Journal of Wuhan University of Technology-Mater. Sci. Ed. Apr.

2010 349
DOI 10.1007/s11595-010-2349-0

Preparation of Reactive Powder Concrete

Using Fly Ash and Steel Slag Powder
1, 2 2 2
PENG Yanzhou , HU Shuguang , DING Qingjun
(1. College of Hydraulic & Enviormental Engineering, China Three Gorges University, Yichang 443002, China;
2. Key Laboratory for Silicate Materials Science and Engineering of Ministry of Education, Wuhan University of Technology, Wuhan 430070, China)

Abstract: To decrease the cement and SF content of RPC by using ultra-fine fly ash (UFFA)
and steel slag powder (SS), the effect of these mineral admixtures on compressive strength of RPC
were investigated. The experimental results indicate that the utilization of UFFA and SS in RPC is
feasible and has prominent mechanical performance. The microstructure analysis (SEM and
TG-DTG-DSC) demonstrated that the excellent mechanical properties of RPC containing SS and
UFFA were mainly attributed to the sequential hydration filling effect of the compound system.
Key words: ultra-fine fly ash; steel slag powder; reactive powder concrete; sequential hydra-
tion; microstructure; strength

1 Introduction ciples for preparation of RPC, in order to reduce the

Reactive powder concrete (RPC), otherwise known
as ultra-high-performance concrete, is developed through
microstructural enhancement techniques for cementitious
materials. The mechanical properties that can be
achieved include the compressive strength of the range
between 200 and 800 MPa, the flexural strength of the
range between 30 and 60MPa, fracture energy of the
range between 1200 and 40,000 J/m2, Young’s modulus
of the range between 50,000 and 60,000 MPa, and
ultimate tensile strain at the order of 1%[1,2].
Conventional RPC is composed of cement and
ultra-fine powders such as crushed quartz and silica fume
(SF). The basic principles for the development of RPC
have been explained by Richard and Cheyrezy[1]. Cement
dosage of RPC is generally over 800-1000 kg/m3 and SF
content is often over 25% (by the weight of cement),
which not only increases the production costs, but also
raises the hydration heat and may cause shrinkage
problems. Replacing cement with mineral admixtures
and decreasing SF content seem to be a feasible solution
to these problems. Therefore, it is very necessary and
significant for RPC technology that exploring and util-
izing reactive mineral admixtures, which meet the prin-
©Wuhan University of Technology and Springer-Verlag Berlin Heidelberg 2010
(Received: Jan.9, 2009; Accepted: Aug.12, 2009)
PENG Yanzhou( 彭彭彭): Ph D; E-mail: pnyzh@163.com
Funded by the Guide Project in National Science & Technology Pillar
Program during the 10th Five-Year Plan Period (2003BA652C)
amount of cement and to decrease the autogenous
shrinkage and temperature gradient shrinkage.
Furthermore, incorporation of mineral admixtures may
positively affect the durability of concrete. Kejin and
Zhi[3] showed that the maximum heat of cement
hydration in binary/ternary cement (fly ash and/or ground
granulated blast furnace slag) concrete decreased with
supplementary cementitious material replacements.
Steel slag is the steel-making industry waste, which
contains a certain amount of cement clinker mineral, such
as C2S and C3S. Therefore, steel slag is a potential min-
eral admixture for concrete industry. However, due to
high content of CaO, MgO and other ingredients, steel
slag may have negative effect on the volume stability of
concrete. When steel slag is treated by appropriate pre-
treatment and ultra-fine grinding technology, the harmful
expansion attributed to CaO, MgO and other harmful
components of steel slag could be controlled in an ac-
ceptable level. Moreover, the ultra-fine grinding tech-
nology could effectively stimulate the reactivity of steel
slag[4-6]. In this study, cement was replaced with ul-
tra-fine fly ash (UFFA) and steel slag powder (SS) at
different proportions and natural fine sand instead of
crushed quartz was used as fine aggregate to develop
RPC. Firstly, the effect of SF content on compressive
strength was determined. Secondly, cement was replaced
with UFFA and/or SS at different proportions. Finally,
the microstructure of RPC samples was studied through
thermal analysis (TG-DTG-DSC) and SEM.
350 Vol.25 No.2 PENG Yanzhou et al: Preparation of Reactive Powder C…

while those of specimens in curing condition T90 for 3

2 Experimental days were tested after the end of curing.
2.4 Microstructure and thermogravimereic
2.1 Materials analysis
OPC 52.5 from Gezhouba Cement Co., Ltd (Hubei Microstructure of the selected RPC mixtures with-
Province, China) was used. The pertinent physical and out sand was investigated by using a JSM 5610 electron
chemical properties of the cement, silica fume from microscope (SEM). The selected mixture specimens were
Wuhan Haoyuan Chemical Building Materials Co., Ltd, cast according to §2.2 and the samples for SEM analysis
ultra-fine fly ash from by Power Plant of Hanchuan and were prepared by taking small pieces from the specimens
steel slag powder provided by Wuhan Green Metallur-
which were cured for a given period. The SEM analysis was
gical Slag Technology Development Co., Ltd. used are
carried out by using an accelerating voltage of 20 kV.
listed in Table 1. Natural fine sand with size of 0.16-0.63
mm was used as a fine aggregate. The specific gravity of Samples for TG-DTG-DSC analysis were measured
sand is 2.65. A polycarboxylate based superpl- asticizer (SP) on a NETZSCH STA 449 C thermogravimetric analyzer,
was used. Furthermore, brass coated steel fibers 13 mm under dry air atmosphere. The grain size was approximately
long with the diameter of 0.2 mm was used to improve the 20 μm. A temperature range between 20 ℃ and 1000 ℃
ductility of concrete and to prevent explosive degrading ℃
with a 10 per minute heating rate was selected.
under compression. The aspect ratio and tensile strength of
the fiber are 65 and 2800 MPa, respectively. 3 Results and Discussion
2.2 Specimens preparation
For each mixture, all components (cement, SS, 3.1 Influence of SF content on compres-
UFFA, SF and sand) were mixed, cast, and vibrated in a sive strength of RPC
similar sequence as conventional concrete. Initially dry In the first stage, optimum SF content of RPC cured
powders (cement, SF, SS and UFFA) and sand were
mixed at low speed for about 3 min. The water and su-
in water with temperature of 20 ℃is determined related
to compressive strength. For this purpose, various mix-
perplasticizer were then added and mixed for about 6 min.
tures with different SF contents were designed and its
Subsequently, steel fibers was added and mixed for an-
other 6min. The entire mixing process took about 15 min proportions are shown in Table 2. Abbreviation SF in
before the concrete mix was ready to cast. table means silica fume was utilized in these mixtures. SF
× ×
Nine 40 mm 40 mm 160 mm prism specimens content is also given in the abbreviations. For instance,
SF20 means silica fume content is 20% by the weight of
were cast for strength testing of each mixture. The
specimens were kept in the molds for 24 h at room tem- binder. The relationship between the compressive strength
℃
perature of about 20 . After demolding, specimens of RPC versus SF content is also shown in Table 2.
As shown in Table 2, SF content affected the com-
were cured in two different kinds of conditions respec-
tively: six prisms curing in 20 ℃
water (T20), and 3 pressive strength of RPC dramatically. The compressive
prisms curing in water with temperature of 90 ℃
for 3 strength rose with increasing amount of SF up to a limit.
Beyond the specific value, increasing the SF content
days (T90).
2. 3 Strength test decreased the compressive strength slightly which means
The strengths (compression and flexure) of speci- some excessive SF showing no reaction remains in the
mens in curing condition T20 were tested at 7 days and system. In other words there is an optimum SF content
28 days respectively according to GB/T17671-1999, giving maximum strength for each mixture.
Table 1 Chemical and physical properties of cement, silica fume, fly ash and steel slag
Compressive
Chemical composition/% Physical promerites strength of ce-
ment/MPa
SiO2 CaO Al2O3 Fe2O3 MgO SO3 Loss in f-CaO Specific density Blaine surface 3 days 28 days
ignition /(kg/m3) area/(m2/kg)
Cement 23.3 57.6 7.2 3.1 1.7 3.0 3.23 — 3.11 427 37.2 61.7
Silica fume 91.7 0.3 1.0 0.8 1.1 — — — 2.20 20 000
Steel slag 13.5 44.3 2.5 20.8 5.9 — — 1.7 3.19 514
Ultra-fine 51.7 3.7 32.1 6.1 1.0 0.2 1.2 — 2.55 659
fly ash
 Journal of Wuhan University of Technology-Mater. Sci. Ed. Apr.2010 351

Table 2 Mix proportions and properties of mixtures with different SF content

Mix proportions(by weight ratio) Flow table Compressive strength/MPa
Cement SF Sand Water* SP /mm 7d 28 d
SF0 1 0 0.04 110 73.9 97.7
SF05 0.95 0.05 0.04 112 74.8 105.4
SF10 0.90 0.10 0.045 112 76 106.5
SF15 0.85 0.15 1.1 0.18 0.045 118 82.1 113.1
SF20 0.80 0.20 0.045 116 79.7 106
SF25 0.75 0.25 0.05 116 78 108.3
SF30 0.70 0.30 0.05 114 77.4 101.6
*Including water from SP
The effect of SF content on strength of RPC is at- Table 3 Mix proportions of mixtures with different UFFA or
tributed to different microstructures and hydration SS content (SF constant)
No. C UFFA SS SF Sand Water* SP
products. Halit Yazici[7] et al reported that the micro-
SF15 0.85 — —
structure of RPC mixtures which had only cement as F10 0.75 0.10 —
binder was very porous and fibrous C-S-H existed in F15 0.70 0.15 —
some spherical pores. Connan et al[8] investigated the F20 0.65 0.20 —
F30 0.55 0.30 —
hydration products of hydrothermaly cured OPC-quartz
F40 0.45 0.40 — 0.15 1.1 0.18 0.035
blends incorporating clay-brick waste and reported that SS10 0.75 — 0.10
the high strength specimen group were depicted pre- SS15 0.70 — 0.15
dominantly a lath-like morphology tobermorite whereas SS20 0.65 — 0.20
the low strength specimens were more needle-like. The SS30 0.55 — 0.30
SS40 0.45 — 0.40
morphology change, through needle-like to lath-like, is
explained with an increase in tobermorite crystallinity
＝＋ ＋
* Including water from SP, binder C SF UFFA SS ＋
after utilization of SF in RPC. These finding are in ac-
cordance with compressive strength results of this study.
The compressive strength of SF15 mixture whose SF
content is 15% at 28 days age is higher than those of
others and reaches up to113.1 MPa. This value is 16%
higher than the control mixture (SF0) which has only
cement as binder.
3.2 Influence of the UFFA or/and SS re-
placement on compressive strength
of RPC Fig.1 Effect of UFFA or SS on compressive strength
In this part, cement was replaced with UFFA or/and SS Secondly, the effect of ternary blends (constant SF ＋
in order to determine the effect of mineral admixtures on SS and UFFA) on compressive strength was determined
compressive strength of RPC. Firstly, cement was substi- on the mixtures presented in Table 4 (by weight ratio).
tuted in different proportions by ultra-fine fly ash (UFFA) Abbreviations F and S in table show UFFA and SS, re-
or steel slag powder (SS) alone. Mixture designs were pre- spectively. UFFA or SS contents are also given in the
abbreviations. For instance, F15S15 means UFFA and SS
sented in Table 3 (by weight ratio) and SF content was kept
content are both 15% by binder weight. Test results are
constant (15% by binder weight) in these mixtures. The
compressive strength of specimens cured in 20 ℃ water for
shown in Fig.2.

a given time is shown in Fig.1. It could be seen from Fig.1

that UFFA or SS replacement reduced compressive strength
of these mixtures compared with the conference mixture
(SF15), but compressive strength values were still over 90
MPa up to 30% SS or 20% UFFA replacement. Moreover,
the compressive strength of both series F and series SS was
less than that of binary cementitious material system (Table
2) owing to lower pozzolanic reactivity of UFFA and SS. So
heat treatment or curing regime should be applied to im-
prove the pozzolanic reactivity of UFFA and SS. Fig.2 Effect of UFFA+SS on compressive strength
352 Vol.25 No.2 PENG Yanzhou et al: Preparation of Reactive Powder C…
Table 4 Mixing proportions of mixtures with UFFA and SS
replacement (SF constant)
No.
SF15
C
0.85
UFFA SS
— —
SF Sand Water* SP
F05S05 0.75
F10S10 0.65
0.05
0.10
0.05
0.10
0.15 1.1 0.18 0.035
F15S15 0.55 0.15 0.15
F20S20 0.45 0.20 0.20
F25S25 0.35 0.25 0.25
＝＋ ＋
* Including water from SP, binder C SF UFFA SS ＋ was 0.5, 0.67, 1, 1.5 and 2 respectively. Nine strength
As shown in Table 4, cement was replaced with SS
and UFFA in different proportions and SF content was
kept constant (15%) in these mixtures. It could be ob-
served from Fig.2 that total replacement level (SS FA) ＋
was critical in terms of compressive strength. Compres-
sive strength decreased slightly up to the 30% total re-
＋
placement level. Beyond this level, 20% SS 20% UFFA
combination reduced the compressive strength evidently.
This is attributed to, at a large extent, the filling effect of
mineral admixtures in cement-based material. According
to Aim and Goff model[9,10], there is a volume fraction (y*)
of mineral admixture which furnishes the mixture with a
maximum packing density. When the volume fraction of
mineral admixture (SS or UFFA) is less than y*, the
packing density of mixture rises according to the increase
of SS or UFFA content and the addition of SS or UFFA
reduces both pore sizes and porosity, and therefore the
hardened paste strength intensifies. However, once the
volume fraction of SS or UFFA attains y*, a little more
increase of SS or UFFA would make the packing density
of admixture decline obviously and therefore the hard-
ened paste strength drops. Hence, when compound ul-
tra-fine admixture is utilized to replace partial cement for
RPC preparation, there is a proper content fraction of
ultra-fine admixture. On the other hand, the binary
＋
(UFFA SS) replacement (Fig.2) caused similar or
slightly greater mechanical performance compared with
using only SS or UFFA (Fig.1), which demonstrated that
＋
UFFA SS combinations had positive effect on com-
pressive strength compared to the UFFA or SS replace-
ment alone. The reason is the so called compound filling
effect of mineral admixtures. XIE Youjun et al[11] re-
ported that utilization of mineral admixtures could ef-
fectively increase the packing density of cementitious
material and when two or three different sized mineral
admixtures were added in cement, the packing density
would be improved more obviously than that of cemen-
titious material when only one was added. The compound
filling effect of mineral admixtures (UFFA and SS) in-
creases the packing density of blends and enhances the
density of paste at low water/binder ratio, which may
improve the compressive strength of hardened paste.
Thus, ternary blends of SF, UFFA and SS may be pre-
＋
ferred rather than only using binary blend of SF UFFA
＋
or SF SS in RPC mixtures.
Thirdly, the effect of SS/UFFA ratio on compressive
＋
strength of RPC was investigated. The SS UFFA con-
tent of mixtures designed for this experimental program
was 20%, 30% and 40% respectively and the content
＋
ratio of SS-to-UFFA in each SS UFFA content mixture
× ×
specimens (40 mm 40 mm 160 mm prism) among
℃
which six prisms were cured in 20 water and three were
℃
cured in 90 water for each mixture are tested. The results
are shown in Fig.3.
As Fig.3 shown, the compressive strength of these
mixtures (cured under the condition of T20 or T90) rose
along with the increase of the SS/UFA ratio up to a limit.
Beyond the specific value, increasing the SS/UFFA ratio
would decrease compressive strength slightly. In other
words there is an optimum SS/UFFA ratio giving
maximum strength for each mixture. The reason for this
is that appropriate increase of the amount of the middle
particles, namely SS particle, in quadruple cementitious
＋ ＋ ＋
materials (C SF SS UFFA) is conducive to the im-
provement of paste density. And when the paste reaches a
higher density, a little more increase of the amount of SS,
i e, a little decrease of the amount of UFFA, would result
in decline of the paste density[11]. Thus, the strength of
RPC rises with the increase of the SS/UFFA ratio at the
beginning, and then drops. Therefore, there is an optimal
SS/UFFA ratio when SS and UFFA substitute for ground
fine quartz sand and partial cement for preparation of RPC
and the optimum ratio is about 1.5 in this study.
Finally, mixing proportion of F12S18 presented in
Table 5 had been selected to prepare RPC. Furthermore,
the brass coated steel fibers (2% by volume) were intro-
duced into mixture F12S18 in order to improve the duc-
tility of RPC. The strength (compression and flexure) of
mixture F12S18 are also shown in Table 5. Compared
with the reference mixture (SF15), whose cement content
is 85% or 850 kg/m3, the incorporation of SS and UFFA
in RPC with the same steel fiber ratio has no significant
strength loss: the compressive and flexural strength of
those specimens achieves 188.3 MPa and 32.8 MPa re-
spectively.
The results mentioned above indicate that using
UFFA and/or SS in RPC is feasible and the mechanical
performance is impressive. Furthermore, the amount of
cement can be decreased markedly which also decreases
the heat of hydration, shrinkage and production costs
with the incorporation of SS and UFFA in RPC.
 Journal of Wuhan University of Technology-Mater. Sci. Ed. Apr.2010 353

Fig.3 Effect of SS/UFA ratio on compressive strength

Table 5 Mixing proportions and strength of RPCs

Strengthb/MPa
No. C UFFA SS SF Sand Watera SP Steel fibers /%
flexure compression
SF15 0.85 — — 0.15 1.1 0.16 0.06 2
34.7 201.4
F12S18 0.55 0.12 0.18 32.8 188.3
a: Including water from SP; b: Specimens were cured in 90 ℃ water for 3 days when testing
3.3 Microstructure and hydration of RPC Analysis on thermogravimetric results of cement
containing SS and UFFA sample is discussed in details in the Refs.[12,13] and is
The microstructure of mixture F12S18 (without only briefly described herein. We have considered that
sand) is shown in Fig.4. It can be seen from Fig.4 that the ℃
the weight loss between 20 and the temperature of the
hardened paste contains some spherical pores and unhy-
drated powder particles in sample a (age 1 d). In ＝ first DTG (Derivative thermogravimetric curve) peak
was due to loss of free water (Wf) in hydrates. For tem-
addtion, the surface of UFFA particles is smooth and has
peratures higher than that of the first DTG peak, water
no obvious signs of pozzolanic reaction (Fig.4(a)). When
losses are due to dehydration of C-S-H gel (weight loss
specimens were cured in T90 for 24 h after demolding, ie,
＝
sample b (T90-1 d, age 2 d), the hydration activity of
Wb) and dehydroxylation of portlandite. The DTG peak
℃ ℃
＋ ＋ ＋
composite system (C SF SS UFFA) improved and
between 420 and 500 was identified as dehy-
droxylation of portlandite (weight loss LCH). The DTG
hydration products accumulating in the surface of fly ash
particles are observed (Fig.4(b)). With the increase of peak between 650 ℃ and 750 ℃
was attributed to de-
＝
curing duration (T90-3, age 4 d), the composite system carbonation of calcite (weight loss LCalcite)[12,13]. For each
continued to hydrate, moreover, the amount of hydration sample, the relationship among the total water content
product Ca(OH)2 diminished due to the pozzolanic reac- (WT), the total weight loss (LT), Wf, bound water content
tion of composite system. As a result, more C-S-H gel Wb, LCH, and LCalcite was formulated as Equations (1) and
came into being, which improved the microstructure of (2). Furthermore, the total portlandite content of each
the cement paste (Fig.4(c)). sample (PT) is evaluated as Equation (3) ：
Samples (mixture F12S18) with varied curing du- ＋ ＋ ＝
WT LCH LCalcite LT (1)
℃
rations (temperature 90 , duration 0, 1 d and 3 d) were ＝ － Wb WT Wf (2)
analyzed by thermogravimetry. The thermogravimetric ＝ ＋
PT LCH×74/18 LCalcite×74/44 (3)
curves of those samples are given in Fig.5.

Fig.4 SEM images of mixture F12S18 at different ages

354 Vol.25 No.2 PENG Yanzhou et al: Preparation of Reactive Powder C…
Table 6 Thermogravimetric analysis results of samples with varied curing duration /%
No. Wf LCH LCalcite
a (age=1d) 0.91 0.47 1.64
b (T90-1d,age=2d) 1.69 0 0.59
c (T90-3d,age=4d) 1.91 0 0.41
The thermogravimetric analysis results of those 3
samples are given in Table 6. As given by Table 6, long
heat treatment durations lead to a higher bound-water/
total water percentage. At age of 1 d (ie, without heat
treatment durations), the bound-water percentage is
35.6% while that reaches 59.8% when the duration is 3d.
It is generally considered that, to a certain extent, the
bound-water content reflects the relative amount of hy-
dration product (C-S-H gel) in paste. The increase of
bound-water content demonstrates that more hydration
product forms in cement paste, which definitely improves
the microstructure and mechanical properties of concrete.
In addition, the total portlandite content, PT, decreased
with the heat treatment duration. For durations longer
than, or equal to 1d, the content of portlandite remained
in concrete is less than 1%. This was mainly attributed to
the sequential hydration of the compound cementitious
system containing SF, SS and UFFA. The sequential hy-
dration of the compound system continuously consumed
portlandite produced by hydration of cement and more hy-
dration products (C-S-H gel) were formed. Furthermore,
unhydrated powder particles almost evenly filled in cement
paste and enhanced the microstructure of the paste[13]. Thus
the microstructure of compound system became increas-
ingly compact (Fig.4), which brought about excellent me-
chanical properties of concrete.
4 Conclusions
a) Test results indicate that reactive powder concrete
containing high volume binary (SF+UFFA or SF+SS) or
ternary (SF+UFFA+SS) blends have no significant me-
chanical performance loss. In other words, utilization of
UFFA and/or SS in RPC production is feasible and
UFFA and SS can be used as alternative silica sources.
b) Both the SS or UFFA content and the content ra-
tio of SS-to-UFFA have an effect on strength of RPC.
There is an optimum SS/UFFA ratio giving maximum
strength for each mixture and the optimum ratio is 1.5 in
this study. The compressive and flexural strength of RPC
℃
specimens cured in 90 water for 3 days, whose content of
SS, UFFA and SF is 18%, 12% and 15% respectively by
weight of binder and ratio of steel fiber is 2% by volume,
are impressive, 188.4 MPa and 32 MPa respectively.
c) The microstructure analysis demonstrated that the
excellent mechanical properties of RPC containing SS
and UFFA mainly resulted from the sequential hydration
Wb/total water
LT Wb PT
percentage
7.88 4.86 35.6 4.69
9.71 7.43 54.4 0.99
10.48 8.16 59.8 0.68
filling effect of the compound system.
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