Feel free to show me a new building without any settlement cracks.
First of all, we need to distinguish between visible and non-visible settlements as well as cracks caused by different material pairings. I do not dispute non-visible settlements or cracks due to material pairings – as already mentioned before – but the thread is about visible cracks in continuously built masonry walls caused by settlements, and here I clearly say: that is not normal.
Please do not take the following statement as an attack, but just because it is beyond your imagination/experience, it is not impossible to build without visible settlements/cracks.
I just had to inquire with three acquaintances. I am happy to show you the new-build houses in the postal code 85 that had no visible settlements/cracks whatsoever and to achieve this they were not surface laminated using fleece etc. either. Built in the last 4 years with professional planning and constructed by specialized companies under construction supervision.
If the contractor follows the recommendations in the soil report in a respectful manner and practices their craft properly, the issue of settlement cracks can be limited to a non-visible extent, and if these do become visible, it is merely the result of insufficient planning, improper installation/use/processing of materials, or in short “human error.” Anyone who does not know the substrate on which they build their future cannot expect any contractor to apply appropriate measures to prevent cracks. The result is then the popular opinion: “Settlement cracks are completely normal.” An estimated 55-65% do not even commission a soil report, and among those who do, too often there is someone on the other side who files the document away under “we have always done it this way” or does not understand it at all and yet builds without consideration. The result is then the widespread disease of buildings.
But in my opinion, it is almost tragic how the thread starter here is being taught the normality of visible settlement cracks – because they are not normal.
You are probably right that the probability of settlement cracks is always present, but in my opinion only as a result of insufficient care during the planning phase/construction period.
An example from practice for crack prevention:
On the ground floor there is a large span of the concrete filigree ceiling. To carry the load, a support beam is needed. For aesthetic reasons, an overlay is chosen. On the upper floor, right at this point there is a wall. That means a concrete pillar would protrude about 30 cm above the concrete floor, and only then would the hollow bricks for the wall be installed. This spot, when plastered, is very likely to crack due to the material pairing (details here would be too extensive). To avoid that, the necessary reinforcement in the concrete ceiling structure was calculated and ultimately installed there as well, so that a floor-level overlay was achieved. Thus no cracks above the screed level later visible and no “how do I cover this up?” drama.
*Edit:
A fourth colleague just joined (also an architect) and said “no visible settlement cracks since construction 5 years ago, because I thoughtfully considered all working steps beforehand.”