ULTRA-HIGH PERFORMANCE CONCRETE

(UHPC) – PRESENT & FUTURE

Presented by: Adj. A/Prof. Ir Dr. VOO YL

CEO & Director

30th Nov 2018

 2018
7.6 BILLION
World Population and CO2

Population  CO2 

1° C
CO2  Global Temp. 
Leaders from
the world’s 8
richest

2C
º
economies
have agreed
to set 2 deg C
as the max.
limit for global
temperature
rise.
?

?
 Concrete Technology Break Through

 One of the biggest breakthrough in 21st century is the invention of

ultra-high-performance concrete (UHPC)
 Concrete Grade 130/145 above (Defined by NF P18 470 -2016)
 With usable structural tensile strength (> 7 MPa) and ductility
 at least 4-6 times stronger than normal concrete (in
compressive strength)
 at least 100 times more durable than conventional concrete
 Longer service and design life
 Support Sustainable Construction
 Still popular

Gaining mileage

RPC / UHPC
Evolution of Concrete Technology
 Strength VS W/C Ratio
300

Compressive Strength (MPa)

250 Ultra High Performance Concrete
(UHPFRC) fck > 130 MPa

200
Very High Strength Concrete
(VHSC) fck = 100 to 130 MPa
150 High Strength Concrete
(HSC) fck = 50 to 100 MPa

100 Normal Strength

Concrete (NSC)
fck < 50 MPa
50

Min. w/c = 0.26

0
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8
W/C ratio 8
 Corrosion Costs and Preventive Strategies in the
United States (FHWA, 2002)

 The U.S. FHWA released a break-through two years study in

2002 on the direct costs associated with metallic corrosion in
nearly every US industry sector, from infrastructure and
transportation to production and manufacturing.
 The study provides current cost estimates for the time and
identifies national strategies to minimize the impact of
corrosion.
 The total annual estimated direct cost of
corrosion in the U.S. is a staggering USD$276
billion (approximately 3.1% of the nation’s
Gross Domestic Product (GDP)).
 UHPC Tech.
Sustainable Construction

 DURABILITY as Key Consideration

 Material / Structural Optimisation
 Environmental Base Optimisation
 Life-Cycle Cost Design
 The Advantage of Using UHPFRC for Bridges
 UHPC doesn’t shrink and minimal creep (reduce time
effect problem)
 Cost Saving;
 Span up to 100m, reduce foundation cost > 40%
 Cheaper & better solution against Steel Structures
 Lighter (ideal for seismic zones)
 Extremely durable and less maintenance
 Shortened Construction Period. (> 20%)
 SUSTAINABLE ASSET
 Environmental Based Optimization
(Example 1 – 50m Single Span Road Bridge, for 132T Vehicle)

OPTION 1
Steel Composite Bridge

OPTION 2
Note: Video Captured after 8 years since constructed. UHPC Composite Bridge
 Inventory Data of Material (Voo and Foster 2010)
Inventory Data of Materials Inventory Data of Materials
185,8 185,8 17,12 17,12
Embodied Energy (GJ/m3) CO2 Emission (t/m3)

7,77 1,07
2,7 1,73 0,48 0,30
DURA-UHPC C60 (wt 15% C40 (wt 15% Strands Reinforcement DURA-UHPC C60 (wt 15% C40 (wt 15% Strands Reinforcement
(2% Steel PFA) PFA) (2% Steel PFA) PFA)
Fiber) Fiber)
 Material Quantity & EE Calculation

Material Quantities (tonnes) Embodied Energy (GJ)

UHPC Comp. Br. UHPC Comp. Br. 2242

114
Steel Comp. Br. Steel Comp. Br.
102 102
95

368
260 205
11,0 8,6 158
6,7 75 75
0 0 0 0 0 0
DURA-UHPC C40 (wt 15% Strands Reinforcement Steel DURA-UHPC C40 (wt 15% Strands Reinforcement Steel
(2% Steel PFA) (2% Steel PFA)
Fiber) Fiber)
 CO2 & 100-yr GWP Calculation
CO2 Emission (tonnes) 100-Yr Global Warming Potential
(tonnes)
415
UHPC Comp. Br. UHPC Comp. Br.
207
Steel Comp. Br. Steel Comp. Br.

121
51

24 19 48 38
15 34 34 29
13 13
0 0 0 0 0 0
DURA-UHPC C40 (wt 15% Strands Reinforcement Steel DURA-UHPC C40 (wt 15% Strands Reinforcement Steel
(2% Steel PFA) (2% Steel PFA)
Fiber) Fiber) 15
 Life-Cycle Design
UHPC superior durability offers double
or more design / service life.

OPTION 1
120 114.1
Steel Composite Bridge
Steel Beam Method as 100% Baseline

100 UHPdC Composite Bridge

80 72.8
Steel Composite Bridge

60
47.7
42.9
34.1
57 %

40

OPTION 2
24%
22%
20
17

0
Mass (ton) EE (GJ) CO2 (ton) GWP (ton Cost
CO2 eq.) UHPC Composite Bridge
 Environmental Impact Calculation
(Example 2 – 40m Span Bridge)
FULLWIDTH
WIDTH15000
15000
FULL
UHPC superior durability offers
WALKWAY
WALKWAY CARRIAGEWAY
CARRIAGEWAY WALKWAY
WALKWAY
2500 10000
10000 2500
2500 double or more service life.
WALKWAY
WALKWAY 50mm THK
50mm THKASPHALT
ASPHALT(1
(1kPa)
kPa) RCPARAPET
RC PARAPET
kN/m
9 kN/m (9.22kN/m)
(9.22kN/m)
200mmTHK.
200mm THK.RC
RCDECK
DECK 120% UHPdC

Conventional Method as 100% Baseline

CONVENTIONAL
CONVENTIONAL
Convetional
2325
2325 SUPER-TEE
SUPER-TEE GIRDER
GIRDER
(G(G
==21.5
21.5kN/m)
kN/m) 100%

79.9% 81.8%
2250
2250 2250
2250 2250
2250 2250
2250 2250
2250 2250
2250
80% 76.3%
CONVETIONAL
CONVETIONALMETHOD
METHOD(VIEW
(VIEWA-A)
A-A)
NSC PC Composite Bridge 62.7%
FULL
FULLWIDTH
WIDTH15000
15000
60%
WALKWAY
WALKWAY CARRIAGEWAY
CARRIAGEWAY WALKWAY
WALKWAY
2500
2500 10000
10000 2500
2500

WALKWAY 50mm RC
RCPARAPET
PARAPET
40%
WALKWAY 50mm THK
THKASPHALT
ASPHALT(1
(1kPa)
kPa)
9
9 kN/m
kN/m (9.22kN/m)
(9.22kN/m)

42 %
40 %

38 %
200mm
200mmTHK.
THK.RC
RCDECK
DECK

32 %
20%
1950 UHPdC
UHPdC U-GIRDER
U-GIRDER
1950
(G(G
==2222
kN/m)
kN/m)

0%
2500
2500 5000
5000 5000
5000 2500
2500
Material (ton) EE CO2 100 yr GWP
UHPdC
UHPdC METHOD
METHOD(VIEW
(VIEWB-B)
UHPC Composite Bridge
B-B)
DURA Group of Companies
 MAKES UHPC as
MAINSTREAM PRODUCTS
• DTSB formed in year 2006 DURA FACTORY
• 2007-2010 R&D Works (Malaysia)
• Business started 2010 – now
• 10 acres lands (40,000 m2)

20
UHPC Batching Facilities

21
Discharged of UHPC (2% vol.)
(W/B = 0.16; flow table value = 210mm)
Casting of UHPC Tee-Beam
CT Scan & X-Ray Ihr logo

Fiber Amount = 158kg/m3 (2% vol.)

32 mil fibers; Total Length = 642 km/m3
4 Points Test Curves (NF P18-470, 2016)

25
QA/QC Test Data Pool
Compressive Strength Vs Fiber Vol.
QA/QC
fck = 150 MPa
fctk,el = 7 MPa
fctkf = 8 MPa

150
Design Working Life (NF P18-410, 2016)

Carbonation

Chloride / Salt

Freeze
& Thaw

Severe
Chloride &
Salt

Severe
Freeze &
Thaw

Chemical
Attacked

Severe
Chemical
Attacked
Durability
Testing
Conducted
in Switzerland
Porosity and Water Absorption Coeff.

NF P18-410 for 150 yrs DWL, Dp < 6%

Chloride Diffusion Coeff.

150 times
lower

NF P18-410 for 150 yrs DWL, Dc < 0.1 x 10-12 m2/s

Water Absorption (BS1881-121)
Water absorption (SIA 262/1-A)
Water Penetration Under Pressure (BS EN12390-8)
Rapid Chloride Penetration Test
Abrasion Resistance (BS EN 13892-3: 2014)
Freeze-Thaw Resistance (BS EN 12390-9:2016)
Carbonation Depth
1 Span – 20m to 29m
Sg. Itik Br. – 25m

Mines Shopping Mall Canal Br. – 22m

Pos Bawong Br3. – 23m

Kok Lanas Br1. – 25m 41

1 Span – 30m to 39m
KT By-Pass ST2 Br. – 35m Sg. Bertam 3 Brs. – 30m

Pos Perwor Br1. – 30m Wisma LKIM Br. – 32m 42

 1 Span – 40m to 49m

Kok Lanas Br2. – 40m Batu Papan Br. – 42m

Kok Lanas Br2. – 40m Rancangan Merah Br. – 42m 43

1 Span – 50m to 59m

Rantau-Siliau Br. – 52m Tumpat Br. – 55m

Sg. Ijok Br. – 50m Kg Merdeka Br. – 59m 44

 Pedestrian Bridges

Nan Hwa School FtBr. – 30m Animation Theme Park FtBr. – 120m

Kuala Sepetang FtBr. – 110m Taayah School FtBr. – 40m 45

 Marine Bridges

Kuala Sepetang FtBr. – 110m

Bum Bum Island Jetty – 280m

Westport Br25. – 78m

Banggi Island Br4. – 30m 46

 Batu 6 Bridge, Single Span 100m
PCI 2016 Design Award – Best International
Transportation Structure
Segmental Box Girder (17t each)

4m Tall; 5m
wide top flange
550t crawler crane
is used mainly to
assembled the
last steel frame
 Assembly
Using Trolley

Assembled
segment
using trolley
Time Lapse Camera
 Post Tensioning by
PSC Freysinet (Malaysia)
Completed After 1 Year
 Batu 6 Bridge (1 span – 100m), 2015

Sustainable Construction
• Immediate Cost Saving > 25%
• Better functionality (wider navigation span)
• Minimal maintenance (no piers)
• Valuable asset (lower risk from destruction) 54
200m long x 17.6m wide RC deck
Supported by 3 beams per span

To Construct a Viaduct at Section 49, Laluan 4

(KM 157 Gerik - Kota Bahru), Ecological Corridor
at Central Forest Spine (CFS), Gerik, Perak D.R.
Precast Segment from Factory
Assembled Near Bridge Site
Beam
Launched
In-Situ Deck Slab
 Fully Integral Bridge

5.9m 5.9m

17.6m wide RC deck

Supported by 3 beams
Open to Traffic
Distinguished guest from
PCI and FIB (Sep 2016)
Sustainable Construction

• Immediate Cost Saving > 10%

• Better durability (factory product)
• Minimal maintenance (no bearing / jointless)
• Valuable asset

14e Journée d'information Holcim 2017, 2017-

06-29 63
To Construct a New Bridge from Kg Baharu to Kg. Teluk,
Manjung District, Perak D.R (2017)

To-date, Malaysia longest

UHPC composite bridge
(13.7m wide x 420m long)
 Integral bridge with
one expansion joint

Sustainable Construction

• Immediate Cost Saving > 10%

• Better durability (factory product)
• Minimal maintenance (no bearing / jointless)
• Valuable asset
To Construct Jetty at Balembang Pulau
Bum Bum, Semporna, Sabah. (2015)
2000km
Precast Jetty Components

Precast Solution:
Good Quality Products
Precast Jetty Components

Good Quality Products

Assembly of Precast Components

Speed in Construction:
Light-weight and
Easy to Install
 Installation of Jetty Components

Durable Design /
Negligible Maintenance
Aesthetically Pleasing
& Cost Effective
Completed Bum Bum Jetty, Sabah
KT By Pass (Malasyia, 2018)

14e Journée d'information Holcim 2017, 2017-

06-29 74
To Construct Bridge Crossing Perak River Linking
Kampung Seberang Manong to Pekan Manong, K.
Kangsar, Perak. (2018)

Designed, Tendered and Awarded by

Public Work Department Malaysia
 General Arrangement
(45m + 70m + 70m + 70m + 45m)

308m
Cross Section (70m)
UHPC U-Beam Detail
Post
Tension
Mock Up
(12/07/18)
Post Tension Mock Up
(12/07/18)
 Midspan Deflection (mm)
200

180
Mdspan Deflection (mm)

160

140
Immediate
120
• Theoretical Immediate Hog = 160 mm
100 • Actual Experimental Hog = 163 mm
80

60
Time-effect
40
• Theoretical Time-effect Hog = 171 mm
20 • Actual time-effect Hog = 172 mm
0
Final
2 Bot 4 bot 5 bot 6 bot
(2nd 1 2 3 4 5 6 7 8 9 10 11 12 13 14
&2 &2 &2 &2
cycle Day Day Day Day Day Day Day Day Day Day Day Day Day Day
top top top top
PT)
Série1 2,5 42,5 95 139 163 163 170 169 170 172 171 172 172 172 172 172 172 172 172
Submerged Lambor Bridge (8 spans x 50m)

UHPC Giant U Girder

Cast In-situ RC Deck
Latest Site Progress (29/11/18)

89
90
14e Journée d'information Holcim 2017, 2017-
06-29
Ikea Cheras SPE Highway (2018-2020)
SPE - 60m
Joint Stitching DURA UHPFRC Ihr logo

(White Lake Bridge, Canada, 2018)

DURA UHPFRC 1st use at White Lake

Bridge (Canada) as In-filled UHPFRC
for Bridge Deck Panel
In-Situ In-Filled DURA UHPFRC
1st DURA Bridge in China
(Guangzhou, 2018)
1st Unreinforced UHPC
Precast /Prestressed
Beams
1st DURA Bridge in China
(Guangzhou, 2018)

100
1.36 km Bankot Bridge (India, 2019)
25 span 50m + 1 span 110m

101
Cable Saddle (Freyssinet Vietnam 2018)
Cable Saddle (Freyssinet Vietnam 2018)
Panorama (Singapore, 2016)
DURA Drymix to Singapore
Precast Bathroom Units (PBUs)
from Tiong Seng Group (Singapore)
PBU (Singapore)
More than 7000 units has been produced
JTC Space @ Tuas (Singapore, 2017)
Mock Up Prefabricated Prefinished
Volumetric Construction (PPVC)
 External Wall for
PPVC (Singapore)
Installation of PPVC
Tiong Seng Group Building (Singapore, 2017) –
DURA Staircase
DURA Staircase
from Tiong Seng
(Singapore)
The Next Explosive Growth in UHPC

 China will be the next biggest consumer in UHPC

 Has there own national standard for UHPC (GB/T
31387-2015)
 To-date, it is mostly used in steel-UHPC Lightweight
Composite Structure Deck (DB43/T 1173-2016)
 Next Development is UHPC box girder!!!
洞庭湖大桥
1480m span, China longest
and world 3rd longest span,
UHPC Overlay

40mm premix

45mm UHPC overlay

Shear Studs

12mm MS Plate
1. Shear Studs
2. Reo. Fitting
3. Mixing Facility

Site Batching facility

50m3/hr or 1000m2 / hr
4. UHPC Laying
5. Compacting &
Levelling
6. Wet Membrane
Curing
7. Steam Curing
8. Mill off Surface
9. Laying Premix