1ST International Symposium Uhpc 2004 Keynote

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Ultra High Performance Concrete: Developments and Applications during 25

years. Plenary Session International Symposium on UHPC September 13 - 15,
2004, Kassel, Germany.
Conference Paper · September 2004
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UN I KASSEL
V E R 5 I T "A" T
Ultra High Performance

Concrete (UHPC)
International Symposium on
Ultra High Performance Concrete
September 13-15, 2004
Edited by
M. Schmidt
E. Fehling
C. Geisenhansluke
kassel •
university
press
Ultra High Performance Concrete (UHPC) with a high compressive
strength of more than 200 MPa and an improved durability marks a
quantum leap in concrete technology. This high performance mate-
rial offers a variety of interesting applications. It allows the construc-
tion of sustainable and economic buildings with an extraordinary
slim design. Its high strength and ductility makes it the ultimate buil-
ding material e.g. for bridge decks, storage halls, thin-wall shell
structures and highly loaded columns.
Beside its improved strength properties, its outstanding resistance
against all kinds of corrosion is an additional milestone on the way
towards no-maintenance constructions.
UHPC has very special properties that are remarkably different to the
properties of normal and high performance concrete. For complete
utilisation of UHPC's superior properties, special knowledge is requi -
red for production, construction and design.
Worldwide this material is under detailed exploration. Several con-
structions or structural elements were already built utilizing UHPC.
However, one of the first hybrid bridges consisting of precast UHPC
elements and a steel construction will be built in Kassel in 2004. The
bridge is designed as a foot and bike bridge with a total length of
150m.
More than 75 experts from all over the world presented their research
results and practical experiences with the new and outstanding
material at the
International Symposium on Ultra High Performance Concrete
which took place in September 13 to 15, 2004. The symposium was

organized by the Departments of Structural Materials and of
Structural Engineering of the University of Kassel, Germany.
The experts gave a broad overview and a deep insight into all
aspects of UHPC including raw materials, micro- and macro-struc-
tures, mechanical behaviour, durability as well as of construction and
design specifications appropriate for this material.
This Conference Proceedings contain the conference papers and
presentations. We hope that the excellent papers will promote
further develop and exploitation of Ultra High Performance Concrete
the construction material of the 21st century.
ISBN 3- 8995 8-086-9
9 783899 580860
Committees
Scientific committee International Symposium on

Invitation Prof. Michael Schmidt,
University of Kassel, D (chairman)
Ultra High Performance Concrete
September 13 - 15, 2004, Kassel, Germany
Prof. Ekkehard Fehling,
and University of Kassel, D (vice-chairman)
Prof. Joost C. Walraven,
Delft University of Technology, NL (vice-chairman)
The development of Ultra High Performance Concrete (UHPC)
Final Program Prof. Paul Acker,
Lafarge Company, F
Prof. Peter Bartos,
with its high compressive strength of more than 200 MPa and its
University of Paisley, GB improved durability marks a quantum leap in concrete technology.
Prof. Ignasi Casanova, This high performance material offers a variety of interesting
Universitat Politecnica de Catalunya, E
Prof. Manfred Curbach, applications. It allows the construction of sustainable and
International Symposium Dresden University of Technology, D
Prof. Robert Day,
economic buildings with an extraordinary slim design. Its high
University of Calgary, CA strength and ductility makes it the ultimate building material e.g.
on Prof. Frank Dehn,
University of Leipzig, D
for bridge decks, storage halls, thin-wall shell structures and
highly-loaded columns.
Ultra High Prof. Harald S. Müller,
Karlsruhe University of Technology, D
Prof. Peter Schießl,
München University of Technology, D Beside its improved strength properties, its outstanding resistance
Performance Prof. Ulrich Schneider,
Vienna University of Technology, A
against all kinds of corrosion is an additional milestone on the way
Prof. Karen Scrivener, towards no-maintenance constructions.
Concrete École Polytechnique Fédérale de Lausanne, CH
Prof. Surendra P. Shah,
Northwestern University, USA The very special properties of UHPC distinguishes it remarkably
Prof. Man-Chung Tang,
from normal and high performance concrete. For complete
University of Kassel
T. Y. Lin International, USA

Prof. Nguyen Tue, utilisation of its advanced properties special know-how is
September 13 - 15, 2004 University of Leipzig, D
Prof. Gerd Thielen,
necessary for its production, construction and design.
German Cement Work Association, D
Kassel, Germany Worldwide this material is under thorough investigation. Several
Organizing committee applications were already been built. One of the first precast UHPC
Symposium’s Secretary: bridges in the world will be built in Kassel in this year. The bridge is
Mr. Carsten Geisenhanslüke designed as a foot and bike bridge with a total length of 150 m. This
Chairman of the Organizing Committee: is one of the reasons to held the conference in Kassel.
Mr. Walter Schreiber
Fehling & Jungmann, Structural and Material Consulting Engineers, Kassel, D
University of Kassel: More than 75 experts from all over the world will present their
Prof. Ekkehard Fehling (vice-chairman) scientific and practical experiences with the new and outstanding
Prof. Michael Schmidt
Mrs. Elvira Berndt material. They will give a broad overview of all aspects of the raw
Supported by: Mr. Torsten Leutbecher materials, the micro- and macro-structure, the mechanical
Mr. Roland Bornemann
Dr. Bernhard Middendorf behaviour, the durability as well as of construction and design
Mrs. Ute Müller procedures appropriate for this material.
Mrs. Claudia Rebmann
Mrs. Nadine Sonntag
Mr. Thomas Teichmann The conference will promote the exchange of scientific and
Contact practical experiences and the common usage of this new and
outstanding building material.
Mr. Carsten Geisenhanslüke
Department of Structural Materials, FB14
We are pleased to welcome you at the University of Kassel!
Mönchebergstrasse 7
34125 Kassel, Germany
Tel: +49 561 804 2601 Prof. Dr.-Ing. habil. M. Schmidt Prof. Dr.-Ing. E. Fehling
Fax: +49 561 804 2662
Email: ghlueke@uni-kassel.de
www.uni-kassel.de/uhpc2004
2 3
Technical Program Technical Program Technical Program
Timetable Monday, September 13 Tuesday, September 14
Sunday, Monday, Tuesday, Wednesday, Thursday, 09.00 - 10.30 Opening Ceremony Session B1 Binders and Fillers
Sep. 12 Sep. 13 Sep. 14 Sep. 15 Sep. 16 - 09.00 - 10.30
9:00 Sunday, M. Schmidt, E. Fehling Chairman: Prof. R. Trettin, Siegen, D
Opening Session Session Sep. 19
to L. Elfgren, J.-E. Jonasson, EMC Cements for Ultra High Performance Concretes
Ceremony B1, C1 D1, E1 R.-D. Postlep
10:30 V. Ronin
President of the University of Kassel Lulea, S
10:30 Post-
N. Witte N. B. Singh Highly reactive ß-Dicalcium silicate for Ultra-High
to Coffee Break Coffee Break Coffee Break Conference
Stadtbaurat of Kassel City Gorakhpur, IND Performance Concrete
11:00 Tour
M.-C. Tang High strength materials – past, present and future J. F. Martirena- Lime-pozzolan Binder as a very fine mineral admixture
11:00 (Berlin or
Session Session San Francisco, USA Hernández in concrete
to Session A1 Heidelberg)
B2, C2 D2, E2 Santa Clara, C
12:30 Session A1 History and Experiences M. Shekarchizadeh, Optimizing mix proportions of Normal Weight
12:30 11.00 - 12.30 A. H. Iranmanesh, Reactive Powder Concrete with Strengths of 200-350
to Lunch Lunch Lunch Chairman: Prof. E. Fehling, Kassel, D I. Talebinejad, A. Bassam MPa
100 years of ACI activities in concrete Tehran, IR
14:00 S. Ahmad
Farmington Hills, USA C. Vellmer, M. Gehrke, Seeing at the nanoscale: reaction of pozzolanic and
14:00 B. Middendorf cementitous materials in UHPC
Session Session P. Acker Ductal® Technology: a Large Spectrum of Properties, a
to Session A2 Kassel, D
B3, C3 D3 St. Quentin Fallavier, F Wide Range of Applications
15:30
P. Buitelaar Ultra High Performance Concrete: Developments and
15:30 Session B2 Silica Fume and Additives
Höjbjerg, DK Applications during 25 years
to Coffee Break Coffee Break Coffee Break 11.00 - 12.30
16:00 Chairman: Prof. N. B. Singh, Gorakhpur, IND
Session A2 Recent Applications A. Korpa, R. Trettin The use of synthetic colloidal silica dispersions for
16:00 14.00 - 16.00 Siegen, D making HPC and UHPC systems, preliminary
Session Closing
to Session A3 Chairman: Prof. M. Schmidt, Kassel, D comparison results between colloidal silica dispersions
Welcome B4, C4 Ceremony
18:00 F.-J. Ulm The next generation of US-Highway Bridge Girders: and silica fumes (SF)
Reception /
Cambridge, USA From UHPC materials to High Performance Structures K. Jayakumar Role of Silica fume Concrete in Concrete Technology
Registration Conference Cultural
20:00 Coimbatore, IND
dinner event Z. Hajar, A. Simon Design and Construction of the world first Ultra-High I. Terzijski Compatibility of Components of High and Ultra High
D. Lecointre, J. Petitjean Performance Concrete road bridges Brno, CZ Performance Concrete
Bagneux, F Utilization of chemical admixtures in HPC concretes
R Hela, J. Zach
Welcome Reception on Sunday N.Kaptijn, J.Blom A new bridge deck for the Kaag bridges: The first CRC Brno, CZ
Tilburg, NL (Compact Reinforced Composite) application in civil T. Kowald, R. Trettin Influence of surface-modified Carbon Nanotubes on
infrastructure Siegen, D
We would like to invite you with sparkling wine and light Ultra-High Performance Concrete
U. Maeder, I. Lallemant- Ceracem, a new high performance concrete:
refreshments on September, 12th 2004 at 06.00 p.m. It takes place
Gamboa, J. Chaignon, characterizations and applications
in our "Gießhaus" at the University of Kassel. The registration for Session B3 Fillers and Aggregates
J.-P. Lombard
the Symposium will start at 04.00 p.m. 14.00 - 15.30
Zürich, CH
Chairman: Prof. K. van Breugel, Delft, NL
A. Möller Ultra High Performance grouts for offshore
Aalborg, DK J. Ma, M. Orgass, N. V. Comparative Investigations on Ultra-High Performance
constructions
Tue, F. Dehn, D. Schmidt Concrete with and without Coarse Aggregates
E. Fehling, K. Bunje, Hybrid Bridge Construction with UHPC in Kassel:
M. Schmidt, W. Schreiber Leipzig, D
Design and Construction
Kassel, D P. Rougeau B. Borys Ultra High Performance Concrete with ultrafine
Epernon, F particles other than silica fume
Session A3 Regulations and Recommendations H.-W. Röth Production of Calcium Carbonate based fine fillers for
Köln, D UHPC
16.30 - 17.45
Chairman: Prof. M. Curbach, Dresden, D P. Haleerattanawattana, Strength-based gradation of coarse aggregate for ultra-
E. Limsuwan high-strength concrete
J. Resplendino First French recommendations for Ultra-High-
Bangkok, TH
Lyon, F Performance Concretes and examples of application
C. Geisenhanslüke, Investigations on UHPC with fly ash and quartz fines
M. Schmidt, U. Wiens State of the Art Report on UHPC materials and design M. Schmidt, E. Schneider
Kassel, Berlin, D of the German Committee for Structural Concrete Kassel, Baden-Baden, D
(DAfStb)
4 5 6
Technical Program Technical Program Technical Program
Tuesday, September 14 Tuesday, September 14 Wednesday, September 15
Session B4 Material Modelling and Prediction Session C3 Design Specific Material Aspects Session D1 Processing and Early Age Behaviour
16.00 - 18.00 14.00 - 15.30 09.00 - 10.30
Chairman: Prof. D. Heinz, München, D Chairman: Prof. H. S. Müller, Karlsruhe, D Chairman: Prof. R. Day, Calgary, CDN
K. van Breugel, Ye Guang Analyses of hydration processes and microstructural E. S. Lappa, C.R. Braam, Static and fatigue bending tests of UHPC J. Schubert, O. Mazanec, Effect of Mixing und Placement Methods on Fresh and
Delft, NL development of UHPC through numerical simulation J. C. Walraven I. Schachinger Hardened Ultra High Strength Concrete
J. Adolphs, A. Schreiber Microstructural Characterisation of Ultra-High Delft, NL Baden-Baden, München,
Hofheim, D Performance Concrete S. Ortlepp, M. Curbach Research into high-strength concrete at high rates of Hannover, D
H. Taghaddos, Prediction of Compressive Strength Behaviour in RPC Dresden, D loading T. Teichmann, Influence of the precasting process on the material
F. Mahmoodzadeh, with applying an Adaptive Network-Based Fuzzy K. Holschemacher, Ultra High Strength Concrete under Concentrated U. Goldbach properties of fibre reinforced UHPC
A. Pourmoghaddam, Interface System Kassel, D
F. Dehn, S. Klotz, Loading
M. Shekarchizadeh S. Staquet, Early-age autogenous shrinkage development of UHPC
Tehran, IR D. Weiße
Leipzig, D B. Espion incorporating very fine fly ash or metakaolin in
K. Droll Influence of Additions of Ultra High Performance
T. Stiel Effect of the Casting Direction on the Mechanical Brussels, B replacement of silica fume
Wiesbaden, D Concretes – Grain Size Optimization
Cardiff, Kassel, UK, D Properties of CARDIFRC H. Ito, I. Maruyama, Expansive behaviour of high-strength expansive
U. Stark; A. Müller Particle Size and Shape – an important factor for
R. Sato concrete and its induced stress
Weimar, D Packing Density L. Kraft, Deformation Characteristics in various Calcium
L. Hermansson Aluminate Cement Admixtures investigated using Hiroshima, J
C. Geisenhanslüke, Modelling and Calculation of High Density Packing of
M. Schmidt Cement and Fillers in UHPC Uppsala, S three different Methods B. Piscaer Cross Fertilisations from the Refractory Industry
Kassel, D Köln, D
T. Teichmann, M. Schmidt Influence of Particle Packing on Structure, Strength Session C4 Design and Construction
Kassel, D Session D2 Fibre Reinforcement
and Durability of UHPC 16.00 - 18.00 11.00 - 12.30
Session C1 Design Specific Material Aspects Chairman: Prof. J. Hegger, Aachen, D Chairman: Dr. F. Dehn, Leipzig, D
09.00 - 10.30 W. Brameshuber, Textile reinforced ultra high performance concrete L. Lohaus, Effects of polymer- and fibre modifications on the
Chairman: Prof. A. Muttoni, Lausanne, CH T. Brockmann, S. Anders ductility, fracture properties and micro-crack
E. Fehling, K. Bunje Design relevant properties of fixed Ultra High B. Banholzer Hannover, D development of ultra-high performance concrete
Kassel, D Performance Concrete Aachen, D Y. Klug, M. Orgass Fibre Reinforced Ultra-High Strength Concretes
N. V. Tue, H. Schneider Bearing Capacity of Short Columns made of UHPC M. Teutsch, J. Grunert Bending design of steel-fibre-strengthened UHPC Leipzig, D
Leipzig, D confined by a Steel Tube Braunschweig, D G. Güvensoy, A. Ilki, Mechanical Behaviour of Ultra High Performance Steel
J. Hegger, D. Tuchlinski Bond Anchorage Behavior and Shear Bearing Capacity J. Jungwirth, A. Muttoni Structural Behavior of Tension Members in UHPC F. Bayramov, Fibre Reinforced Concretes under Cyclic Loading
Aachen, D of Ultra High Performance Concrete Beams Lausanne, CH M. A. Taºdemir Condition
K.-H. Reineck, Tests on ultra-high performance fibre reinforced J. Aronoff; A. Katz; The Behaviour of Very High Strength Reinforced Istanbul, TR
S. Greiner concrete for designing hot-water tanks and UHPFRC- Y. Frostig Concrete Structures with CFRP Reinforcing Bars A. Si-Larbi, E. Ferrier, Flexural behaviour of Ultra High Performance
Stuttgart, D shells Haifa, IL P. Hamelin Concrete reinforced with mixed short fibers and CFRP
K. Holschemacher, Bond of Reinforcement in Ultra High Strength B. Freytag, J. Juhart, The use of UHPC in composites – Ideas and rebars
Lyon, F
D. Weiße, S. Klotz Concrete L. Sparowitz, realisations
Leipzig, D R. Bornemann, S. G. Faber UHPC with steel and non-corroding high strength
E. Baumgartner Kassel, D polymer fibres under static and cyclic loading
Session C2 Design Specific Material Aspects Graz, Spittal, A
11.00 - 12.30 Session D3 Durability
Chairman: Prof. N. V. Tue, Leipzig, D 14.00 - 15.30
K. Habel, E. Denarié, E. Structural response of hybrid “UHPFRC-concrete Chairman: Prof. W. Brameshuber, Aachen, D
Brühwiler, Lausanne, CH members under bending G. Herold, H. S. Müller Investigation on the Durability of Ultra High Strength
K. Bunje, Loading Capacity and Behaviour of Ultra High Karlsruhe, D Concrete
E. Fehling Performance Concrete Structural Elements subject to L. Ay Curing tests on ultra high strength plain and steel
Kassel, D Shear and Punching Loads Stockholm, S fibrous cement based composites
J. Brauns, K. Rocens Stress state optimization in steel-concrete composite D. Heinz, F. Dehn, Fire Resistance of Ultra High Performance Concrete
Riga, LV elements L. Urbonas (UHPC) – Testing of Laboratory Samples and Columns
J. Hegger, S. Rauscher, Push-Out Tests on Headed Studs embedded in UHPC Munich, D under Load
C. Goralski, Aachen, D D. Heinz, H.-M. Ludwig Heat Treatment and the Risk of DEF Delayed
T. Leutbecher, E. Fehling Structural Behaviour of UHPC under Tensile Stress Munich, D Ettringite Formation in UHPC
Kassel, D and Biaxial Loading F. Dehn Temperature Behaviour of Ultra High-Performance
Laboratory of materials and constructions,
Leipzig, D Concrete (UHPC) - A Micro Analytical Reflect
7 8 9
Technical Program Social Program Hotel Accommodation
Wednesday, September 15 Accompanying Persons Program
Session E1 Applications Social Program Hotel Accommodation

09.00 - 10.30
Chairman: Prof. J. C. Walraven, Delft, NL
" Welcome reception (September 12, 2004) The participants can book rooms at preferential rates in several
" Conference dinner (September 13, 2004)
B. Middleton, R. Day, Durability and Mechanical Properties of High
L. Cowe Falls Performance Concrete for Ultra-Thin Whitetopping hotels located in Kassel. To get a complete hotel list please visit our
" Cultural event (September 14, 2004)

Calgary, CDN Pavements symposium’s website (www.uni-kassel.de/uhpc2004).
J. Kaufmann Development of special mortars for an application in
" Guided city tours

Varta Hotel Guide Room rate per night Location of
Dübendorf, CH centrifugal casting process Hotels
Category single/double Hotel
" Fulda boat trip

C. Vogt, B. Lagerblad, Optimization of UHPC for selective stabilization of
La Strada *** 78 € / 90 € (w.b.) 1
T. Hugo-Persson deep boreholes
Courtyard by Marriot ** 49 € / 49 € (w.b.) 2
Stockholm, S Schlosshotel
X. Pu, C. Wan, Y. Wang, Kilometer Compressible Material and Its Preparation ** 48 € / 66 € (w.b.) 3
Wilhelmshöhe
H. Pu, C. Wang Accompanying persons program Gude ** 79 € / 104 € (i.b.) 4
Chongqing, China Astoria * 51 € / 71 € (i.b.) 5
P. Racky Cost-effectiveness and sustainability of UHPC Moevenpick *** 82 € / 112 € (o.b.) 8
Accompanying persons are invited to the opening and closing
Kassel, D Kurfuerst Wilhelm I. * 60 € / 87 € (i.b.) 11
sessions of the Symposium, the Welcome reception on Sunday
Stadthotel Kassel 57 € / 77 € (i.b.) 6
evening, the Dinner on Monday evening and a cultural event on Chassalla * 52 € / 72 € (i.b.) 7
Session E2 Applications
Tuesday evening. 69 € / 87 € (i.b.)
11.00 - 12.30
Chairman: Prof. F.-J. Ulm, Cambridge, USA
Also, various sightseeing tours will be organized in and around standard
Mercure Hessenland ** 9
E. Fehling, M. Schmidt, Ultra High Performance Composite Bridge above the Kassel. 77 € / 97 € (i.b.)
N. V. Tue, K. Bunje, Fulda in Kassel – Accompanying Investigations as comfort
Basis for the required Agreement of the Authorities – Sunday, Monday, Tuesday, Wednesday, Schweizer Hof * 62 € / 79 € (i.b.) 10
T. Teichmann
Sep. 12 Sep. 13 Sep. 14 Sep. 15 Deutscher Hof 49 € / 67 € (i.b.) 11
Kassel, D
(w.b. = breakfast not included)
S. S. Gaharwar, S. Kumar, A Visionary Approach for the Health Monitoring of 9:00 Opening
(i.b. = breakfast included)
R. Kumar, M.V.B. Rao Ultra High Performance Concrete Bridges in Indian Ceremony and
New Delhi, IND Conditions Welcome The locations of the hotels offering special rates are shown on the
N. V. Tue, H. Schneider, Application of UHPC Tubes as Building Members Morning enclosed citymap. The University and location of Symposium is
G. Schenk Sightseeing Hillside Park marked with a red dot.
Leipzig, D Tour in Kassel Wilhelmshöhe
A. Lichtenfels Ultra-High Performance Fibre Reinforced Concrete for (Museum Castle
Keltern, D shells Wilhelmshöhe;
G. Zimmermann, Membrane Concrete Grid Shells Sightseeing in
T. Teichmann, Museum Tour Boat trip on the Park with
Welcome
M. Grohmann Afternoon (Neue Galerie, the Fulda river famous
Reception
Kassel, D Orangerie) (incl. Coffee) fountain; Coffee
break) 12
16.00 - 17.15 Closing Ceremony 3 8
10 5 6
J. C. Walraven Designing with ultra high strength concrete: basics, 11
potential and perspective 7
Delft, NL Post-Conference Tours (September 16 - 19) 2 9
M. Schmidt, E. Fehling Visions in UHPC Post-Conference Tours to Heidelberg or Berlin can be booked by
Kassel, D Will the tower of Babylon come true?
filling-in the enclosed registration form. To get more informations
Closing Ceremony please visit our symposium’s website
(www.uni-kassel.de/uhpc2004).
4 1
10 11 12
Registration Informations Kassel and its University
Registration Commercial exhibition The city of Kassel

A commercial exhibition for products, services and projects is
organized during the Symposium. There are stands of variable sizes
Participation to the Symposium and the excursions available. Companies and organizations interested in participating
organized for accompanying persons may be registered by may contact the Symposium’s Secretary for reservation before
filling-in the enclosed Symposium Registration Form, August 1, 2004.
according to the instructions therein, and sending it by fax
or mail with payment, directly to the conference office. Language
The Symposium’s language is English.
before after
August 1, 2004 August 1, 2004 To get to Kassel Kassel is situated in the very heart of Germany. It is offering fast and
€ 380,- € 410,- By plane: easy access by the ICE-train or motorway. Visitors who appreciate
Delegate
! to Frankfurt or Hannover Airport nature, love the arts and want to relive history will get their money's
Lecturer € 280,- € 280,- (from there about 1.5 hrs by train) worth in this town, with its host of internationally famous art
By train: treasures, historic monuments, and cultural and educational
Accompanying person € 130,- € 150,- ICE-train station Kassel-Wilhelmshoehe institutions. Kassel is the town of the famous Documenta exhibition
Cancellations: before August 31: 75% refund; after August 31: no refund Hourly trains from: of modern art.
! Hannover (airport)
These fees include, for delegates and lecturers: ! Berlin Kassel is an ideal venue for conferences and congresses - its central
! Frankfurt (airport) location, the excellent facilities, the efficiency of its hotels and its
! Attendance to Opening and Closing Ceremonies ! Munich fringe amenities such as Wilhelmshöhe, the biggest hillside park in
! Attendance to the Symposium Technical Sessions From ICE station to the venue: Europe formed in the 17th century, and the Kurhessen Thermal
! Two coffee-breaks per day ! Tram line 1 or 2 Stop Holländischer Platz/Universität Baths, the Casino and the Palace. Add to these the museums, State
(September 13-15) By car: Theatre, pedestrian precincts and shopping malls.
! Welcome reception on Sunday, September 12 ! Autobahn A7 - Exit Kassel-Nord
! Conference Dinner on Monday, September 13 ! follow Dresdener Strasse to Zentrum/town centre
! Cultural event on Tuesday, September 14 ! At Crossing Dresdener Strasse - Ysenburgstrasse turn right
! One copy of the Symposium Proceedings ! Behind Fulda river bridge turn left
! Behind Buildings of University turn right twice towards
parking spaces
The campus of the
P
Location of
The “Herkules” and the Symposium
“Lions Castle” -
The town’s landmarks More informations:
of Kassel in the biggest Tram 1 or 2 www.kassel-tourist.info
hillside park of Europe Stop
Hollaendischer Platz
www.kassel.de
www.uni-kassel.de
13 14 15
The forthcoming UHPC bridge in Kassel
The Symposium is supported and co-sponsored by:
fédération internationale du béton (fib)

American Concrete Institute (aci)
Deutscher Beton- und Bautechnik-Verein e.V. (dbv)
Deutscher Ausschuss für Stahlbeton im DIN (DAfStb)
Department of Structural Materials, FB14
Mr. Carsten Geisenhanslüke
Mönchebergstrasse 7
34125 Kassel
Germany
Tel:+49 561 804 2601

Fax:+49 561 804 2662
Email:ghlueke@uni-kassel.de
Web: www.uni-kassel.de/uhpc2004
Ultra High Performance Concrete: Developments and
Applications during 25 years
Summary
During the last 25 years exciting new developments have been taking place in the develop-
ments of cementitious materials. The compressive strength rose from circa 60 MPa to more
than 300 MPa. This is made possible by techniques for the densification of the microstructure of
the fresh cement paste with the use of efficient surface active agents (super plasticizers) and
ultra fine reactive particles. Two systems were developed in the seventies: Macro Defect Free
concrete (MDF) and the Densified Systems containing homogeneously arranged, ultra-fine Par-
ticles (DSP). In my paper I will discuss the last system including new developments and the
applications of these materials.
Keywords: HPC, UHPC, DSP, CRC, HRUHPC, wear protection, concrete repair, offshore,
industrial floors.
1 Introduction
In this paper, based on the Danish experiences and my personal experiences during 19 years
with UHPC in two Dutch companies and in two Danish companies, I will explain the develop-
ment and applications of the High Performance Concrete (HPC), Ultra High Performance Con-
crete (UHPC) and Heavy Reinforced High Performance Concrete and Heavy Reinforced Ultra
High Performance Concrete (HRHPC and HRUHPC).
A normal hardened Portland cement paste is a heterogeneous and porous material in which the
porosity to some extent reflects the original spaces between the cement particles within the
chemical structure. This is primarily because the surface forces between the cement-particles
tend to prevent these from sliding in relation to each other during mixing and casting, and the
finer the cement particles; the greater is the effect of the surface forces. Because of this a rela-
tively high amount of mixing water is necessary to get a certain workability with the mortar or
concrete. The overall porosity of 25-30% in volume compromises two pore families: gel pores
and capillary pores. Compared to materials like steel or sintered alumina, a Portland cement
paste develops low mechanical strength during its harding. The weakness of these mechanical
performances has been mostly related to the capillary porosity and the excess of water needed
for the workability of the fresh cement paste. Already 2000 years ago Lucretius made this ob-
servation:’ The more vacuum a thing contains within it, the more readily it yields.......’. Féret,
who developed the empirical relationship between strength and volumes of cement, water and
air, first applied this principle to concrete in 1892. Many other strength vs. porosity relationships
has been made since work reasonably well for “ordinary” cementitious materials over the nar-
Plenary Session International Symposium on UHPC September 13 - 15, 2004, Kassel, Germany. Peter Buitelaar
row range of porosities, or water/cement ratios, that are found in convential concrete practice,
since there is no doubt that the total porosity is the most important single determinant of
strength. Because they involve only the total porosity, these relationships must represent a con-
siderable simplification of the system; the pore size distribution, the pore shape whether the
pores are empty or filled with a fluid and the nature of the solid material itself must also be im-
portant, particularly when dealing with materials outside of the range of normal concretes and
mortars.
2 The development of HPC and UHPC

The role of Hans Henrik Bache, researcher during his whole professional career, as a pioneer in
the development of HPC, UHPC and HRUHPC is of great importance for the concrete history in
the future and finally starts to be recognized by others. Professor Pierre-Claude Aïtcin wrote in
his highly recommended book High Performance Concrete the following observations: “The first
interesting results obtained by the Scandinavians in usual concrete, the very impressive discov-
eries of Bache and co-workers in Denmark and a significant research effort in the early 1980s in
several other countries, resulted in the rapid acceptance of silica fume as a supplementary ce-
mentitious material for concrete almost everywhere in the world in less than 5 years.” and “In
fact, Bache’s work showed that the ultimate compressive strength of concrete depends not only
on the quality, quantity and efficiency of the cementitious materials used, but also on the degree
of compaction and ultimate porosity of the solid matrix formed after the hardening process is
completed. About 100 years after first being proposed (Féret, 1892), the w/b law concerning
compressive strength can be said to have been extended!”
Photo 1: Professor Emeritus Hans Henrik Bache (left) and Knud Lund Eriksen.
2.1 The development of HPC in the sixties and seventies
Around 1964 the first research started in the Concrete and Research Laboratory in Denmark to
investigate the possibilities to produce a soft cast concrete with a higher compressive strength.
The strongest concrete made had an fc of about 60 – 80 MPa with a w/c ratio of 0.30. Three
important questions raised during research had to be answered:
1. Is it possible to reach a much denser packing in cement paste than corresponding to a

w/c ratio of 0.30?
2. Will this, when possible, result in a much higher strength?
3. Could a much higher strength than be utilized in concrete?
Treval C. Powers from the Portland Cement Association reports about strengths of about 280
MPa in small specimens of heavily compacted cement paste, indicating possibilities to achieve
much denser packing of cement, and through this, higher strengths. The comparisons with other
fine particles showed that cement particles are less dense packed than other fine particles with
approximately the same particulate shape and size distribution. From purely geometrical con-
siderations it should thus be possible to pack cement particles much denser, corresponding to a
w/c ratio of 0.20 instead of a w/c ratio of 0.30. Vibratory compaction at light pressure was used
to make small samples since this is a much better method for compacting without a risk to crush
the aggregates like in high pressure compaction. The results of the tests demonstrated Powers
conclusions but didn’t lead directly to a stronger concrete. But it gave new indications that a
much denser packing of cement particles was possible.
Figure 1: Relationship between compres-

500 MPa
sive strength and porosity for vibrated and
under pressure compacted hardened ce-
ment paste (Bache 1970).
100 MPa
The experiments resulting in cement
paste strength of up to 350 MPa, thus 5 –
50 MPa cement 10 times higher than the strength of ce-
paste ment paste in normal concrete.
0.3 0.4 0.5 0.6 0.7

Relationship between compressive strength and porosity
In the period 1967 – 1972 more investigation was made in the combined action of pressure and
vibration to compact concrete. It was with this process possible to improve the concrete quali-
ties and also to produce low cement/ high amount of aggregates mixes with an fc of 100 – 130.
Based on the classic theory (Griffith, 1921) for the tensile strength of brittle materials Bache
made his model of strength for brittle materials built up of particles joined at points of contact.
Griffith’s theory still provides us with a lot of information, it is not only giving a qualitative expla-
nation of the importance of the porosity to the strength but it also tells us that the strength will
increase if pores and/or the crack size is reduced, and that the strength will also increase if the
pores and cracks are filled with material that can “reinforce” the pores and/or cracks, even while
the material itself is not particularly strong.
In sintered ceramic there is a dependence on the particle size but the use of extra fine grinded
cement particles did only resulted in a fast strength development but not in a stronger matrix.
This was of course because at that time it was not possible to disperse ultra fine cement parti-
cles in an aqueous suspension to get a dense packing of the fine particles due too the very high
attractive surface forces.
Around 1970 Stephen A. Brunauer from the Portland Cement Association developed a special
cement containing surface active substances added during the grinding process which elimi-
nated the attractive surface forces in cement/ water mixes. Research with the “Brunauer” ce-
ment started in Denmark in 1971 and large concrete objects were made. Brunauer was never
able to produce a concrete and visit the research lab in Denmark interested in the Danish ex-
periences. Bache suggested using the same quantity by volume of cement paste instead of the
same quantity by weight as Brunauer, which requires 50% more cement and was thus able to
produce concrete.
In the same period synthetic surface active agents, the so called superplasticizers, were devel-
oped. In Japan concrete structures were build with a fc 90 MPa in the middle of the seventies.
Hattori made soft cast concrete in the laboratory with a w/c ratio of 0,25 and a fc up to 120 MPa.
2.2 The development of the DSP system in the seventies

Due too the development of the superplasticizers it became finally possible to disperse ultra-fine
– and normal cement particles much better in an aqueous solutions and thus permitting a dense
packing between the cement particles. Bache starts to make special graded cement blends with
30% ultra fine cement to establish a very dense particle packing. After contact with a Norwegian
colleague during a seminar in Stockholm he became familiar with micro-silica, a by-product from
the silicon- and ferrosilicon industry. For several reasons this ultra fine powder would be much
better than ultra-fine ground cement:
• The micro-silica particles are much finer than the finest cement grains.
• The micro-silica particles are amorphous; this makes them very suitable for dense pack-
ing between the angular and sharp cement particles.
• The micro-silica is less reactive in the first hours than very fine cement particles.
Micro-silica in concrete has been studied and used in civil engineering since the early 1950.
Micro-silica consists of ultra fine (less than 1 micron), superpozzolanic, and amorphous silica
particles. The superpozzolanic reactivity converts a part, depending on the amount of micro-
silica; of the less useful calcium hydroxide crystals into the useful calcium silicate hydrate
binder. The abundance of the ultra fine particles places some 100.000 micro-silica particles
around each cement particle in a typical mixture.
Cement
particles
Fine aggregates Micro-silica
Photo 2: Micro-silica particles. Figure 2: Dense packing of the mortar.
At 8 May 1978 the first specimens with concrete and micro silica were made, the next day the
heat cured cylinders showed a very promising mechanical strength of fc 128 MPa. The D.S.P.
paste incorporates:
• A certain amount of special cement.

• A large dose of micro-silica.
• An effective superplasticizers provided in a dosage large enough to insure
physiochemical deflocculating of the cement- and micro-silica particles as well.
• An effective mixing to produce a completely consolidated paste with a minimum content
of water.
By making a very dense packing of the cement particles and filling the spaces between with the
much finer micro-silica particles there is only a little space to fill with water. During mixing the
water will surround each particle in a thin layer and works like lubrication. The w/b ratio is 0,18 -
0,25. This results in an ultra strong – and very dense binder with a very low porosity. By com-
bining the binder phase with fine and coarse aggregates it is possible to produce different mate-
rials like f.i. grouts, mortars and concrete.
Later research was focussed on modifying the aggregates since the strength of the hardened
binder was much more than the strength of normal aggregates in contradiction to normal con-
crete practice. Some increase was achieved with hard granite and basalt but a real increase of
the strength was obtained with the use of calcinated bauxite, up to more than fc 280 MPa.
Bache presents his very impressive discoveries on the second international conference on
superplasticizers in concrete in 1981 and shocked the concrete community which still had trou-
ble to produce a 25 tot 30 MPa concrete in the field.
A Cement paste. B Superplasticized cement C DSP binder paste.

paste.
Figure 3: The structure of cementpaste in fresh concrete based on: A Portland cement; B Portland
cement with a superplasticizer and C Portland cement with a superplasticizer and well dispersed micro
silica.
Different companies and joint ventures were founded in that period. First companies were Aal-
borg Portland and Elkem. Licensees were sold to specialized companies for different special
applications like tools and moulds. The key strategy is to find industrial applications for the new
developed materials.
Especially in the period until 1990 large research is made to investigate: Durability, density,
wear resistance, chemical resistance, storage of nuclear waste, chloride permeability, corrosion
protection, etc.
In the period 1982 – 1986 intensive research was started to find solutions for the high autoge-
neous shrinkage and the brittleness of the DSP materials. Due to the good coordination be-
tween research and sales, new applications were found and a range of products was
developed. Mixes were optimized with high percentages of aggregates with an optimum particle
size.
2.3 The development of the Compact Reinforced Composite (CRC)

Already in 1986 research was made in the Netherlands by the author and co-workers to investi-
gate multi fibre mixes in combination with DSP concrete to develop less brittle structures.
Soon after the development of the DSP materials many questions rose if the strong materials
could be used efficient in load carrying structures. This because of the fact that the very strong
matrix was also very brittle. Based on fracture mechanics a large body or structure will be much
more brittle than small bodies or structures made of the same material.
Photo 3: From an extreme brittle binder. Photo 4: To an extreme ductile composite.
The use of a high concentration of strong aggregates will increase both the strength and the
fracture energy. The addition of small steel fibre reinforcement will result in even greater im-
provements but both modifications didn’t avoid that cracks were forming at very low tensile
strains (approx. 0.2 mm/m).
Due to the possibility to give the matrices high viscosity, what gave the possibility to add high
amounts of fibres compared to conventional concrete, a certain ductile behaviour could be ob-
tained. This, with the fact that the fixation on the fibres was extremely well, led to the idea to
exploit this much better.
This resulted in the development of the Compact Reinforced Composite (CRC) in 1986 by Hans
Henrik Bache. CRC is a very strong and stiff composite material with exceptionally high ductility.
CRC is build up of strong, densely arranged main reinforcement in a strong, rigid and ductile
matrix of UHPC. The 4 basic principles of CRC are:
1. To enable brittle matrix materials (UHPC) to strain under tensile loading. This is
achieved by making a matrix material with a high modulus of elasticity and high fracture
energy and reinforcing that matrix with a high volume of fine, strong and stiff fibres.
2. To increase still further the ultimate tensile strain of the matrix material when this de-
forms together with the main reinforcement. This is secured by effective fixation of the fi-
bre reinforced UHPC to the main reinforcement. The reinforcement will acts as a stiff
frame en thus ensures the formation of a multiple crack zone system with very large ten-
sile strain capacity.
3. To ensure a high degree of local and global ductility by means that ensure a small brit-
tleness numbers: the UHPC is given very high ductility with the use of fibers and a high
volume of strong aggregates.
4. To enable a very dense and homogeneous particle and fibre packing at micro and
macro level during casting by effective use of geometrical and kinematical principles.
The UHPC must thus have a substantially viscous behaviour during the whole process
(mixing, casting and compaction), even with very dense main reinforcement, assisted by
well designed mechanical vibration.
CRC consists of the following materials:

• UHPC with aggregates a diameter up to 1/3 of the space between the main reinforce-
ment rebars and a w/binder ratio 0,13 – 0,18.
• 5 – 20% Main reinforcement (high strength steel, traditional rebars, carbon, etc.).
• 5 – 10% steelfibers.
CRC has the following properties:
• Compressive strength 150 – 400 MPa

• Strength in bending 100 – 350 MPa
• Strength in shear 15 – 150 MPa
CRC is in fact reinforced concrete, but deviates fundamentally from it in several ways, which is
reflected in a load capacity more like that of structural steel. The design principles, the composi-
tion and production are different than from traditional reinforced concrete.
2.4 The development of new DSP systems

In 1993 Contec ApS was founded to be able to solve various problems with the original DSP
concrete and to develop new materials like selfleveling fast setting and shrinkage compensated
mortars and a large range of products between HPC and UHPC. Contec ApS also developed
the heavy reinforced HPC and UHPC for different applications like industrial floors and ultra thin
white toppings.
Photo 5: HRUHPC. Photo 6: selfleveling fast setting and shrinkage
compensated UHPC.
In the period 1992 – 1994 there was a close cooperation between the large French contractor
Bouygues and Aalborg Portland to develop commercial applications for the Compact Reinforced
Composite.
In 1994 Bouygues (Richard and Cheyrezy) developed in cooperation with other industrial part-
ners like Lafarge a new DSP concrete, named Reactive Powder Concrete, with down scaled
particles size and multi fiber reinforcement. With the use of very fine aggregates and fillers a
very dense packing is made possible by eliminating a part of the wall effect of the particles as
earlier suggested by Bache in the nineteen eighties. RPC showed very high compressive and
bending tensile strength with high amounts of steelfibers and a combined heat – and pressure
treatment, to remove air and the excess of mixing water and to get chemical reactions to
change the material properties, but this will not always be possible for large constructions.
Figure 4: Pedestrian bridge in Sherbrooke. Figure 5: UHPC beams in Cattenom.
In 1996 Quillery developed their DSP concrete named BSI (Special Industrial Concrete).
At this moment the two leading French companies in the production of UHPC: Bouygues (was
RPC is now Ductal) and Quillery (was BSI is now Ceracem) including new industrial partners
are reformulating their original developments and are concentrated on self compacting multifibre
mixes. The products are mainly used for prefab applications like beams, panels and bridges and
architectural applications like façades panels, bus shelters, street furniture and flower pots.
Besides the well known suppliers of UHPC, many new players are expecting to enter the UHPC
market in the next 10 year, especially when specialized applications are developed in the next
years. Due too the involvement of several specialized companies in the nearly future it will be
more and more difficult to get patent rights on material compositions, it will than thus be more
necessary to get patent rights on applications in combination with a material composition.
3 Applications of UHPC
After the development of the UHPC it was necessary to find applications where will be full bene-
fit of the properties. The success of a specialized small material supplier is depending on inno-
vative employees with a very good commercial, technical and theoretical know-how including a
high dosage of persistence since practical failures and damages are also a part of the develop-
ment and learning process. The different applications for the HPC, UHPC and HRUHPC which I
present are based on the Danish experience in general and the authors experience during the
last 19 years.
3.1 Wear protection

Because of the connection Aalborg Portland had with the FLS Group, who is designing, building
and supplying cement factories worldwide and there own cement plant in Aalborg Denmark, the
first applications of UHPC were protection against wear of their different installations and trans-
port systems. UHPC is used for more than 25 years as wear protection in hydraulic- and pneu-
matic transport and storage systems of abrasive materials like coal, fly ash, cement, steel, silica
sand and chemicals.
Photo 7: Replaceable part of scoop feeder. Photo 8: Parts mounted together.
The scoop feeder (design Knud Lund Eriksen, 1981) for a cement mill (photo’s 7 and 8) is usu-
ally made of cast steel and has a total service life of max. 6 months due too the heavy wear.
The six replaceable sections are made of reinforced UHPC with about 10% V/V main rein-
forcement and steel fibers to give ductility, in fact already a CRC structure, and had an Fc 250
MPa. The service life of 15 – 20 year is a large extension compared to the original scoop
feeder.
The UHPC has the following advantages in wear protection:
• Application: casting, shotcrete, handpatch.

• Wear resistance: equal to that of melted basalt, special steel and high tech ceramic
materials.
• Wear resistance can be designed.
• To cast in-situ and jointless or prefab.
• Impact resistance: high – very high, especially compared to wear resistance tiles.
• Temperature range: - 50°C till +1250 °C (special binder and aggregates).
3.2 Concrete repair

One of the first large applications was the rehabilitation of the Kinzua Dam Stilling Basin in Oc-
tober and November 1983. This basin had, despite earlier repairs in 1973 – 1974, due to cavita-
tion erosion, holes until 1.10 m dept in the 1.50 thick concrete slab. The specified unreinforced
1.540 m3 DSP concrete with a thickness of 30 cm and with an fc of 90 MPa was placed in sec-
tions.
Photo 9: Damaged stilling basin. Photo 10: Kinzua dam.
Despite several problems, most of them related to the lack of sufficient knowledge with HPC,
like cracks, autogenous shrinkage, applicability and workability the overlay is working according
the expectations. With the present knowledge it would be better to place a reinforced HPC con-
crete as levelling layer with a high wear resistant topping from 5 cm UHPC.
In Venezuela various tests are made to repair large damages in the Raúl Leoni Dam (“Guri”).
Very large damage due too cavitation erosion occurred in the inlet/ outlet, the toe and the spill-
ways. Repairs in the outlet with small bended high strength steel plates (accessibility is only
possible through a manhole) fixed with drilled in anchors and welded together didn’t function.
Photo 11: The Raúl Leoni Dam (“Guri”). Photo 12: Equipment ASTM C 1138-97 test.
The ASTM C 1138-97 test, developed by U. S. Army Engineer Waterways Experiment Station
(WES), Vicksburg, MS. to simulate extreme cavitation erosion like in hydraulic structures,
showed large abrasion-erosion from the grinding balls but no wear of the UHPC.
In the Netherlands various repairs are made with UHPC since 1988 and 1989 in locks and
sluices with abrasion-erosion. The damage were large holes with a depth until 30 cm till the lean
concrete and a wear over the whole surface a wear of 7 – 10 cm.
Photo 13: Complex Sambeek. Photo 14: Repair with UHPC underwater.
The emergency repairs underwater were done by divers, they simply casted the premixed
UHPC which was let down by hand in a bucket, in the large holes. The large repair on the floor
in the basin was done with only a minimum of leak water. After high pressure cleaning, the plac-
ing of reinforcement anchored to the sub concrete and a filling out layer of underwater concrete
C 25 a topping of 25 mm UHPC was placed with a double vibration screed on guiding rails. Until
the last inspections in 2003 no wear to measure but new wear occurs at the unprotected con-
crete.
Photo 15: Reinforcement for the levelling concrete. Photo 16: Placing 25 mm UHPC topping.
In the Netherlands a solution was made for the repair of several foundation piles of a small
bridge in the Zaan river in 1990 and this solution was demonstrated to different consultants and
engineers by the author by placing a large concrete pile in a transparent plastic form filled with
water. The protective layer of the pile was cast with UHPC what was simply filled in from above
through the water. In the actual repair job a concrete pump was used to fill the formwork with
UHPC.
Due too the very positive experience of the consultant, the same repair system with UHPC was
tested further and finally described in the tender for the repair of the jetty of Venterminales in
Venezuela. The 254 hollow pre-stressed foundation piles, with a diameter of 50 cm and a wall
thickness of 10 cm, were seriously damaged in the splash-down zone (4 m under- and 2 m
above the water level) by chloride initiated corrosion. A fast repair was thus necessary to extend
the service life of the jetty.
Photo 17: Damage at the piles. Photo 18: Jetty with scaffolding.
The repairs method was as follow:
• Removal of not sound concrete, cleaning and sandblasting under and above water.
• If necessary placing new or extra reinforcement.
• Placing and connecting moulds with diameter of 56 cm.
• Pumping UHPC reinforced with steelfibers in the mould from the bottom of the mould.
• Demoulding after 36 hours.
Photo 19, 20, 21 and 22: Placing moulds, casting with pump and repaired piles.
After 13 years no damage visible and no chloride penetration to measure, while similar repairs
with cement based products in Venezuela with concrete showed damage again after 2 - 5
years.
Photo 23: Shotcreting UHPC. Photo 24: UHPC Shotcrete with dense
reinforcement
Shotcreting with UHPC is done for repairs of deteriorated concrete in very thin covers, for wear
protection and for re-strengthening of structures according the HRUHPC principles. The advan-
tages are:
• Constant high quality of the UHPC.
• Less demand on skills nozzle man.
• Minimum rebound and dust.
• Can be sprayed in very dense reinforcement.
• Fast strength development.
• Can be finished with a smooth surface.
• Both wet and dry methods are possible.
3.3 Offshore
The first jobs for the hydro carbon industry were based on the very positive experience with the
rehabilitation of the jetty from Venterminales in Pto. Cabello, Edo. Carabobo in Venezuela and
were done in a similar way as that job to place a UHPC lining around the piles. After the first
rehabilitation of foundation piles in both steel- and concrete of oil production platforms for the
PDVSA (Petróleos de Venezuela,S.A.) in the lake of Maracaibo in Venezuela in 1992 and 1993
for corrosion protection and rehabilitation, UHPC is used to upgrade the platforms of the Ekofisk
field, a solution developed by Norwegian consultants in co-operation with the owners of the plat-
forms, in the North sea in 1995 and to rehabilitate various other platforms later. The use of
grouts for the filling of members of offshore platforms is not a new application since it is done for
more than 30 years but the properties of the UHPC are resulting in a much higher bearing ca-
pacity and an extreme good corrosion protection.
A lining around piles or members and/or the filling of them is necessary in existing structures
due to subsidence of the seabed, unforeseen topside load, increased wave load or weakening
of the structure by corrosion, fatigue or accidents. The UHPC is to use for:
• Strengthening individual intact members by local- or complete filling.

• Placing additional members which will be filled to restrength selected areas.
• Increasing the load bearing capacity: filling up to 4 times and with special CRC solutions
much more.
• Filling under dimensioned and/or damaged members for additional strength.
• Solving fatigue problems in local area’s with CRC solutions.
Also for new constructions UHPC and HRUHPC can be used for strengthening and by that the
constructions can be made much more slender and thus reducing wave loads, the dead load of
the platform and the steel dimensions. With special CRC solutions it is possible to reinforce fa-
tigue sensitive areas and to replace steel in corrosive sensitive area’s like in the splash-down
zone and the deck structure.
Due to the positive effect on the environment and the savings on traditional fuels for power
plants there is a great interest in offshore windmill parks. Due to the extreme wave – and wind
loads an extreme good fixation in the sea bed is important.
UHPC for offshore windmills:
Foundations: the UHPC is grouted in the bed-

rock and the casing to create a maximum fixa-
tion.
Connections: the UHPC is grouted in the con-

nection between the mono-pile and the transi-
tion part.
Advantages:
• Ultra high strength and stiffness.

• Fast strength development.
• Extreme fatigue strength.
• Possible to correct pile intolerance to
ensure a vertical tower.
For the offshore special HRHPC braces cast in-situ can be developed to restrength fatigue criti-
cal areas like jackets and tubular from offshore platforms and offshore windmills. Practical tests
are already made to restrength and to protect platform jackets made from concrete as well as
made from steel. Decks of offshore platforms and supply vessels can be restrength and pro-
tected against corrosion and impact with an HRUHPC overlay bonded to the original deck plate.
Very large offshore windmills with a high fatigue resistance and a large service life can be built
in HRUHPC.
3.4 Security industry

Since the beginning of our history we are trying to protect our valuable belongings against bur-
glary and fire. For more than 20 years structures are designed for high-strength, lightweight se-
curity barriers for use in the manufacturing of classified safes, vaults and ATMs. Security
barriers are tested according standards, made by insurance institutes in cooperation with test
institutes, based on RU values (Resistance Units), each type of barrier needs a minimum of RU
to be accepted to store a certain amount of valuables.
Photo 25: The use of an oxyacetylene torch. Photo 26: Tougher than the rest!
During the tests different specified tools are used to try to create an opening with clearly speci-
fied dimensions in the wall of the specific construction. UHPC and HRUHPC barrier materials
are continuously tested and approved by the leading test institutes in Europe, Africa, Asia and
the USA - classified in medium-end and high-end classes. UHPC security products are used all
around the globe due to the fact that barrier solutions are sold to some of the world’s leading
manufacturers of safes, vaults and ATMs. Small barriers like ATMs and safes are made with a
double steel wall, often in combination with special designed and patented reinforcement and/or
profiles, which is filled with UHPC of different compositions (depending on the necessary RU
required).
Photo 27: Casting of door for vault. Figure 6: A prefab made strong room.
Large vaults and the so called strong rooms are build from prefabricated HRUHPC in combina-
tion with special connection systems. With this prefab system is it possible to create large vaults
and strong rooms in different locations and on different floors in a building.
Since the last years various security products made in UHPC/ HRUHPC, or in combination with
other materials, are also developed for the protection of humans and other valuables against
ballistic and blast impact.
3.5 Prefab structures

The use of HRUHPC makes it possible to construct gigantic but non brittle structures, extremely
slender, elegant and sometimes daringly designed. The new concept with a new philosophy and
new principles for structural design as recent developed by Bache must be a new challenge for
architects to design structures which are very visual very attractive. Until today however
HRUHPC is mainly used to make prefab structures like balconies, galleries and stairs thus the
properties of the HRUHPC are still, unfortunately, not used in the most significant way.
As Professor Man-Chung Tang from T.Y. Lin International said several times during his presen-
tation: we have to think "out of the Box". He also wrote in his proceeding: "Let us be more inno-
vative! It appears to be a good idea to think of UHPC not as concrete as we know it now. We
should try to develop new structural concepts that can utilize the strength and superb perform-
ance of this material. With time, this will happen!"
Well, thinking out of the box is already possible and we are now able to use the new concept as
recent developed by Bache which will make it possible to create new giant structures.
Photo 28: Gallery made in HRUHPC. Photo 29: Slender stair made in HRUHPC.
A very good example of the use and the potential possibilities of the HRUHPC principles are the
prefab panels placed on the bascule bridges in the motorway N 44 in the Netherlands. To re-
place the existing wooden bridge decks different alternative solutions were investigated by the
Civil Engineering Division of the Ministry of Transport, Public Works and Water Management in
the Netherlands. A solution with HRUHPC prefab panels was chosen as the best solution con-
cerning costs, maintenance and durability within the maximum weight tolerance of the operating
machinery.
Testing of two small panels in the lab from TNO Building and Construction Research resulted in
amazement by the engineers present: “If you want to see concrete flutter look to this” and
“Amazing how flexible a plate with these dimensions can be, you see the plate clearly bulge
under the load”. This project demonstrates on a small scale what is possible to reach with the
HRUHPC: light, thin and ductile constructions with strength possible as that from structural
steel.
Photo 30: Testing panels in TNO. Photo 31: Placing panels on the bascule bridge.
An example how successful a simple idea can be are the so called prefab in UHPC cast Mush-
rooms, these thin (edge 18 mm, middle 78 mm and ø 1100 mm) Mushrooms are, after cold-
milling a circle out of the asphalt, placed in the asphalt to form a road bump. Ambulances,
fireworkers and busses are able to pass easy while normal cars are lifting their wheels one by
one.
Photo 32: Surface of the Mushroom. Photo 33: Mushrooms placed.
3.6 Industrial floors, - pavements and Ultra Thin White toppings

For more than 20 years HPC, UHPC and HRUHPC are used as toppings in the food-, the food
processing- and the heavy industry. The qualities of the material like very high early- and final
strength, high wear resistance, not sensitive for placing on wet sub base and environment
friendly makes it an excellent flooring product. Making good quality floors is not only depending
on materials, almost each material from well known suppliers is of good quality, but is also de-
pending on a combination of technical know how and good workmanship. Especially in the case
of thin toppings success, or failure, are depending on factors as bonding, workability, placing
conditions, finishing and curing. The preparations have to start with an examination of the exist-
ing sub base. Also the purpose, the loads (mechanical, thermical and chemical), aesthetics and
other relevant aspects of the floor have to be checked with the owners and users of the floor.
Especially in de food processing industry details are very important to avoid damage and con-
tamination of food and/ or installations with bacteria’s. After the examination it is possible to
make a good solution and a choice for a topping system.
Photo 34: UHPC topping in the heavy industry. Photo 35: HPC topping in the food industry.
Various types of HPC and UHPC toppings are developed during these 20 years and a wide
range of products are available. The compressive strength is still the parameter for HPC and
UHPC, the difference between a HPC and an UHPC is thus than most of the time only the qual-
ity/ type of the aggregates.
Photo 36: Placing self levelling UHPC. Photo 37: Powerfloating granolithic UHPC.
One of the first large applications of the HRHPC/ HRUHPC overlay is as a white topping on
damaged pavements and industrial floors and in cargo ships. The unique properties of the
HRHPC/ HRUHPC makes it possible to place the overlay as an “independent” topping (indus-
trial floors) or wearing course (ultra thin white topping) on a cracked and/ or polluted sub base
or even on an under dimensioned sub base made from different materials like asphalt concrete,
concrete, wood, ceramics or steel.
The concrete overlay contains one or more layers of welded mesh reinforcement (bar diameter
6 – 20 mm and bar spacing 15 – 50 mm). The concrete mixture contains both steel fibers and
acrylic fibers and is based on a special composite of pre-blended materials. The HPC/ UHPC
can be mixed at the building site or in a batching plant and can be transported with dumpers or
truck mixers. The flow and workability are such that the material is easy to compact with the use
of a laser screed or a double vibration screed.
A large research project in the Netherlands is executed during the last 6 years to develop a new
revolutionary HPC concrete wearing course on orthotropic steel bridges which is also extending
the service life of the total construction by solving fatigue problems in specific deck details.
Photo 38: Caland bridge in the Netherlands. Photo 39: Placing tent.
After the large test period a Pilot project is executed on the Caland bridge to test the method on
an actual project. The application phases were as follow:
• Removing existing asphalt wearing course and placing tent.
• Inspection deck and repair of cracks.
• Placing profiles with dowels at sides and ends.
• Shot blasting deck plate for good adhesion.
• Applying sprinkled in epoxy interface layer.
Photo 40: Placing the interface layer. Photo 41: Reinforcement principle.
• After hardening of the epoxy unbonded aggregates are removed.

• Placing distance keeper ø8 mm with on top 3 layers ø8 mm spaced at 50 mm.
• A mobile concrete plant was used to mix the HPC.
• A double vibration screed compacted en levelled the HPC.
• After setting the surface was floated and polished to obtain a dense smooth surface.
• Hereafter the surface was protected for 24 hours with wet burlap.
• The surface of the HPC was shotblasted to obtain a high skid resistance.
• The whole Pilot project from the first step until re-use took less than 120 hours!
Photo 42: Casting HPC. Photo 43: In use again.
Fatigue cracks are a large problem for orthotropic steel bridge decks, especially cracks in the
steel deck plate are of great concern due to their effect on traffic safety. Much is learned from
the pilot project and this experience and know-how will be very useful for larger projects which
will be executed in the following years.
Strain measurements on the re-surfaced Caland Bridge show a stress reduction with a factor 4 -
5 in the fatigue critical structural details. This equals the reduction factor measured on the small
test samples in the Adhesion Institute of the Delft University of Technology and the computer
simulations. Further investigations on a part of an orthotropic steel deck plate with fatigue
cracks and a HRHPC overlay show also a significant stress reduction in the trough wall (stiffen-
ers). It could thus be possible to leave certain fatigue cracks un-repaired when the HRHPC
overlay will be placed what will result in a shorter shutdown time and additional savings on re-
pair costs. The pilot project demonstrated that it is also practically possible to place the HRHPC
overlay on an orthotropic steel bridge deck even when traffic, including heavy loaded freight
trains, is allowed to use a part of the bridge deck. Much more detailed specifications can now be
made based on information obtained during the execution and evaluation of the pilot project.
Preparations are started for the restrengthening of large orthotropic steel bridge decks. The
planning is to resurface the Moerdijk Bridge (32,000 m2) and the Hagestein Bridge (7,500 m2) in
the summer of 2005. Other orthotropic steel bridge decks will follow soon after. Fatigue prob-
lems in with orthotropic steel bridge decks are not an unique problem for the Netherlands alone,
several similar problems are known in other countries and therefore a lot of international atten-
tion and interest have been received for the RHPC overlay as a rehabilitation and restrengthen-
ing method.
4 New applications
By combining the HRUHPC with other materials large ceramic/ metal-based hybride structures
can be made that exhibit unique combinations of great strength in all directions; great hardness
and extremely great fracture toughness. This make it not only possible to design and build gi-
gantic structures and extremely slender, elegant and daringly designed structures but also to
make non-brittle ceramics for medical (implants and bone replacements) and industrial applica-
tions (tooling, pumps, engines). In nearly future the use of HRHPC will not be focused only on
applications in civil engineering because the composite is also offering new solutions for other
fields of application. Especially when the HRHPC is used in combination with other materials to
produce new composite materials there are interesting solutions and applications possible.
Figure 7 and 8: Large thin, non brittle, CRC structures designed by Arch. Anja Bache
Other possible and very interesting application of UHPC and HRUHPC is the replacement of the
sliding steel gates in the Eastern Scheldt Storm Surge Barrier in the Netherlands. The 62 sliding
steel gates are composed of a vertical plate construction, a main girder system and a vertical
girder system and have a width of 41,0 m¹ and a height (depending on the location of the piers)
between 5,9 and 11,9 m¹.
Photo 44: The Storm Surge Barrier. Photo 45: Corroded steel gates.
The replacement of the sliding steel gates will maybe be necessary in the nearly future because
of the very high maintenance costs and the repeated application under special conditions of a
special coating to avoid corrosion.
An internal research project initiated by the Civil Engineering Division of the Ministry of Trans-
port, Public Works and Water Management in the Netherlands shows that it is possible to re-
place the existing sliding steel gates with HPC/HRUHPC gates within the maximum weight
tolerance of the existing gate-operating machinery. The present design for the HPC/HRUHPC
sliding gates consists of a HPC concrete for the girders and a HRUHPC for the plate construc-
tion (75 mm thick and reinforced with 3 layers ø8 - 50mm).
Possible more weight reduction and additional strength can be reached by the use of high
strength steel and/ or the use of carbon fibre- or other fibre reinforcement in the plate construc-
tion. Because the expected service life of the HPC/HRUHPC sliding gates will exceed the 100
years without additional maintenance it seems both practical and economical a very interesting
solution.
Figure 9: Details concrete gate. Figure 10: Concrete gate.
UHPC and HRUHPC can replace many existing structures made from other materials or new to
build structures. Complete UHPC bascule bridges can be build with a shot blasted HRUHPC
deck, the whole structure can be cast in prefab and on-site the prefab parts can than be con-
nected together with UHPC joints.
Gates and hatches in sluices and locks can be precasted and connected in the same way with a
joint. Critical areas with possible impact can be cast in HRUHPC.
refab
5 New material developments

The strength and properties of an UHPC will go in an upwards direction in the nearly future, 200
– 500 MPa will be possible within the next 20 years. For this it will also be necessary to produce
more artificial made aggregates to be able to reach these high strengths. With the much better
available research equipment and computer modelling the microstructure can be investigated
much better than before what will result in new developments including the incorporation of
much more additives to control and to influence the properties of the matrix. New types of addi-
tives will be developed and they don’t have to be special developed for concrete. The use of
special polymers like in MDF (Macro Defect Free) concrete will be interesting again to produce
new types of UHPC. Heavy reinforcement in different materials and different forms will be used
on all material levels thus also to reinforce the nano- and microstructure of the matrix. Future
HRUHPC will thus incorporate a wide range of materials from different sources in both the
binder part and the reinforcement part.
6 Conclusion
Although UHPC is much earlier developed than is known by many engineers and that there are
several applications were UHPC is used for 25 years it is in general still an unknown material.
During the last 10 years new applications are found for the use of heavy reinforced ultra high
performance concrete and it seems that the C.R.C. concept starts to find its way between other
composite materials and composite structures. HRUHPC offers new and sometimes exiting
possibilities: lighter structures, larger structures, hybride structures, new design and new prod-
ucts with a potential for a better economy and resource consumption than with more traditional
concrete, steel and other building materials.
When designers, architects, engineers and structural engineers are more open for the “new
concrete” and the “new technology” and are more willing to investigate and to innovate with the
existing knowledge than much more can be achieved. To make use of the large potential for
HRUHPC there must be a change of direction and a break with conventional practice to be able
to understand the material properties and possibilities. For this it will be necessary that the in-
dustry will cooperate in a much better way with Technical Universities, institutes, governments
and end-users and that knowledge and practical experience will be much more exchanged be-
tween those parties.
7 Acknowledgements
I especially like to thank Hans Henrik Bache, a great engineer and scientist but also a good mo-
tivator and a visionary, for his interesting lessons during all those years and his inspiring com-
ments and advice, it is a great honour for me that I’m able to help to make some of his more
than 25 years old dreams come true.
I like to thank Niek Kaptijn from the Civil Engineering Division of the Ministry of Transport, Public
Works and Watermanagement in the Netherlands and René Braam and all the employees from
the Stevin lab of the Delft University of Technology in the Netherlands for their support and help
with the different projects in the Netherlands and for their contributions in the different proceed-
ings.
I like to thank Professor Michael Schmidt and the Scientific Committee for the kind invitation to
present this paper as part of the plenary session at the International Symposium on Ultra High
Performance Concrete 2004 in Kassel.
8 References
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publication SP-180, Bond and development of Reinforcement, 1998.
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Performance Concrete, 29 – 31 May 1996, Paris, France.
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Spezial Band 2. ISBN 3-8167-6265-4. Fraunhofer IRB Verlag 2004.
[4] Bache, H.H. High strength concrete development through 25 years. CBL report no. 17. Cement- and
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[5] Bache, H.H. Model for Strength of Brittle Materials Built up of Particles Joined at points of Contact.
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[6] Bache, H.H. Densified cement/ ultra fine particle based materials. The second International
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[8] Bache, H.H. Concrete and Concrete Technology in a Broad Perspective. CBL reprint no. 26.
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Ultra High Performance Concrete: Developments and Applications during 25

Conference Paper · September 2004

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Ultra High Performance

International Symposium on Ultra High Performance Concrete

which took place in September 13 to 15, 2004. The symposium was

ISBN 3- 8995 8-086-9

Scientific committee International Symposium on

T. Y. Lin International, USA

Session E1 Applications Social Program Hotel Accommodation

" Cultural event (September 14, 2004)

" Guided city tours

" Fulda boat trip

Registration Commercial exhibition The city of Kassel

The Symposium is supported and co-sponsored by:

fédération internationale du béton (fib)

Tel:+49 561 804 2601

2 The development of HPC and UHPC

1. Is it possible to reach a much denser packing in cement paste than corresponding to a

Figure 1: Relationship between compres-

0.3 0.4 0.5 0.6 0.7

2.2 The development of the DSP system in the seventies

Fine aggregates Micro-silica

Photo 2: Micro-silica particles. Figure 2: Dense packing of the mortar.

• A certain amount of special cement.

A Cement paste. B Superplasticized cement C DSP binder paste.

2.3 The development of the Compact Reinforced Composite (CRC)

Photo 3: From an extreme brittle binder. Photo 4: To an extreme ductile composite.

CRC consists of the following materials:

CRC has the following properties:

• Compressive strength 150 – 400 MPa

2.4 The development of new DSP systems

Figure 4: Pedestrian bridge in Sherbrooke. Figure 5: UHPC beams in Cattenom.

3.1 Wear protection

Photo 7: Replaceable part of scoop feeder. Photo 8: Parts mounted together.

The UHPC has the following advantages in wear protection:

• Application: casting, shotcrete, handpatch.

3.2 Concrete repair

Photo 9: Damaged stilling basin. Photo 10: Kinzua dam.

The repairs method was as follow:

• Strengthening individual intact members by local- or complete filling.

UHPC for offshore windmills:

Foundations: the UHPC is grouted in the bed-

Connections: the UHPC is grouted in the con-

• Ultra high strength and stiffness.

3.4 Security industry

3.5 Prefab structures

Photo 32: Surface of the Mushroom. Photo 33: Mushrooms placed.

3.6 Industrial floors, - pavements and Ultra Thin White toppings

• After hardening of the epoxy unbonded aggregates are removed.

Figure 9: Details concrete gate. Figure 10: Concrete gate.

5 New material developments

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