking, water penetration, and thermal stress, making it suitable for critical infrastructure such as high-rise buildings, bridges, and tunnels.
13. Concrete Composition with Treated Aggregate and Fiber Reinforcement Incorporating Waste Concrete Aggregate, Ultrafine Fly Ash, Nano-Cerium Dioxide, Polypropylene Resin Balls, and Steel Fibers
SHANXI LIXINTAI CONCRETE CO LTD, 2022
Environmentally friendly concrete that reduces cracking through a combination of advanced aggregate treatments and innovative fiber reinforcement. The concrete combines waste concrete aggregate, ultrafine fly ash, and nano-cerium dioxide to enhance its durability, while incorporating polypropylene resin balls and steel fibers for enhanced crack resistance. The treatment process involves mixing the aggregate and cement, followed by grinding through a 200-mesh sieve to produce a uniform dry material. The final product is then mixed with the remaining aggregate and cement, and ground to produce a workable concrete.
14. Concrete Composition with Carbon Fiber, Micro-Silica Fume, and Titanate Coupling Agent Integration
Hangzhou Ruiding Building Materials Co., Ltd., HANGZHOU RUIDING B&M CO LTD, 2021
Crack resistant concrete with improved durability and extended service life. The concrete contains specific materials like carbon fiber, micro-silica fume, titanate coupling agent, and shrinkage reducing agents. The micro-silica fume, carbon fiber, and coupling agent are mixed together first to enhance concrete compactness. Then coarse aggregate is added to fill voids. This reduces the amount of water needed. Shrinkage reducing agents further lower water content. By reducing water, the concrete has less shrinkage and cracking.
15. Method of Integrating Polymer Microspheres with Specific Thermal Expansion Coefficients in Concrete Mixtures
Fujian Shenbao Building Materials Co., Ltd., 2021
A method for improving the durability of concrete structures exposed to environmental conditions. The method involves incorporating polymer microspheres into the concrete mixture to enhance its thermal resistance properties. The polymer microspheres, which are dispersed throughout the concrete matrix, absorb and release moisture as the concrete expands and contracts due to temperature changes, thereby reducing the likelihood of cracking. The polymer microspheres can be formulated to have specific thermal expansion coefficients that match the concrete's thermal expansion characteristics, ensuring optimal performance.
16. Concrete Composition with Basalt Fiber, Dispersible Latex Powder, and Air-Entraining Agent for Enhanced Strength and Crack Resistance
SHANDONG HONGDA PROPERTIES CO LTD, 2021
High-strength anti-crack concrete that combines improved fiber reinforcement with enhanced chemical stability and mechanical properties. The innovative formulation incorporates basalt fiber, dispersible latex powder, and air-entraining agent to achieve a 42.5R cement-based concrete with significantly enhanced compressive strength while maintaining superior durability and resistance to cracking. The fiber reinforcement is strategically optimized with a balanced addition ratio to balance compressive and tensile strengths, ensuring reliable crack resistance without compromising overall concrete performance.
17. Lauric Acid-Alumina Composite Phase Change Material with Expanded Graphite for Concrete Stabilization
HANGZHOU QIANSHEN COMMERCIAL CONCRETE CO LTD, 2021
Lauric acid-alumina composite phase change material for concrete stabilization, particularly in reinforced concrete. The material is prepared by mixing lauric acid with expanded graphite, cooling the mixture, and drying it to constant weight. This composite phase change material (PCM) effectively controls internal temperature and prevents concrete shrinkage-induced cracking through its thermal stability and phase change properties.
18. Concrete Composition with Polycarboxylic Acid Agent and Reticulated Polypropylene Fiber Reinforcement
YANTAI MENGTE CONCRETE CO LTD, 2021
Anti-cracking concrete with enhanced durability through a novel water-reducing agent and fiber reinforcement system. The concrete incorporates a polycarboxylic acid water-reducing agent and strategically placed 16mm reticulated polypropylene fibers that significantly reduce crack propagation. The combination of these innovative components provides superior anti-cracking performance compared to conventional methods, enabling more durable and crack-resistant concrete structures.
19. Concrete Composition with Advanced Cement Components, Graphene Oxide, and Boron Nitride for Enhanced Durability and Environmental Resistance
SHAANXI UNIVERSITY OF SCIENCE & TECHNOLOGY, Shaanxi University of Science and Technology, 2021
High-performance concrete for critical infrastructure applications like long-span bridges, tunnels, and dams, which exhibits superior durability and resistance to environmental degradation compared to conventional high-performance concrete. The innovative formulation combines advanced cement components, including fly ash, coal liver stone powder, and phosphorous slag powder, with secondary hydration and filling effects to create a dense, uniform structure. The development incorporates graphene oxide and boron nitride to enhance hydration, thermal conductivity, and cracking resistance, while dispersing activators further improve the hydration reaction and aggregate stabilization. This results in a concrete with exceptional resistance to chloride ion penetration, carbonization, and thermal degradation, making it suitable for critical infrastructure applications where durability and environmental resilience are paramount.
20. Concrete Composition with Polymer Microspheres and Hydrolyzed Polymaleic Acid Tincture
SHENZHEN BAOJINHUA CONCRETE CO LTD, 深圳市宝金华混凝土有限公司, 2020
Crack-resistant concrete that improves durability through enhanced crack resistance. The method involves incorporating polymer microspheres into concrete mix, which are combined with hydrolyzed polymaleic acid tincture. The polymer microspheres, with their increased surface area, enhance dispersion and prevent agglomeration. This combination creates a crack-resistant concrete that not only prevents cracking but also protects against chloride penetration and reinforcement degradation.
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