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Review Article
Article history: An advanced development in construction industry was achieved by applying ultra-high-
Received 12 August 2020 performance concrete technology (UHPC). Intensive research efforts had been concen-
Accepted 17 December 2020 trated in construction to produced amazing levels of qualities with strength greater than
Available online 20 December 2020 150 MPa and high durability that had never been thought possible before. With this tech-
nology, it is possible to construct structures beyond the usual designs but with limited use
Keywords: in construction since it is not commercially viable to replace conventional concrete in most
Ultra-high-performance concrete applications. This is attributed to the high cost of materials, the lack of their availability,
(UHPC) limited design codes, and complicated manufacturing and curing techniques. This paper
Fundamental reviews the evolution of UHPC and the suggested ideas to replace its expensive composites
Raw materials by cementitious materials. However, concrete made with these alternative materials will
Properties not be of the same quality as the standard UHPC. Another promising choice, which seems
Application to be more practical and easier to promote UHPC technology in construction, is looming on
the horizon. It is based on the utilization of UHPC in hybrid structures by combining UHPC
with other construction materials. The cost of production will hopefully be reduced with
such composite structures that have the advantages of the combined materials. Therefore,
it is recommended to continue research into this choice which will increase the potential
of UHPC to be more accepted in many different construction applications.
© 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC
BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
* Corresponding author.
E-mail address: md.bajaber@gmail.com (M.A. Bajaber).
https://doi.org/10.1016/j.jmrt.2020.12.051
2238-7854/© 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 0 : 1 0 5 8 e1 0 7 4 1059
However, this concrete was associated with a lack of ten- figure, the compressive strength was between 20 and 40 MPa
sile strength and ductility, leading to failure in beam and slab during the first half of the century [6].
structures. Accordingly, this led to the second generation of After the middle of the 20th century, a challenge arose to
concrete, in which reinforcement with steel bars was thought increase the strength to carry greater loads for more advanced
to be a solution to these problems. Joseph Monier and Francois constructions. During those decades, the compressive
Coignet were the first pioneers of concrete reinforcement strength exceeded 40 MPa, as shown in Fig. 2 [4]. This was
during the second half of the 19th century. They granted many achieved through careful selection of aggregates since weak
patents for reinforcing different types of structures. Since ones may not be strong enough to carry heavy loads, and
then, the combination of steel bars and concrete was the through decreasing the ratio of water to binder material. This
dominant construction material throughout the 19th and 20th ratio is inversely proportional to the compressive strength, as
centuries. Fig. 2 shows the increase in the compressive shown by Fig. 3. The reduction of water content was possible
strength of concrete during the 20th century. As shown in the through the invention of water-reducing admixtures [8] which
enable the engineers to increase the strength without
affecting workability.
Table 1 e Optimum mix proportions for 1 m3 of UHPC Table 2 e Physical and chemical/mineralogical properties
mixturea. of the dune sand.
Mix component Weight (Kg) Typical Range (Kg)b Property Range (%)
Premix Materials Fineness modulus 0.9e3.0
Fine dune sand 1005 490e1390 Coefficient of uniformity 2.0e4.0
Portland cement 900 610e1080 Specific gravity 2.6e2.7
Silica Fume 220 50e334 Water absorption 0.4e0.5
Water 163 126e261 SiO2 (quartz) 80e98
Superplasticiser 40 9e71 CaSO4 2H2O (gypsum) 4e14
Steel Fibres 157 40e250 CaCO3 (calcite) 3e12
Total Weight 2485
a
Ahmad, Hakeeem, and Maslehuddin [22].
b
Tayeh et al. [23]. along with very fine quartz sand (0.15e0.60 mm), quartz
powder (smaller than 10 um) and fibres without coarse
aggregate. Nematollahi et al. [19] defines UHPC as a cement
voids between larger particles [12]. Improvement in the UHPC based composite material which consists of fine materials
packing system will surely increase strength and enhance with optimized grading curves, very high strength discrete
durability and the overall performance of UHPC concrete. micro steel fibers and a very low water cement ratio less than
In fact, UHPC is a new form of concrete with a new type of 0.25. Other researchers define the UHPC based on its superior
composite construction material. Its high compressive mechanical and durability properties. For example, Aroraa
strength and ductility are achieved by an optimized packing of et al. [20] defines UHPC as a multi-scale microstructure-
fine and ultrafine particles, as well as the inclusion of steel designed material tailored for very-high compressive
fibres. This optimization, in particular, will evenly distribute strength, high flexural and tensile strength, and high ductility.
all particles at the micro scale to pack the spaces, surrounded Li, J. et al. [21] defines the term as an innovative composite
by larger particles. Accordingly, a dense matrix is achieved material that can serve as a potential candidate for concrete
with low permeability, to provide a concrete with superior structures exposing to aggressive environments.
properties [10,14e16]. Based on the above definitions, we could come up with a
Different definitions have been given to UHPC. Some re- definition which combines UHPC major component and su-
searchers define the term based on its major components. For perior properties along with the basic technologies behind the
example, Farzad et al. [17] defines UHPC as a cement-based UHPC production. Thus, UHPC is a new generation of cement-
material formed with an enhanced gradation of granular based construction material tailored for very high compres-
components, a water-to-cementitious materials ratio less sive strength, high ductility, and sustainability based on:
than 0.2, and a significant portion of internal fibers. Mishra & micro-scale optimization of fine and ultrafine aggregates (sil-
Singh [13] define UHPC as a special type of concrete that ica fume and sand), lower content of water to cement ratio
consist of highly fine-grained reactive admixtures (i.e. silica with added superplasticizer, and reinforcement with high-
fume and fine quartz), fibers and superplasticizers while strength steel fibers.
having more binder content and low water-to-binder ratio.
Azmee & Shafiq [18] define the term as a fiber reinforced, 2.2.2. UHPC components
superplasticized, silica fume-cement mixture with a very low High-strength, ductile, and sustainable UHPC concrete is
water to cement ratio (W/C), characterized by the presence of made up of constituent materials like fine-grained sand,
a very fine quartz sand that ranges from 0.15 to 0.60 mm in Portland cement, silica fume, water, superplasticizer, and
diameter, instead of the ordinary aggregate. Ahmad et al. steel fibres, as shown in Fig. 5 [19,22].
(2016) define UHPC as a mixture produced by using high con- Details of these constituent materials are given in the
tents of cement, silica fume (0.1e1 um) and superplasticizer following subsections. Typical mix proportions of these ma-
terials for one cubic meter of UHPC are presented in Table 1
and presented graphically in Fig. 6.
Fig. 11 e Some urban furniture and decorative arts made from UHPC.
1066 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 0 : 1 0 5 8 e1 0 7 4
modified flow table test method described in ASTM C1437 UHPC concrete by improving the workability and pumpability
and ASTM C230/C230M [64]. of fresh concrete. It would also improve the matrix density of
6. ASTM C1856/C1856M e 2017, Standard Practice for Fabri- the solid concrete, which would strengthen the mechanical
cating and Testing Specimens of Ultra-High Performance properties of concrete, as well as the ability to resist chloride
Concrete. This practice includes procedures for measuring ions and weathering activities [26]. Finally, it would reduce the
properties of fresh UHPC and procedures for making and cost of concrete production and manpower costs due to the
testing specimens of hardened UHPC. The practice refers to elimination of some labour-intensive processes. It would cut,
existing practices and test methods and includes modifi- also, transportation and maintenance costs [68].
cations to these referenced standards for application to Table 6 describes the most important properties of some
UHPC [65]. supplementary cementitious materials, including silica fume
(SF), fly ash (FA), and Ground Granular blast-furnace slag
(GGBS).
3. Alternative materials for UHPC Silica fume (SF), as mentioned before, is the finest material
among all other cementitious materials. Therefore, it is the
To promote UHPC technology in construction, alternative most preferred material to replace the cement of UHPC con-
materials are explored to replace Portland cement and other crete, especially when high strength and a high degree of
expensive materials, such as steel fibres. Therefore, this part impermeability are required. However, it is an expensive
of the paper presents some of these alternative materials material, and this is why Ahmad, Hakeem, and Maslehuddin
which are naturally available or obtained from the waste [69] utilized other waste materials existing locally with low
materials of other industries. cost to replace such silica fume.
Fly ash (FA) is a fine powder by-product material produced
3.1. Supplementary cementitious materials from the smoke coming from burning coal in the combustion
process of electrical power stations. The mineral impurities can be retarded if the surface of the fresh UHPC mixture is
are fused when they pass through the combustion chamber. covered properly [74].
With the exhaust gases, they are carried out and collected by a
proper dust collection system into spherical particles, most of 3.2. Alternative fibre materials
which are less than 45 mm, with an average of 15e20 mm [6].
Fly ash, in general, is a pozzolan material which acts like Fibres which can be spread uniformly and randomly are
Portland cement when it is mixed with water. On one hand, it usually used to reinforce concrete. Asbestos fibres were used
would improve the concrete’s workability, but on the other before. But due to the health risks associated with these fibres,
hand, it would reduce the early strength of the concrete. other materials were used, such as steel fibres, glass fibres,
However, with the extended process of hydration, it would synthetic fibres, such as polypropylene, and natural fibres,
gain much more strength than it would have with Portland such as palm tree fibres. They are used mainly to release
cement alone. stresses and to block the extension of cracks [79]. As a result,
Ground granular blast-furnace slag (GGBS) is a by-product
from the iron production process when iron ore is coked in
the blast furnace. After it is cooled, it is further crushed to
form fine particles, with a length less than 45 mm. This ma-
terial, when it is mixed in the presence of water, will hydrate
and set in the same way as Portland cement [26]. GGBS has a
considerable effect on the setting time of the UHPC concrete.
The setting time can be retarded If UHPC mixture is mixed
with the ground granular blast furnace slag [26].
the holes. Figs. 16 and 17 shows hybrid hollow core specimens application for UHPC which attracts many researchers to
before and after casting ordinary concrete. Types (i) and (iii) do investigate the composite structure. Orthotropic steel deck, a
not require any steel reinforcement. Type (ii) may not require deck steel plate covered by a roadway surface, is used widely
any steel reinforcement but for smaller widths. in many types of bridges, especially, in long span steel bridge
The results of these studies confirmed that each of the as shown in Fig. 18 [99,100]. Despite having the advantages of
three alternative concepts is structurally promising and can lightweight and high load capacity, this type of structure
be utilized in designing simply supported precast units for suffers from cracks due to the fatigue problem under the load
residential and commercial buildings without the use of steel [101,102].
reinforcement. Further research is needed to uphold this Fatigue cracks are observed in many orthotropic steel deck
viewpoint. In corrosive environment, this may prove to have bridges around the world such as: the Severn Bridge in En-
significant advantage worthy of consideration. gland, the Sinntal bridge in Germany, the Westgate bridge in
For using UHPC as a repair material, Tayeh et al. [92] Australia, the bridge of Leverkusen in Germany [103]. This
investigated the use of UHPC as a repair material for old fatigue problem has been studied by many researchers to
normal concrete (NC). The interfacial bond and the perme- improve its performance.
ability characteristics were evaluated. The results showed One of the best prospective solution to resist this fatigue is
that the behaviour of the composite was firm and stable due to to use UHPC overlay as a deck pavement instead of the orig-
the UHPC overlay which bonded strongly with the old con- inal pavement [99,104]. The fatigue response of using UHPC
crete. The study revealed that UHPC was efficient and stable overlay with orthotropic steel deck was studied by Zhu et al.
for concrete repair. Also, Roy et al. [93] used an effective [103]. The study showed that UHPC overlay can significantly
mixture of UHPC as a repair material for normal concrete. The reduce the magnitude of the stress at the deck side. Also, the
study was conducted to investigate the bond strength be- transversal bending behaviour under bending moments of the
tween UHPC and the substrate of normal concrete. The study steel-UHPC composite deck was studied by Luo et al. [100]. The
revealed that UHPC was effective for repairing deteriorated study found that the UHPC overlay has a considerable effect
structures. on the ultimate load capacity of the deck.
Another utilization of UHPC in hybrid structure is in
timber-concrete composites. The two materials are
bonded together either with mechanical fasteners or rigid 5. Conclusion
connections. Their advantages are utilized in one com-
posite to achieve better performance. Detailed reviews of The new generation of concrete (UHPC) has an amazing level
this timber-concrete composite, including its connection of qualities that had never been thought possible before. After
systems, were carried out by Yeoh et al. [94] and Rodri- reviewing the subject thoroughly, the following conclusions
guez et al. [95]. were found:
Combining UHPC with wooden structures was also
investigated by Ferrier et al. [96]. A hybrid beam was made of 1. It was clear that most of the researchers at the state of the
glued-laminated (glulam) wood and UHPC planks. The inves- art emphasized that the mechanical and environmental
tigation showed that the use of UHPC was optimized with performance of UHPC surpassed all expectations, creating
better performance and efficiency based on greater bending a potential for wider applications in construction.
stiffness and significant increase in the structure capacity. 2. The mechanical properties of the new generation of con-
With UHPC, it is possible to reduce the depth and to increase crete are greatly superior to the properties of conventional
the span of the beam without affecting the structure’s concrete. These incomparable values are a function of
performance. water to binder ratio, ultrafine powders, optimized packing
Also, Hajek et al. [97] studied the possibilities of using of particles, method of curing, and microstructural
UHPC in timber-concrete composite floor structures. They reinforcement.
designed a composite consisting of a timber beam and a thin 3. With this technology, it is possible to construct structures
lower-weight UHPC deck. Since it is difficult to use mechanical beyond usual designs, which are lighter, larger, or with
joints, they proved that gluing is a good method to connect the longer span. Its special workability enables the fresh con-
two different materials. The study showed that the new type crete to be cast in irregular or very slender shapes to form
of composite would enable the design of a UHPC deck with a structures with aesthetic appearance or extraordinary
relatively small thickness (less than 30 mm). finish.
Holy & Vrablik [98] summarized the research findings on 4. However, the use of UHPC in construction is limited since it
fabrication of timber-concrete composite structures and is not commercially viable to replace conventional con-
suitable methods of coupling between the two materials. They crete in most applications for the following reasons:
presented ways to develop pedestrian and cyclist footbridges a. An economic factor represented by the high cost of
using innovative hybrids with efficient materials and better some of its constituent materials, as well as the lack of
construction methods. their availability. For instance, the cost of steel fibres can
Steel-UHPC composite bridge is also an important utiliza- be greater than the rest of the matrix materials
tion of UHPC in hybrid structure. It is a current field of combined.
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 0 : 1 0 5 8 e1 0 7 4 1071
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Declaration of Competing Interest
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connections between longitudinal stringer and deck plate in gram was a research work for concrete development in con-
railway bridge orthotropic steel decks. Eng Struct struction engineering. The goal of the research position is to
2017;153:32e42. pursue additional research and training in order to have better
[102] Shao X, Qub W, Cao J, Yao Y. Static and fatigue properties of skills to pursue a career in academia and research.
the steel-UHPC lightweight composite bridge deck with
large U ribs. J Constr Steel Res 2018;148:491e507. Dr. Ibrahim Yahya Hakeem: Assistant Professor, Department of
[103] Zhu Z, Xiang Z, Zhou YE. Fatigue behavior of orthotropic Civil Engineering Najran University. He received his Ph.D. (Civil
steel bridge stiffened with ultra-high performance concrete Engineering ; thesis: Structural Behavior of Unreinforced Hybrid
layer. J Constr Steel Res 2019;157:132e42. Slab Elements Cast with Ultra-High Performance Concrete (UHPC)
[104] Chen S, Huang Y, Gu P, Wang JY. Experimental study on from the KFUPM, Saudi Arabia in 2014. He obtained his M.S. Civil
fatigue performance of UHPC-orthotropic steel composite Engineering ; thesis: Characterization of an Ultra-High Perfor-
deck. Thin-Walled Struct 2019;142:1e18. mance Concrete (UHPC) from KFUPM in 2011 and B.S. in Civil
Engineering in 2001 from Aden University , Yemen. Dr. Hakeem
Dr. Mohamad Abdullah Bajaber: A post-doctoral researcher, has teaching and research experience of more than 15 years. He
Department of Civil Engineering, Najran University. The author has over 10 publications in refereed journals and conference
was born in Jeddah, Saudi Arabia. He received his B.S. and M.S. proceedings. He has worked as the Principal Investigator and Co-
degrees in Industrial Engineering from King Abdulaziz University. Investigator in several funded research projects. Recently, he has
He has worked in several private companies for twenty-five years focused his attention on the development and utilization of UHPC
with good experience in project engineering and contracts man- which is viewed as the next generation of concrete, and began his
agement. Under the supervision of Dr. M. Taha from King Abdu- work during his M.S. thesis through a funded project and has
laziz University and the technical support of Dr. T. Hegazy from published several papers in this area. Dr. Hakeem research in-
Waterloo University in Canada, the author completed the re- terests include the following: Structural analysis; Ultra-High Per-
quirements for the Doctor of philosophy in Civil Engineering in formance Concrete (UHPC) developer ; development of hybrid
May 2017. The thesis was to develop a decision support system for construction using UHPC ; durability and protection of reinforced
prequalifying and selecting a contractor for construction projects. concrete structures in aggressive media; Repair materials and
In August 2020, he completed one-year post-doctoral followship repair systems, composite structures and sustainable structural
program, supervised by Najran University, and financially materials.