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 CONCRETE ADVICE No. 59
Licensed copy: uninorth, University of Northumbria, 04/07/2017, Uncontrolled Copy, Concrete Society

Crack width measurement

Richard Barnes, PhD CEng MICE FHEA FICT

Crack measurement involves recording cracks at the concrete surface to provide a

descriptive record which can be complemented with photographs. The important features
to record are: pattern of cracking, spacing, length, number of cracks, orientation with
respect to reinforcement, concrete surface condition and crack width. The pattern of the
[1, 2]
cracks helps to identify the likely cause . This document aims to offer advice on
measuring the maximum surface crack width.

In all structures, a few cracks will be wider

1 Assessment of cracks
Many concrete structures or elements will
exhibit cracks in some form. Generally
cracks should not be regarded as a defect
or a failure. The significance of cracks as a
potential defect will depend on whether
they represent a workmanship or design
failure, and on the designers assumptions
as to what level of cracking was
anticipated. Cracks are only a defect if
they seriously affect the performance of
the element or structure and not a function
of the design of the structure.
Examples of cracking which could be
regarded as a defect are:
than specified, but this should not
necessarily cause concern unless the
wider cracks are at critical locations. Some
engineering judgement is required to
determine their significance and this will
depend on the location in the structure, the
type of structure and the environment.
2 Tools for the job
The most convenient way to measure
crack widths at the surface is to use a
crack comparator, such as that shown in
Figure 1. This is a clear card with lines of
specific width marked on the card.

excessive amounts of plastic shrinkage

wide shrinkage restraint cracks in water-
retaining/water-excluding elements
excessive amounts of restrained early
thermal contraction cracking in deep or
thick elements

The assessment of cracks is very

subjective and it is difficult to quantify the
number or size of cracks which constitute
any of these conditions as many unrelated
factors play their part.
Fig. 1 Crack comparator card
Design codes which limit crack width and
spacing make no attempt to define the A pocket comparator comprised of a loupe
measuring techniques to be used. (small magnification device) and a suitable
reticule, can also be used; also referred to
as an optical comparator. See Figure 2.
 Page 2 of 4 CONCRETE ADVICE NO. 59

Alternatively a hand-held microscope with a

suitable scale can be used. These are not as
practical as a simple crack comparator, especially
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for cracks in slabs which for a hand-held

microscope requires the measurer to lie down on
the slab in order to get a reading. Also they
generally require a flat surface and good lighting
conditions which are not always present on a
construction site.

Fig. 4. Crack movement gauge

More sophisticated gauges include LVDT, electrical

resistance, electrolytic tilt sensors, lasers etc.

3 Measuring the crack

Fig. 2 Crack optical comparator
Crack widths can generally be measured to an
accuracy of 0.1mm with either device although
some pocket comparators and hand-held
microscope claim a greater accuracy.
The use of feeler gauges is not recommended as
cracks are rarely in a straight line and false
readings can arise.
For a fresh crack, Figure 5a, dimension X should
be measured. If the crack is not recent, it may well
be weathered or trafficked at the surface and
possibly exaggerated by a few millimetres, see
Figure 5b. For cracks with obvious breakdown at
the surface, dimension Z should be recorded as
measuring the dimension Y over-estimates the
crack width.

It may be necessary to assess if a crack is still

moving, for example to determine whether it is due
to ambient temperature changes, shrinkage or to
early thermal contraction. This may be done by a) Fresh
using simple tell-tales bonded across cracks,
which will show if further movement takes place. If
a more precise measure of the movement is
required a mechanical device such as Demec
gauge (Figure 3 and 4) or similar may be used to
measure the relative movement of studs bonded on
the concretes surface at a set distance apart b) Weathered
across the crack.
Fig. 5 Crack opening

If the crack is cleaned prior to measurement then

care must be taken not to inadvertently widen the
crack. Some water and light scrub with a soft bristle
brush should be adequate; a wire brush should not
be used.

These methods can be accurate for wide cracks,

but when two people measure the width of a crack
of the order of 0.10.2mm it is unlikely that they will
obtain similar or even repeatable results. Cracks
are not simple, parallel-sided canyons and
therefore there is always an element of doubt about
where and exactly what to measure. See Figure 6.
Fig. 3. Demec gauge
 Page 3 of 4
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Each minor division is 0.02mm
LHS cracks is 0.3mm
RHS crack is <0.02mm
Fig. 6 Magnified crack
4 How many measurements
This depends on the element under investigation
and the nature of the cracking. Discussion of the
survey size and approach needs to be agreed on a
case by case basis. It may be necessary to record
1 or more of the following:
Width, length, location, orientation and pattern.
Nature of crack e.g. vertical steps, clean,
ragged, islands, fibres visible.
Size depth and location of spalled areas.
Size and location of areas of delamination.
Size and location of areas of scaling.
Size, location and description of deposits and
staining.
Loss of exposed reinforcement section size.
Other defects and damage.
Crack width measurements should be taken at
several locations along the length of each crack.
The number will depend on the length but say at
metre intervals with a minimum of two.
5 Classifying the crack
[1]
Cracks may be separated into two classes :
Dormant cracks which are unlikely to open,
close or extend further. These cracks are
subdivided as follows:
fine cracks: <0.5mm wide
medium cracks: 0.51.5mm wide
wide cracks: >1.5mm wide.
Live cracks which may be subject to further
movement due to changes in the concrete
temperature and/or moisture state, loading etc.
In practice it is likely that few cracks will be fully
dormant, with movements due to structural effects
being accommodated at non-structural cracks; for
example, vertical early thermal cracks in cylindrical
tanks will tend to open and close as the tank is filled
and emptied.
CONCRETE ADVICE NO. 59
6 Movement of cracks
A crack which has been formed initially by one
mechanism may subsequently be affected by
another mechanism, and this could be significant if
the crack control steel is insufficient.
It is important to assess future crack movements
before remedial work is carried out, as such
movements will affect the choice of materials and
the best time to carry out the work. For example
vertical cracks in tank walls, caused by restrained
early thermal contraction, may open and close due
to the action of hoop stresses in the tank walls.
Also, in external paving, cracks may continue to
open and close indefinitely, due to daily and
seasonal temperature variations.
7 Design to limit crack width
Reinforcement does not prevent cracks occurring in
concrete, but can be used to limit the maximum
crack width at the surface and spacing.
Maximum allowable widths of cracks under normal
service loads are set to ensure that the structure is
aesthetically acceptable, durable and where
appropriate, watertight.
Crack width was originally limited by Codes for
aesthetic reasons, the general consensus being
that a 0.3mm width was not visible from 3m viewing
distance.
[3]
Eurocode 2, BS EN 1992-1-1 limits crack widths
at the surface of the concrete; the limits are similar
[4]
to those in previous Standards, such as BS 8110
[5]
and BS 8007 .
BS EN 1992-1-1 clause 7.3(1) in conjunction with
Table 7.1N (modified in UK National Annex in Table
NA.4) suggests that cracks up to 0.3mm wide are
generally aesthetically acceptable.
BS EN 1992-3, Liquid retaining and containing
[6]
structures , defines four levels of watertightness,
ranging from 0 to 3. In general it recommends a
limiting crack width ranging from 0.05mm to 0.2mm
depending on the head of water.
This approach takes account of the fact that when
water percolates through cracks, it dissolves
calcium hydroxide salts from the cement matrix and
then, on contact with carbon dioxide in the
atmosphere, deposits crystals of calcium
carbonate.
 Page 4 of 4 CONCRETE ADVICE NO. 59

This action, a form of autogenous healing, can be

effective at sealing cracks, although the process is 8 Cover to reinforcement
likely to produce unsightly stains on the surface.
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The design approach in BS EN 1992-3 takes into
account that the likelihood of a crack being sealed
by this mechanism depends on:
the width of the crack
the head of water
whether the crack is tapered or parallel.
Autogenous healing is unlikely to occur if the crack
is liable to further movement when the structure is
commissioned.
In accordance with BS EN 1992-1-1 allowable
crack widths are characteristic values at the 95%
level, so it can be expected that some cracks may
exceed their design size limit. It should also be
noted that plastic cracks occur before the bond
between the concrete and reinforcement has been
developed and so the reinforcement plays no part
in controlling the crack width.
Surface crack width depends on the percentage
reinforcement and depth of cover. The depth of
cover is usually dictated by the exposure
conditions.
The nominal cover (Cnom) to reinforcement
necessary for durability should be used in the
design calculations. However if the required cover
for durability is, say, 35mm with a crack width of
0.3mm at this thickness, but the actual cover ends
up being 70mm, then the surface crack width will be
proportionally greater. This is because cracks are
controlled by the reinforcement and typically widen
to the surface.
Where the surface crack width is limited for the
purpose of appearance, the full cover should be
assessed to calculate the area of reinforcement for
the desired crack width. See the National Annex to
BS EN 1992-1-1 Table NA.4 Recommended values
for max.

References
nd
1. The Concrete Society. TR22 Non-structural cracks in concrete. 2 Edition. The Concrete Society,
Camberley, 2010.
2. Concrete Bridge Development Group, TG2 Guide to testing and monitoring the durability of concrete
structures. Concrete Bridge Development Group, Camberley, 2002.
3. BSI. BS EN 1992-1-1:2004. Eurocode 2: design of concrete structures, General rules and rules for
buildings, BSI, London.
4. BSI. BS 8110: 1997. Structural use of concrete, BSI, London.
5. BSI. BS 8007: 1987. Design of concrete structures for retaining aqueous liquids, BSI, London.
6. BSI. BS EN 1992-3:2006. Eurocode 2: design of concrete structures, Liquid retaining and containing
structures, BSI, London

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Issued Feb 2017

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