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UHPC BUILDING ENCLOSURES

ULTRA-HIGH PERFORMANCE CONCRETE


AS INNOVATIVE BUILDING ENCLOSURE
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AGENDA

UHPC as Innovative Building Enclosure


 UHPC- Introduction
 Reasons to use UHPC
 UHPC Case Studies
• Liberty Park World Trade Center, New York
• Emerson College Little Building, Boston
• Boston University Theater Center, Boston
• Central Bank Iraq, Bagdad
• Others
 Summary of Lessons learnt
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UHPC - ULTRA HIGH PERFORMANCE CONCRETE
Beams of Equal Load Bearing Capacity

UHPC

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DEFINITION OF UHPC

Class 28 days
compressive strength
Regular concrete 2 300 to 6 500 PSI
High Performance Concrete (HPC) 6 500 to 9 500 PSI
Very High Performance Concrete (VHPC) 9 500 to 16 000 PSI
Ultra High Performance Concrete (UHPC 16 000 to 30 000 PSI

UHPC are materials with cement Matrix and characteristic


compressive strength in excess of 16 000 PSI,
possibly attaining 30 000 PSI, containing fibers or mesh in order to
achieve ductile behavior under tension.

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ORIGINATION OF UHPC
Modern history of concrete, considering it as a mix of cement, gravel, sand and water, began in the
1800 early 19th century with the development of Portland cement which has the ability to bind all of
them together in the presence of water

Combination of iron rods with concrete in the mid-19th allowed the development of ‘reinforced
1860 concrete’, the construction material par excellence in the 20th century

Fiber-reinforced concrete (FRC) technology started being developed in the 1970s, with a huge
1970s increase in both the matrix performance and durability

The term High-Performance Concrete (HPC) was coined in the 1980s to refer to a concrete with a
1980s compressive strength between 6700 and 14500 MPa and with improved durability properties

The term Ultra-High-Performance Concrete (UHPC) was coined in 1994, referring to an optimized
1994 particle-packing material with an increase in both compressive strength (above 160 MPa) and
durability

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UHPC CHARACTERISTICS
Ultra High Performance Concrete (UHPC)
1. Ductility. Exceptional ductility. Behaves more like steel than concrete. Blast proof.

2. Strength. Exceptional strength and impact resistance. 25,000 PSI compression.

3. Durability. Low maintenance. Resistance to abrasion carbonation, freeze thaw.

4. Finish. Thin structure surface, homogeneity. Reads any pattern in formwork.


5. Watertight. Lowest porosity of any mineral material. Compact cementitious matrix.
6. Lightweight. Enormous weight savings. Positive impact on schedule and environment.
7. Moldability. New Shapes and geometries are possible. Even perforations.
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UHPC CHARACTERISTICS
1. DUCTILITY

Micro- Cracking

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UHPC CHARACTERISTICS
2. STRENGTH

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UHPC CHARACTERISTICS
3. DURABILITY
Low porosity
Exceptional Durability
Conventional Concrete
(3000 psi)
UHPC has one of the lowest
porosities of any mineral
material
High Performance Concrete
(6700 psi) • Resistance to abrasion,
• Carbonation,
• Chloride ion penetration,
UHPC (16000 psi)
• Freeze thaw phenomena

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UHPC CHARACTERISTICS

UHPC vs GFRC
UHPC GFRC
Traditional concrete formula
Granulate size < 600 µm
Cement Matrix Granular size = 2.4mm
diameter average
diameter average
Metallic /Polyvinyl Alcohol
Fibers Glass fibers
Fibers
Water/Cement Ratio 0,24 to 0,26 0,3 to 0,5

Porosity 1,5 to 6% Around 15%

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UHPC CHARACTERISTICS
4. FINISH
 Very homogeneous quality surfaces.

 Very fine cementitious matrix allowing to


replicate all mold asperities and textures
-small and big scale-

 Very fine particles help fluidity.

 Mass pigmentation can be added.


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UHPC CHARACTERISTICS
5. WATERTIGHTNESS
100% Watertight

UHPC is Waterproof
Granular packing work. Closed porosity Connected porosity

Very low porosity. Less than 2%


of non connected porosity.

UHPC has very few added water


compared to cement. W/C = 0,15
to 0,30.
UHPC Containment channels UHPC Containment tanks
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UHPC CHARACTERISTICS
6. LIGHTWEIGHT
Ultra-Thin UHPC Panels and Elements

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UHPC CHARACTERISTICS
7. MOLDABILITY
Horizontal mold

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UHPC CHARACTERISTICS
7. MOLDABILITY

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UHPC CHARACTERISTICS

Reinforced Fiber-reinforced Fiber-reinforced Mesh-reinforced


Concrete Concrete FRC UHPC UHPC
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UHPC CHARACTERISTICS

Fiber-Reinforced UHPC

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UHPC CHARACTERISTICS
UHPC Mixing

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UHPC CHARACTERISTICS

Mesh-Reinforced UHPC

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UHPC CHARACTERISTICS
Blast and Ballistic Resistance

Mesh-Reinforced UHPC Mesh-Reinforced UHPC


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UHPC CHARACTERISTICS
Blast and Ballistic Resistance

100.000

10.000

Normalized pressure [-]


1.000

0.100

0.010
0.010 0.100 1.000 10.000 100.000
Normalized impulse [-]

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UHPC PRECAST PLACEMENT

MONOLITHIC UHPC STAIR

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UHPC PRECAST PLACEMENT

MONOLITHIC UHPC PORTAL

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UHPC ARCHITECTURAL FINISHES

Marble Aggregate on face White cement and aggregate

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UHPC ARCHITECTURAL FINISHES

GREY COLOR RANGE

White Pigment White Pigment Standard Black Pigment Black Pigment


5% 3% Grey 3% 5%

NON-STANDARD SURFACE FINISHES & TEXTURES

Polished Line Textured Cerated Stamped Anti-Slip Anti –Slip 2

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UHPC ARCHITECTURAL FINISHES

Acid edged finish Washed finish

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UHPC ARCHITECTURAL FINISHES
Painted finish

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REASONS TO USE UHPC

Reasons to use UHPC instead of Precast or GRC/GFRC


• Lightweight • Finish (finer, denser, smoother)
• Superstructure weight limitations (Age, design • Geometry (Complicated shapes,
or error) perforations, slender elements)
• Seismic (Less weight on structure) • Durability (maintenance free)
• Thinner panels • Watertightness (Vapor barrier)
• Floor space gains (40-60 mm vs 150-200 mm) • Sacrificial formwork
• More space for insulation, fireproofing or solar • Dynamic Loading (Blast, Ballistics)
• Longer panel span (floor to floor - fewer panels) • Sustainability – Improved carbon footprint
• Construction time acceleration (less crane time) • Combinable with natural stone, terracotta
• Lower Construction Cost (No 2ndary supports) and brick – structural backer

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UHPC CASE STUDIES - Weight Restriction
WORLD TRADE CENTER LIBERTY PARK

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UHPC CASE STUDIES - Weight Restriction
WORLD TRADE CENTER LIBERTY PARK
2” UHPC Planter Element (top)
Cantilevered UHPC Planters

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UHPC CASE STUDIES – Weight Restriction

WORLD TRADE CENTER LIBERTY PARK


Cantilevered UHPC Planters

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UHPC CASE STUDIES – Weight Restriction
WORLD TRADE CENTER LIBERTY PARK
Cantilevered UHPC Planters

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UHPC CASE STUDIES – Weight Restriction
WORLD TRADE CENTER LIBERTY PARK

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UHPC CASE STUDIES – Weight Restriction
WORLD TRADE CENTER LIBERTY PARK

UHPC Panel 15 feet long 1 ¼ inch thick

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UHPC CASE STUDIES - Larger Span / No secondary support
UHPC FAÇADE PANELS
SHOPPING CENTER GERMANY 8 ft x 4 ft x 1 inch Granite look

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UHPC CASE STUDIES - Larger Span / No secondary support
UHPC FAÇADE PANELS
8 ft x 4 ft x 1 inch Granite look

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UHPC CASE STUDIES - Larger Span / No secondary support

UHPC FAÇADE PANELS


SHOPPING CENTER GERMANY 8 ft x 4 ft x 1 inch Granite like speckle

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UHPC CASE STUDIES – Complicated Geometry

UHPC LATTICE SYSTEM


Boston University Theater Center

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UHPC CASE STUDIES – Complicated Geometry

Making the rubber molds

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UHPC CASE STUDIES – Complicated Geometry
UHPC LATTICE SYSTEM

Sandblasted finish

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UHPC CASE STUDIES - Load deficient aged steel structure

EMERSON COLLEGE, LITTLE BUILDING, BOSTON

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UHPC CASE STUDIES - Load deficient aged steel structure

HEAVY HISTORIC DIMENSIONAL STONE FACADE

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UHPC CASE STUDIES - Load deficient aged steel structure

THE SOLUTION:

UHPC Historical
Façade Replica

Façade Reshaping
following 3D Scan
of Historic Stone
Facade

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UHPC CASE STUDIES - Load deficient aged steel structure

UHPC Historical Façade Replica

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UHPC CASE STUDIES - Load deficient aged steel structure

UHPC Historical Façade Replica

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UHPC CASE STUDIES - Load deficient aged steel structure
UHPC Historical Façade Replica

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UHPC CASE STUDIES - Load deficient aged steel structure

UHPC Historical Façade Replica

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UHPC CASE STUDIES - Load deficient aged steel structure

UHPC Historical Façade Replica

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UHPC CASE STUDIES - Load deficient aged steel structure

UHPC Historical Façade Replica

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UHPC CASE STUDIES - Load deficient aged steel structure
UHPC Historical Façade Replica

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UHPC CASE STUDIES - Load deficient aged steel structure
UHPC Historical Façade Replica

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UHPC CASE STUDIES – Blast resistance / High Ductility

CENTRAL BANK IRAQ

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UHPC CASE STUDIES – Blast resistance / High Ductility

CENTRAL BANK IRAQ

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UHPC CASE STUDIES – Blast resistance / High Ductility
CENTRAL BANK IRAQ

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UHPC CASE STUDIES – Blast resistance / High Ductility

CENTRAL BANK IRAQ

ATFP / BLAST REQUIREMENT

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UHPC CASE STUDIES – Blast resistance / High Ductility

CENTRAL BANK IRAQ

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UHPC CASE STUDIES – Blast resistance / High Ductility

CENTRAL BANK IRAQ

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UHPC CASE STUDIES - Capillary System for energy harvesting
UHPC ENERGY HARVESTING FACADE & ROOF
using capillary mat system

15W/sf ~ 22,000 W total output

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UHPC CASE STUDIES – Capillary System for energy harvesting

Panel thickness = 2 ¼ inch

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UHPC CASE STUDIES - Capillary Sytem for energy harvesting
UHPC ENERGY
ETA-Fabrik, HARVESTING
University Darmstadt FACADE
2015 & ROOF

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UHPC CASE STUDIES - Capillary System for energy harvesting
UHPC ENERGY HARVESTING FACADE & ROOF

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UHPC CASE STUDIES - Capillary System for energy harvesting
UHPC ENERGY HARVESTING FACADE & ROOF

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UHPC CASE STUDIES – Capillary System for energy harvesting

UHPC ENERGY HARVESTING FACADE & ROOF

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UHPC CASE STUDIES – Capillary System for energy harvesting
UHPC ENERGY HARVESTING FACADE & ROOF

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UHPC CASE STUDIES – Under designed steel structure
UHPC BRICK VENEER FACADE
Manchester New Square

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UHPC CASE STUDIES – Underdesigned steel structure
UHPC BRICK VENEER FACADE

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UHPC CASE STUDIES – THIN & LIGHTWEIGHT

GRC BRICK FAÇADE - Limited in length and needs secondary support

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UHPC CASE STUDIES – THIN & LIGHTWEIGHT
UHPC BRICK VENEER including /excluding insulation

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MASTERING
CHALLENGING
CURTAIN WALLS
& FACADES

FACADES
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