REACTIVE POWDER REACTIVE POWDER CONCRETECONCRETE

A DEVELOPING ULTRA HIGH A DEVELOPING ULTRA HIGH STRENGTH CONCRETESTRENGTH CONCRETE

ByByDivakar.YDivakar.Y

I Sem M.Tech (Structural Engg)I Sem M.Tech (Structural Engg)Dept of Civil EnggDept of Civil Engg

BIT,BangaloreBIT,Bangalore

Under The Guidance of:

Prof. K.JAYARAMProf. & HeadDepartment of Civil Engineering

INTRODUCTIONINTRODUCTION

Concrete of today is a versatile Concrete of today is a versatile material. material.

But there is a quest amongst But there is a quest amongst concrete engineers for a still higher concrete engineers for a still higher strength, higher performance and strength, higher performance and higher durability concrete. higher durability concrete.

DEFINITIONS…DEFINITIONS…Up to 1975 Ordinary concrete -M15 to M25Up to 1975 Ordinary concrete -M15 to M25

High strength concrete -M30 to M45 High strength concrete -M30 to M45

Up to 1990 Ordinary concrete -M15 to M45Up to 1990 Ordinary concrete -M15 to M45 High strength concrete -M50 to M75High strength concrete -M50 to M75

Since 2000Since 2000 Ordinary concrete -M20 to Ordinary concrete -M20 to M60M60

High strength concrete -M70 to M120High strength concrete -M70 to M120

Today 2006Today 2006 Ordinary concrete -M20 to M60 Ordinary concrete -M20 to M60 High strength concrete -M70 to M120 High strength concrete -M70 to M120 Ultra High strength concreteUltra High strength concrete

in field -M120 to M250 in field -M120 to M250 in Laboratory -M120 to M810in Laboratory -M120 to M810

INTRODUCTIONINTRODUCTION REACTIVE POWDER CONCRETEREACTIVE POWDER CONCRETE

A DEVELOPING ULTRA HIGH STRENGTH CONCRETEA DEVELOPING ULTRA HIGH STRENGTH CONCRETE

RPC with trade name ‘DUCTAL’ was RPC with trade name ‘DUCTAL’ was developed in France in the early 1990s developed in France in the early 1990s

The concept of RPC was first developed by The concept of RPC was first developed by Mr.Richard and Mr.Cheyrezy at Bouygues, Mr.Richard and Mr.Cheyrezy at Bouygues, laboratory in France laboratory in France

The world’s first RPC structure, the The world’s first RPC structure, the Sherbrooke Bridge in Canada, was Sherbrooke Bridge in Canada, was constructed in July 1997 constructed in July 1997

COMPOSITION OF RPCCOMPOSITION OF RPC

Cement Cement 1 -100micron1 -100micron Sand Sand 150-600 micron150-600 micron Quartz powder Quartz powder 5-25micron5-25micron Silica fume Silica fume 0.1-1micron0.1-1micron Steel fibres (optimal) Steel fibres (optimal) L-3 to25mm; D-0.15 to L-3 to25mm; D-0.15 to

0.2mm0.2mm Superplasticizer Superplasticizer Steel aggregates Steel aggregates <800micron<800micron

WaterWater No Course aggregatesNo Course aggregates ! !

Principles for Developing RPCPrinciples for Developing RPC

Richard and Cheyrezy indicate the Richard and Cheyrezy indicate the following principles for developing following principles for developing RPC.RPC.

Enhancement homogeneity by elimination of Enhancement homogeneity by elimination of coarser aggregates.coarser aggregates.

Enhancement of compacted density by Enhancement of compacted density by Optimization of the granular mixture.Optimization of the granular mixture.

Enhancement of the microstructure by post-set Enhancement of the microstructure by post-set heat-treatment. heat-treatment.

Contd..Contd..

Enhancement of ductility by addition of Enhancement of ductility by addition of small-sized steel fibres.small-sized steel fibres.

Application of pressure before and during Application of pressure before and during setting to improve compaction setting to improve compaction

Utilization of the pozzolanic properties of Utilization of the pozzolanic properties of silica fumesilica fume

The optimal usage of super plasticizer to The optimal usage of super plasticizer to reduce w/b and improve workabilityreduce w/b and improve workability

MECHANICAL PERFORMANCE AND MECHANICAL PERFORMANCE AND DURABILITY OF RPCDURABILITY OF RPC

The RPC family includes two types of concreteThe RPC family includes two types of concreteRPC 200 & RPC 800RPC 200 & RPC 800

ComparisonComparison BY Mr.Richard and Mr.CheyrezyBY Mr.Richard and Mr.Cheyrezy

RPC 200RPC 200 RPC 800RPC 800

Compressive strength(using Quartz sand ) Compressive strength(using Quartz sand ) MPaMPa

170-230170-230 490-680490-680

Compressive strength(using Steel Compressive strength(using Steel aggregate ) MPaaggregate ) MPa

-------------- 650-810650-810

Flexural strength MPaFlexural strength MPa 30-6030-60 45-14145-141

Heat-Treating in deg.centigradeHeat-Treating in deg.centigrade 20-9020-90 250-400250-400

Comparison of HPC (80 MPa) and Comparison of HPC (80 MPa) and RPC 200RPC 200

by Bickley J.A and Mitchell Dby Bickley J.A and Mitchell D

HPC HPC (80MPa)(80MPa)

RPC RPC 200200

Compressive strength MPaCompressive strength MPa 8080 200200

Flexural strength MPaFlexural strength MPa 77 4040

Modulus of elasticity GPaModulus of elasticity GPa 40 40 6060

Fracture toughness J/mFracture toughness J/m22 <10<1033 30x1030x1033

Durability of RPC compared to HPCDurability of RPC compared to HPC

Abrasive wearAbrasive wear 2.5 times lower2.5 times lower

Water absorptionWater absorption 7 times lower7 times lower

Rate of corrosionRate of corrosion 8 times lower8 times lower

Chloride ions diffusionChloride ions diffusion 25 times lower25 times lower

by Bickley J.A and Mitchell D

Oxide composition of Cementations Materials (Concrete Technology by M.L.Ghambir page 36)

Oxide Oxide Composition, Composition, % by Weight% by Weight

Portland Portland Cement Cement

Silica Silica FumeFume

Fly AshFly Ash Blast Furnace Blast Furnace SlagSlag

CaOCaOSiO2SiO2AL2O3AL2O3Fe2 O3Fe2 O3MgOMgOSO3SO3Na2ONa2OK2OK2O

63.063.020.020.0 6.36.3 3.63.6 2.42.4 1.51.5 0.150.15 0.50.5

4.154.15 93.093.0 0.20.2 0.050.05 0.510.51 0.050.05 0.20.2 0.220.22

2.52.552.552.528.228.210.510.5 1.61.6 0.20.2 0.040.04 0.90.9

42.442.4 32.332.3 13.313.3 0.30.3 6.46.4 2.12.1 -- --

Mixture proportions of RPC and HPCMixture proportions of RPC and HPC((Based on lab exp conducted by Mr.Dili and Mr.Santhanam)Based on lab exp conducted by Mr.Dili and Mr.Santhanam)

MaterialsMaterials Mixture proportionsMixture proportions

RPC RPC RPC-FibreRPC-Fibre HPCHPC HPC- FibreHPC- Fibre

CementCement 1.001.00 1.001.00 1.001.00 1.001.00

Silica fumeSilica fume 0.250.25 0.250.25 0.120.12 0.120.12

Quartz powderQuartz powder 0.310.31 0.310.31 ------ ------

Standard sand grade 2Standard sand grade 2 1.091.09 1.091.09 ------ ------

Standard sand grade 3Standard sand grade 3 0.58 0.58 0.580.58 ------ ------

River sandRiver sand 2.402.40 2.402.40

20mm aggregate 20mm aggregate 1.401.40 1.401.40

10mm aggregate10mm aggregate 1.501.50 1.501.50

30mm steel fibre30mm steel fibre 0.200.20

36mm steel fibre36mm steel fibre 0.200.20

AdmixtureAdmixture 0.030.03 0.030.03 0.0230.023 0.0230.023

waterwater 0.250.25 0.250.25 0.40.4 0.40.4

RESULTSRESULTS ((Based on lab exp conducted by Mr.Dili and Mr.Santhanam)Based on lab exp conducted by Mr.Dili and Mr.Santhanam)

1.1.Fresh Concrete PropertiesFresh Concrete PropertiesRPCRPC

The workability of RPC is 120-140mm (ASTM C 109 ) The workability of RPC is 120-140mm (ASTM C 109 ) The density of fresh RPC 2500-2650 kg/m3The density of fresh RPC 2500-2650 kg/m3

HPCHPC The workability of HPC is 120-150 mm (ASTM C 231)The workability of HPC is 120-150 mm (ASTM C 231)

The density of fresh HPC 2500-2650 kg/m3 .The density of fresh HPC 2500-2650 kg/m3 .

2.Compressive Strength2.Compressive Strength ((Based on lab exp conducted by Mr.Dili and Mr.Santhanam)Based on lab exp conducted by Mr.Dili and Mr.Santhanam)

40

60

80

100

120

140

160

180

200

0 7 14 21 28

RPC-F Hot water curing

RPC-F Normal curing

RPC Hot water curing

RPC Normal curing

HPC Hot water curing

HPC Normal curing

Com

pre

ssiv

e S

tren

gth

Com

pre

ssiv

e S

tren

gth

Mpa

Mpa

Time daysCompressive Strength of RPC & HPC

3. Water absorption3. Water absorption

0

0.5

1

1.5

2

2.5

3

3.5

3 7 14 21 28

HPC-F Normal curing

HPC Normal curing

RPC-F Hot water curing

RPC-F Normal curing

RPC Hot water curing

RPC Normal curing

Wat

er a

bso

rpti

on p

erce

nt

Wat

er a

bso

rpti

on p

erce

nt

Time days

Water absorption of RPC &HPC

(Based on lab exp conducted by Mr.Dili and Mr.Santhanam)

4.Water permeability4.Water permeability ((Based on lab exp conducted by Mr.Dili and Mr.Santhanam)Based on lab exp conducted by Mr.Dili and Mr.Santhanam)

Surface water permeability of RPC and HPCType of concrete

Wat

er p

erm

eab

ilit

y, 0

.000

1mm

/sec

0

0.5

1

1.5

2

2.5

3

3.5

RPC Fibered RPC HPC Fibered HPC

14thday

28thday

5.Flexural strength (as per IS 516) at 5.Flexural strength (as per IS 516) at 28 days (MPa)28 days (MPa)

RPCRPC RPC-FibreRPC-Fibre HPCHPC HPC-HPC-FibreFibre

NCNC HWCHWC NCNC HWCHWC NCNC HWCHWC

1111 1212 1818 2222 88 1010

(Based on lab exp conducted by Mr.Dili and Mr.Santhanam)

BENEFITS OF RPCBENEFITS OF RPC RPC is a better alternative to HPCRPC is a better alternative to HPC

It has the potential to structurally compete It has the potential to structurally compete with steel. with steel.

Its superior strength combined with higher Its superior strength combined with higher shear capacity results in significant dead shear capacity results in significant dead load reduction and limitless structural load reduction and limitless structural member shape. member shape.

With its ductile tension failure mechanism, With its ductile tension failure mechanism, RPC can be used to resist all stresses except RPC can be used to resist all stresses except direct primary tensile stresses. This direct primary tensile stresses. This eliminates the need for supplemental shear eliminates the need for supplemental shear and other auxiliary reinforcing steel. and other auxiliary reinforcing steel.

Contd..Contd..

RPC improve seismic performance reduces RPC improve seismic performance reduces inertia loads with lighter members. inertia loads with lighter members. reduced cross sections of members provides reduced cross sections of members provides higher energy absorption. higher energy absorption.

Low and non-interconnected porosity reduces Low and non-interconnected porosity reduces mass transfer, making penetration of mass transfer, making penetration of liquid/gas or radioactive elements nearly non-liquid/gas or radioactive elements nearly non-existent.existent.

Cesium diffusion is non-existent and Tritium Cesium diffusion is non-existent and Tritium diffusion is 45 times lower than any diffusion is 45 times lower than any conventional containment materials.conventional containment materials.

STATUS & APPLICATIONS OF RPCSTATUS & APPLICATIONS OF RPC The firm HDR Engineering Inc. is responsible The firm HDR Engineering Inc. is responsible

for the development and promotion of RPC in for the development and promotion of RPC in North America.North America.

An application of RPC can be seen in the An application of RPC can be seen in the Pedestrian Bridge 197m span, 3.3m wide, Pedestrian Bridge 197m span, 3.3m wide, 3.0m deep, 30mm thick slab, in the city of 3.0m deep, 30mm thick slab, in the city of Sherbrooke, Quebec, Canada. Sherbrooke, Quebec, Canada.

Seonyu foot Bridge 120m span, 4.4m wide, Seonyu foot Bridge 120m span, 4.4m wide, 1.3m deep, 30mm thick slab, in Seoul, Korea 1.3m deep, 30mm thick slab, in Seoul, Korea

Sakata Mirai footbridge, in Japan.Sakata Mirai footbridge, in Japan.

Sewer , Culvert and pressure pipes in Army Sewer , Culvert and pressure pipes in Army engineer waterways experiment engineer waterways experiment station,Viksburg , MS.station,Viksburg , MS.

RPC has also been used for isolation and RPC has also been used for isolation and containment of nuclear waste of several containment of nuclear waste of several projects in Europe. projects in Europe.

This product was nominated for the 1999 This product was nominated for the 1999 Nova Awards from the Construction Nova Awards from the Construction Innovation Forum.Innovation Forum.

Contd..Contd..

LIMITATIONS OF RPCLIMITATIONS OF RPC

The least costly components of conventional The least costly components of conventional concrete are basically eliminated or replaced concrete are basically eliminated or replaced by more expensive elements.by more expensive elements.

The fine sand used in RPC becomes equivalent The fine sand used in RPC becomes equivalent to the coarse aggregate of conventional to the coarse aggregate of conventional concreteconcrete

The Portland cement plays the role of the fine The Portland cement plays the role of the fine aggregate and the silica fume that of the aggregate and the silica fume that of the cement of conventional concrete. cement of conventional concrete.

Contd..Contd..

The mineral component optimization alone The mineral component optimization alone results in a substantial increase in cost over results in a substantial increase in cost over and above that of conventional concrete (5 to and above that of conventional concrete (5 to 10 times higher than HPC) 10 times higher than HPC)

Applying pressure to mix and applying heat Applying pressure to mix and applying heat treatment in the field has got technological treatment in the field has got technological difficulties and cost.difficulties and cost.

RPC should be used in areas where weight RPC should be used in areas where weight savings can be realizedsavings can be realized

Since RPC is in its infancy, the long-term Since RPC is in its infancy, the long-term properties are not yet knownproperties are not yet known. .

A maximum compressive strength of 198 MPa A maximum compressive strength of 198 MPa was obtained by Mr.Dili and Mr.Santhanam. was obtained by Mr.Dili and Mr.Santhanam. This is in the RPC 200 range (175 MPa -225 This is in the RPC 200 range (175 MPa -225 MPa)MPa)

The maximum flexural strength of RPC The maximum flexural strength of RPC obtained was 22 MPa, by Mr.Dili and obtained was 22 MPa, by Mr.Dili and Mr.Santhanam is lower than the values quoted Mr.Santhanam is lower than the values quoted 40 MPa. A possible reason for this could be the 40 MPa. A possible reason for this could be the higher length and the diameter of fibre used in higher length and the diameter of fibre used in this study. this study.

A comparison of the measurements of the A comparison of the measurements of the physical, mechanical and durability properties physical, mechanical and durability properties of RPC and HPC shows that RPC has better of RPC and HPC shows that RPC has better strength (both compressive and flexural) and strength (both compressive and flexural) and lower permeability compared to HPClower permeability compared to HPC

DISCUSSIONS

The extremely low levels of water and chloride ion The extremely low levels of water and chloride ion permeability indicate the potential of RPC as a good permeability indicate the potential of RPC as a good material for storage of nuclear waste.material for storage of nuclear waste.

The elimination of reinforcement, reduction of The elimination of reinforcement, reduction of permanent loads of structure and reduction of permanent loads of structure and reduction of concrete quantities, generate major cost savings concrete quantities, generate major cost savings

RPC needs to be studied with respect to its resistance RPC needs to be studied with respect to its resistance

to other toxic wastes emanating from nuclear plants to other toxic wastes emanating from nuclear plants (such as Cesium 137 ion in alkaline medium ) to (such as Cesium 137 ion in alkaline medium ) to qualify for use in nuclear waste containment qualify for use in nuclear waste containment structures.structures.

Contd..

A comparative workout A comparative workout

Section Section parametersparameters

RPC X-ShapedRPC X-Shaped SteelSteel PSCPSC RCCRCC

Section depthSection depth 360 mm 360 mm 360 mm360 mm 700 700 mmmm

700 mm700 mm

WeightWeight 130 kg130 kg 110 kg110 kg 470 kg470 kg 530kg530kg

A comparison of beam cross sections of equal moment capacity A comparison of beam cross sections of equal moment capacity

Flexural Strength or Fracture Flexural Strength or Fracture Energy?Energy?

Flexural Strength or Fracture Flexural Strength or Fracture Energy?Energy?

Impact ResistanceImpact Resistance– Drop Hammer Test -– Drop Hammer Test -

Impact resistance of:Impact resistance of:Reactive Powder Concrete (RPC)Reactive Powder Concrete (RPC)

Impact resistance of:Impact resistance of:Reactive Powder Concrete (RPC)Reactive Powder Concrete (RPC)

Impact resistance of:Impact resistance of:Reactive Powder Concrete (RPC)Reactive Powder Concrete (RPC)

Impact resistance of:Impact resistance of:Reactive Powder Concrete (RPC)Reactive Powder Concrete (RPC)

Impact resistance of:Impact resistance of:Reactive Powder Concrete (RPC)Reactive Powder Concrete (RPC)

Concrete paving

Protect the Palace of Westminster from terror attacks .

Pedestrian Bridge,Pedestrian Bridge,Sherbrooke, CanadaSherbrooke, Canada

Pedestrian Bridge,Pedestrian Bridge,Sherbrooke, CanadaSherbrooke, Canada

Pedestrian Bridge,Pedestrian Bridge,Sherbrooke, Canada.Sherbrooke, Canada.

Half-canopy in steel form of Half-canopy in steel form of Shawnessy Shawnessy

Light Rail Transit Station, Calgary, CanadaLight Rail Transit Station, Calgary, Canada

Canopies ready for transportation. Canopies ready for transportation.

Shawnessy Light Rail Transit Shawnessy Light Rail Transit Station, Calgary, CanadaStation, Calgary, Canada

CONCLUSIONSCONCLUSIONS RPC is an emerging technology that lends a new RPC is an emerging technology that lends a new

dimension to the term “high performance concrete”.dimension to the term “high performance concrete”. It has immense potential in construction due to It has immense potential in construction due to

superior mechanical and durability properties than superior mechanical and durability properties than conventional high performance concrete, and could even conventional high performance concrete, and could even replace steel in some applications. replace steel in some applications.

The development of RPC is based on the application of The development of RPC is based on the application of some basic principles to achieve enhanced homogeneity, some basic principles to achieve enhanced homogeneity, very good workability, high compaction, improved very good workability, high compaction, improved microstructure and high ductility. microstructure and high ductility.

RPC has an ultra-dense microstructure, giving RPC has an ultra-dense microstructure, giving advantageous waterproofing and durability advantageous waterproofing and durability characteristics. characteristics.

It could, therefore be a suitable choice for industrial It could, therefore be a suitable choice for industrial and nuclear waste storage facilities and many other and nuclear waste storage facilities and many other applications.applications.

THANK YOUTHANK YOU