To achieve more accurate prediction of the potential failure location and to conduct a deeper analysis of the failure mechanism of concrete constructions, it is critical to probe the evolution process of internal meso-cracks that bear various intensities of load. While a computer Tomography (CT) test provides a non-destructive detection technique for obtaining the internal meso-damage state of concrete, traditional image processing and Digital Image Correlation (DIC) are ineffective in extracting meso-damage information from concrete CT images. On the other hand, by observing the shape change law of concrete’s internal holes under load, it is proposed to use the hole roundness and area fraction formula, developed based on the stereology principle and morphology, to characterize and predict the potential failure location. Four features particularly addressed include the CT image as a whole, image equal partitioning, crack and non-crack areas, and representative holes. The approach is to explore the variation law of critical hole shape parameters, especially the hole roundness under different loading stages, and analyze the relationship between the change in hole shapes and the final macro-crack positions. It is found that compared with the average area fraction, the average hole roundness value of cross section images is more sensitive to the change in stress. In both uniform partitioning and non-uniform partitioning, the average hole roundness value near the final macro-crack location exhibits an increase trend with the stress, while the smoothing effect caused by the hole roundness averaging always exists. Near the final macro-crack location, the roundness of each individual hole is positively associated with the stress, while away from the final macro-crack location such a relation may not be observed. This trend expounds the evolution process of meso-damage in concrete, and the finding can be used to predict the accurate locations of macro-cracks.
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