Ultra-High Performance Concrete - From Fundamental To Applications - ScienceDirect

11/03/2020 Ultra-high performance concrete: From fundamental to applications - ScienceDirect
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Case Studies in Construction Materials

Volume 9, December 2018, e00197
Case study
Ultra-high performance concrete: From fundamental to applications

N.M. Azmee , N. Shafiq
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Abstract
Over the last twenty years, remarkable advances have taken place in the research and application of ultra-high performance concrete (UHPC),
which exhibits excellent rheological behaviors that include workability, self-placing and self-densifying properties, improved in mechanical
and durability performance with very high compressive strength, and non-brittleness behavior. It is the ‘future’ material with the potential to
be a viable solution for improving the sustainability of buildings and other infrastructure components. This paper will give an overview of
UHPC focusing on its fundamental introduction, design, applications and challenges. After several decades of development, a wide range of
commercial UHPC formulations have been developed worldwide to cover an increasing number of applications and the rising demand of
quality construction materials. UHPC has several advantages over conventional concrete but the use of it is limited due to the high cost and
limited design codes. This paper also aims to help designers, engineers, architects, and infrastructure owners to expand the awareness of
UHPC for better acceptance.
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Keywords
Ultra-high performance concrete; Fundamental; Application; Challenge
1. Introduction
UHPC is an advanced cementitious material with high strength and excellent durability. It offers the potential to become a practical solution
to improve the sustainability of buildings and other infrastructure components [1]. For the past two decades, UHPC is gaining increased
interest in many countries with the usage ranging from building components, bridges, architectural features, repair and rehabilitation,
vertical components such as windmills towers and utilities towers to oil and gas industry applications, off-shore structures, hydraulic
structures and overlay materials [2]. Among all these applications, road and bridge constructions are the most popular for UHPC application
[3]. The usage of UHPC for bridges and bridge components can been seen in various countries including Australia, Austria, Canada, China,
Czech Republic, France, Germany, Italy, Japan, Malaysia, Netherlands, New Zealand, Slovenia, South Korea, Switzerland and the United States
(US) [2]. Most projects in the mentioned countries have been motivated by government agencies as initial demonstration projects intended to
encourage further implementation. However, for most of the countries, these demonstration projects did not create the anticipated
acceptance with slow follow-up implementation [4]. It appears that the lack of design codes, limited knowledge on both the material and
production technology, and high costs limit the implementation of this outstanding material beyond the initial demonstration projects [2].
Both private and governmental bodies are now increasing their attention and pushing for more efforts towards utilizing this innovative and
promising material.
The German Research Foundation initiated a €12 million (USD$15 million) research program back in 2005, which involved 34 research
projects at more than 20 local research institutes [5]. The main objective of this program was to expand the awareness of UHPC to make it a
reliable, commonly available, economically feasible, and regularly applied material. Major research initiative on UHPC can also be seen in
South Korea. In 2007, Korean Institute of Construction Technology funded an USD$11 million Super 200 program to study the use of UHPC
in cable-stayed bridges [6]. Introduction of UHPC in Malaysia started back in 2006 by Dura Technology (DURA) with its first bridge
application in 2010. During several years of intensive research and development, DURA together with The Malaysia Public Work Department
https://www.sciencedirect.com/science/article/pii/S2214509518301360 1/23
collaborated in designing and building UHPC bridges focusing on rural area [4]. After its inception, DURA has dominated the UHPC market
in Malaysia. From 2010 until now, a Outline Download
total of 90 UHPC Share
bridges have Export with over 20 in construction stages [2].
been completed
Successful achievements on the application of UHPC can be seen throughout the world. However, there are still barriers limiting its
applications. Ongoing research and investigation efforts are filling up knowledge gaps in order to commence innovative, affordable,
sustainable, feasible and economical UHPC in the future, as it will be a great impact on increasing its acceptance. In this paper, general
introduction on UHPC is provided with the latest information on its definition, development, applications and challenges.
2. Definition and development of UHPC
2.1. Definition of UHPC

UHPC is a relatively new generation of cementitious material with very high strength, ductility and durability [7]. Fig. 1 shows that, UHPC
strengthened with fiber can be treated as a combination of three concrete technologies of self-compacting concrete (SCC), fiber reinforced
concrete (FRC) and high-performance concrete (HPC) [8]. French interim recommendations (AFGC 2002) [9] defined UHPC as a concrete with
a characteristic compressive strength of at least 150 MPa with the use of steel fiber reinforcement to ensure ductile behavior under tension.
UHPCs with compressive strength of 130 MPa – 150 MPa strengthened with either steel or other fibers are considered as lower strength
UHPC [9]. Normally, the term UHPC is used to describe a fiber reinforced, superplasticized, silica fume-cement mixture with a very low water
to cement ratio (W/C), characterized by the presence of a very fine quartz sand that ranges from 0.15–0.60 mm in diameter, instead of the
ordinary aggregate.
Download : Download high-res image (66KB) Download : Download full-size image
Fig. 1. Different types of special concrete [8].
In fact, some researchers have suggested that UHPC is not a concrete, due to the absence of coarse aggregate in the mixture [10,11]. However,
the term ‘concrete’ is selected rather than ‘mortar’ to describe UHPC added with fine steel fibers to enhance the ductility [[12], [13], [14]].
To date, there are several types of UHPC that have been developed in different countries and by different manufacturers such as Ceracem®,
BSI®, compact reinforced composites (CRC), multi-scale cement composite (MSCC), and reactive powder concrete (RPC) [[15], [16], [17]]. In
Malaysia, UHPC started its industrial-commercial penetration as a sustainable construction material in late 2010 under the name Dura® [17].
2.2. Development of UHPC

Being the most popular manmade material in the world, concrete is the basic building material that will continue to be in demand far into
the future. It is estimated that the world concrete production is about 6 billion cubic meters per year with China currently consuming about
40% of the world’s concrete production [18,19]. Superior qualities of concrete such as strength and its durability, ability for it to be placed in
many forms, and its low price have made concrete to be considered as the most famous and important material in the construction industry.
Concrete is primarily used for its strong compressive strength [20]. Over the last decades, large progress has been taking place on the field of
concrete development. Intensive research efforts began in 1930s to improve concrete compressive strength. Fig. 2 shows the significant
concrete technology achievements for the last 40 years [21].
Fig. 2. The development of concrete compressive strength for over 100 years [21].
From the graph, it can be seen that the concrete technology progressed slowly during the 1960s with the maximum compressive strength of
15 MPa to 20 MPa. The concrete compressive strength tripled to 45 MPa to 60 MPa over a period of about 10 years. Concrete strength reaches
its plateau at about 60 MPa in early 1970s believed due to the technological barrier of the existing water reducer. The available water reducer
at that particular time failed to reduce the water to binder ratio (W/B) any further [13]. During 1980s, it is realized that the high-range water
reducers, called superplasticizers (SP), can be used to progressively reduce W/B down to 0.30. Reducing the W/B below this was considered a
taboo until Bache [22] reported that, with high dosage of SP and silica fume (SF), it was possible to reduce W/B to 0.16. Concrete compressive
strength of up to 280 MPa was achieved through compacted granular materials by optimizing the grain size distribution of the granular
skeleton. These resulted in the creation of a material with a minimum number of defects, such as micro cracks and interconnected pore
spaces, to achieve ultimate strength and durability enhancement.
These technological breakthroughs together with some fundamental knowledge on low-porous materials have led to the development of
ultra-high performance Portland cement-based materials that present remarkable mechanical properties [1,14,23]. In general, the
developments of UHPC are best described in four stages which are before 1980s, 1980s, 1990s, and after 2000.
Before 1980s; Due to the lack of advanced technology, producing UHPC is only limited in the lab and it required special methods such as
vacuum mixing and heat curing. At this time, researchers tried different kind of methods to achieve denser and more compact concrete to
improve its strength. It was reported that, with vacuum mixing together with a temperature curing, the compressive strength of concrete
could go up to 510 MPa [24]. Although high compressive strength of concrete can be achieved, the preparation was very difficult and energy-
consuming.
In the early 1980s; The micro defect free cement (MDF) was invented [25,26]. The MDF approach uses polymers to fill up the pores and to
remove all the defects in cement paste. This process requires specific manufacturing conditions, including laminating of the material by
passing it through rollers. MDF concrete can have compressive strength of 200 MPa. However, expensive raw material, complicated
preparation process, large creep, and brittleness had limit its applications [26]. After the invention of MDF, dense silica particle cement (DSP)
was prepared in Denmark by Bache [22]. Unlike MDF, the preparation of DSP does not require extreme manufacturing conditions. Improving
the particle packing density eliminated the defects in DSP. DSP concrete contains high amount of SP and SF, it also uses heat and pressure
curing. The maximum compressive strength of DSP can reach up to 345 MPa. However, despite the ultra-high strength increase, these
materials become more ‘brittle’. Steel fibers have been introduced in the 1980s to improve the brittleness issue of DSP concretes. This type of
steel fiber supplemented concrete can be considered as a relatively new material. It can be characterized by an extremely dense micro
structure, very high strength, superior durability, and high ductility. Two good examples are CRC and slurry infiltrated fiber concrete
(SIFCON), which occurred right after DSP. Both CRC and SIFCON exhibit excellent mechanical properties and durability. However, due to the
lack of effective SP, both CRC and SIFCON have workability issues, which hinder in-situ applications [26,27].
In 1990s; Richard et al. [7] used components with increased fineness and reactivity to develop RPC via thermal treatment. RPC is a major
milestone in the development of UHPC. Its concept was based on the placement of different particles in a very dense arrangement. RPC is the
most commonly available type of the UHPC used in laboratory and field experiments and it is characterized by high binder content, very high
cement content, very low W/C, use of silica fume (SF), fine quartz powder, quartz sand, SP and steel fibers [7,23,28]. These steel fibers are
generally 12.5 mm in length and 180 μm in diameter [7]. The coarse aggregates are eliminated for homogeneity enhancement of the matrix.
The compressive strength of RPC ranges from 200 MPa to 800 MPa. The typical composition and mechanical properties of the RPC as
suggested by Richard & Cheyrezy [7] are presented in Table 1. Unlike its predecessors, RPC shows very excellent workability. This workability
property is an advantage and the most essential requirement for large-scale applications of cement-based materials. In the late 1990s, the first
UHPC developed through RPC technology was commercialized under the name Ductal®. In 1997, the world’s first RPC structure as shown in
Fig. 3 was built for pedestrian bridge in Sherbrooke, Canada [1,12,[29], [30], [31]]. It was the first time that RPC had been used for building up
the whole structure. Despite the successful of RPC structures, the applications are still limited due to its expensive material and production
cost.
Table 1. Typical composition and mechanical properties of UHPC [7].


Constituent (kg/m3) RPC 200 RPC 800
Portland cement 955 1000
Fine sand (150–600 μm) 1051 500
Ground quartz (d50 = 10 μm) – 390
Silica fume 239 230
Superplastisizer (Polyacrylate) 15 19
Steel fibers 168 630
Total water 162 190
Compacting pressure – 50 MPa
Heat treatment 20 °C/90 °C 250 °C – 400 °C
Compressive strength (MPa) 170 – 230 490 – 680
Flexural strength (MPa) 25 - 60 45 - 102
Fig. 3. Sherbrooke pedestrian bridge in Canada [29].
From year 2000 onwards, much progress has been made on the development of UHPC. With further developments of the concrete
technology, engineers realized that the advanced concrete, besides the high strength, should also have other excellent properties, which led to
the term UHPC and UHPFRC [29]. A wide range of new concrete formulations has been developed to cover an increased number of
applications. At present, sustainable UHPC formulations are proposed by various researchers aimed to lower both its material and initial cost
[[32], [33], [34], [35], [36], [37], [38], [39], [40]]. Supplementary cementitious materials, such as fly ash (FA), ground granulated blast furnace slag
(GGBS), rice husk ash (RHA) and SF, are used for replacing part of cement in the effort of producing sustainable UHPC and reducing its
current cement usage. Furthermore, it is also reported that UHPC can be prepared with normal temperature curing without sacrificing its
properties. Because of the emergence of environmental friendly UHPC with relatively low cost, the applications of UHPC are gaining
interests. From the 2000s, several countries have engaged in various applications of UHPC. In France, a lot of structures such as bridges,
facades and slabs have been built with UHPC [41]. UHPC also has growing applications in maintenance and development of US highway
infrastructures [42]. In Australia, significant activities on UHPC development have been carried for bridge structures [43]. In Switzerland,
UHPC has been mostly applied to in-situ reinforcement of structures [44]. UHPC bridges have been built in the Netherlands and Spain [[45],
[46], [47]]. In Malaysia, UHPC has been used for bridge structures as an effort for sustainable bridge construction initiative. To date, a total
number of 113 UHPC bridges have been constructed or under construction in Malaysia since 2010 [4]. Fig. 4 shows one of the completed
UHPC bridges in Malaysia, located in Perak.
Fig. 4. Completed UHPC bridge in Malaysia [17,48].

3. UHPC principles and compositions
3.1. UHPC production principles

Over the past 15 years of concrete remarkable advances, many researchers have developed UHPC up to a level where they are ready for
applications. The compressive strength for designed UHPC could reach up to 200 MPa. The basic idea of producing a concrete with a very
high strength and dense microstructure had already been put forward in the 1980s [22]. However, the practical breakthrough came after the
development of efficient SP that enabled the production of easy flowing concrete with a high proportion of optimally packed ultrafine
particles to minimize the composite porosity using extremely low W/B.
Several researchers [1,7,21,35,34,37,49] have identified the basic principle in designing UHPC, which can be summarized as follows:
1 Minimizing composite porosity by optimizing the granular mixture through a wide distribution of powder size classes and reducing the
W/B.
2 Enhancement of the microstructure by the post set heat treatment to speed up the pozzolanic reaction of SF and to increase mechanical
properties.
3 Improvement of homogeneity by eliminating coarse aggregate resulting in a decrease in the mechanical effects of heterogeneity.
4 Increase in ductile behaviour by adding adequate volume fraction of small steel fibers.
Application of the first four principles leads to a concrete with a very high compressive strength and the addition of the steel fibers helps to
improve both tensile strength and ductility of the concrete [7].
3.2. UHPC mixture compositions

The key factor in producing UHPC is to improve the micro and macro properties of its mixture ingredients in order to ensure mechanical
homogeneity, maximum particle packing density and minimum size of flaws [1,23,50, [51], [52], [53]]. The selection of UHPC compositions
should not focus solely on the relative proportions of different grain sizes, but also on the appropriate selection of materials with proper
physical and chemical properties. Some commercially available UHPC mixtures are shown in Table 2. From the table, it can be observed that
high volume of cement content, SF, and sand are normally used in UHPC. The initial cost of UHPC far exceeds the conventional concrete
(CC), great efforts have been made on minimizing material cost without sacrificing the beneficial properties of UHPC.
Table 2. Compositions of commercial UHPC [26,54,55].
Materials (kg/m3) BCV® BSI® Cemtec®
Portland cement 1114 1050 712 911
Fine sand 2115 1072 514 1020 911
SF (Premix) 169 268 231 225
Ground quartz – – 211 –
Accelerator – – – 30 –
Steel fibers 156 234 858 156 173
SP 21.5 40 44 30.7 38
Water 159 211 180 109 200
4. Mixture design and standard
4.1. Mixture design for UHPC

Mixture design is a selection of raw materials in optimum proportions to provide concrete with required properties in fresh and hardened
state for particular applications. The design of UHPC aims to achieve a densely compacted cementitious matrix with good workability and
strength. However, complex material in hardened state of UHPC is anticipated due to its higher number of possible constituent
combinations. In recent years, several studies have been conducted aiming at optimizing the mixture proportion of UHPC [36,39,53,[56], [57],
[58], [59]].
Various models have been reported for the mixture design of UHPC. For instance, Larrad and Sedran [56] proposed a linear packing density
model (LPDM) for the mixture design of UHPC. However, this model was limited as it was unable to address the relationship between
materials proportions and packing density due to its linear nature. This model was later improved considering the virtual density theory
Outline
known as solid suspension model (SSM) [56]. This Download Sharethe production
new model allows Export of a fluid mortar with a 0.14 W/B and a compressive
strength of 236 MPa with a 4-day curing at 90 °C [56]. De Larrad and his team once again did further improvement on the latter model based
on the compaction index concept and virtual packing density. This third generation of packing models known as compressible packing
model (CPM) was proposed for UHPC design [60]. Richard & Cheyrezy [7] have successfully developed two UHPC products, namely RPC 200
and RPC 800 by optimizing the granular mixture using CPM.
Geisenhansluke and Schmidt [61] designed a locally produced UHPC mixture based on particle shape, size, and density. They reported that
utilizing multi-grained fine particles could lessen the cement content. In another study, Fennis et al. [57] developed an ecological UHPC
mixture based on particle packing technology. With the adopted approach, they reported a cement content reduction by more than 50%.
Lohas and Ramge [58] proposed a robust UHPC mixture based on SP water demand (SWD) approach for achieving desired workability
depending on the water to powder ratio.
Park et al. [62] developed an UHPC with a compressive strength of 180 MPa, by considering the effect of W/B, type, and replacement
proportion of filler. Wille et al. [53] presented an UHPC with a compressive strength exceeding 200 MPa, which was obtained through local
materials without any special type of mixer and heat treatment. Their design was based on the spread flow properties obtained from mini
slump measurement. It was found that the variation in spread results of UHPC mixtures caused the variation of air content. In order to
predict the compressive strength of UHPC, a statistical relationship was proposed by considering the combined effect of air voids and W/C.
Under the guidance of CPM density model, Gong [63] studied the dense packing effect of the gradation of mineral powders and found that
the filling effect became more prominent with the decrease of W/C. Yu et al. [39] developed an eco-friendly UHPC by using the modified
Andreasen & Andersen particle packing model (shown in Eq. (1)) to achieve a densely compacted cementitious matrix produced with a
relatively low binder dosage of about 650 kg/m3. In this study, they have successfully developed an UHPC with 28 days compressive and
flexural strengths of 150 MPa and 30 MPa, respectively. Details on the particle packing concept will be further discussed in the next section.
(1)
Where: P(D) represents the weight percentage of sand passing the sieve with size D, Dmax is the maximum particle size (μm), Dmin is the
minimum particle size (μm), and q is the distribution modulus which is related to the sand particle size. For fine particles, q can be set at 0.23
(q < 0.25).
Beside empirical methods, statistical experimental design methods based on artificial neural networks (ANN) are used in optimizing both
products and processes for UHPC [64]. These methods have already been adopted in different studies on concrete behavior to optimize the
UHPC mixture in achieving the desired performance [65]. Taghados et al. [66] proposed the use of an adaptive neuro- fuzzy inference system
(ANFIS) to predict the compressive strength of UHPC, based on the mix design and curing conditions. In addition to cement dosage, the cost
and the availability of steel fibers adopted in UHPC mixture are major concerns. Ghafari et al. [67] developed a statistical model using
response surface methodology (RSM) for predicting the maximum flexural strength of self-compacting steel fiber-reinforced UHPC with
varying steel fiber contents. With this model, optimization of fiber content can be predicted. In another study [59], used a statistical mixture
design (SMD) model for optimizing the mixture design of UHPC. The effect of individual ingredients and their interactions were studied for
predicting the compressive strength of UHPC using minimum cement content of less than 670 kg/m3 and without applying heat curing [59].
As discussed earlier, curing condition of UHPC has a major impact on its compressive strength. However, the aforementioned models have
not addressed this effect. Ghafari et al. [67,68] recommended several ANN models for predicting the performance of UHPC under different
curing conditions. Compared with SMD model, this ANN model can predict the compressive strength and the slump flow with higher
accuracy, due to its distributed and nonlinear nature. Based on this model analysis, the optimum amount for cement and silica fume was
found to be at 24% and 9% by volume of concrete respectively [68].
In the past 25 years, the outcome in concrete technology has allowed the production of UHPC with excellent rheological behavior, which
includes workability, self-placing and self-densifying properties, improved in mechanical and durability performance with very high
compressive strength and non-brittleness behavior [69]. The development of UHPC usually starts with the design of the granular structure of
the aggregates; of which the selection and characterization of suitable fines for optimum packing density are of key importance. The design of
UHPC aims to achieve a densely compacted cementitious matrix with good workability and strength [70]. In short, to gain the desired
properties of a UHPC, well-chosen raw materials and sophisticated technical procedures are typically required. In most publications, the
mixture designs for UHPC are based on the benchmark mixture developed by Richard and Cheyrezy [7]. Compared to CC, a high binder
amount and SP dosage are normally utilized in the production of UHPC. With appropriate combination of cementitious materials, adequate
sand gradation, and incorporation of fiber reinforcement and SP, UHPC can be produced to deliver high flowability with improved
mechanical properties and durability [7,60]. However, these outstanding mechanical properties come with costly and sophisticated technology
preparation. The high material cost, complex fabrication technique together with the limited available resources severely limits its
commercial development and application in modern construction industry, especially in the developing countries [39,44,71,72]. These
restrictions further motivate the development of cost-effective UHPC using alternative materials with similar functions to substitute the
expensive composites of UHPC to increase its acceptance level.
4.2. UHPC standards

In mid 2016, two French national standards for UHPC known as NF P18-470 and NF P18-710 were published for UHPC to replace the
technical guidelines and professional recommendations generally used in designing UHPC. Before these standards were developed, several
recommendations and guidelines are referred to for designing and producing UHPC. Below are some of the available guidelines that have
Outline
been commonly referred by researchers Download
in producing Share
UHPC [69,74]. Export
1 French Interim Recommendations [75]
2 German Recommendations [76]
3 Japanese Recommendations [77]
However, these technical guidelines and professional recommendations have been found to be inadequate, as the documents did not have an
“official” status, which made referencing and using them in projects difficult. Availability of the new standards allows clear and codified
specifications, which helped further acceptance of UHPC at the international level. The standardization process of UHPC in France was
launched in December 2012. These standards were technically elaborated based on the earlier French AFGC recommendations [75,78] and
technical feedback of more than 15 years of UHPC projects and realizations [79]. These standards served as provisions for an appropriate
material purchasing, developing and adjusting mixture design, and controlling the production processes. Complying with these documents
shall help in achieving quality UHPC and promote widened acceptability. Similar standardization efforts can also be seen in other countries
such as Switzerland, China, Canada, and Japan [79].
As suggested in NF P18-470 [73], UHPC refers to a material with a cement matrix and a characteristic compressive strength of about 150 MPa,
containing metallic fibers in order to achieve ductile behaviour under tension. Due to the use of admixtures such as SP, UHPC mixes
generally have a low W/B. Special attention should be paid in controlling the quantity of water added to the concrete by the different
ingredients of mixing water, water in aggregate and admixtures. All UHPC materials must satisfy the requirements stated in NF P18-470 [73]
as tabulated in Table 3. The mix design of UHPC should obey the following procedure as stated in NF P18-470 [73]:
1 Establish the nominal mix design.
2 Confirm the mix design by suitability tests.
3 Follow-up manufacture by routine checks.
Table 3. UHPC materials requirement as per NF P18-470 [73].
Properties Recommended value
Maximum aggregate size ≤10 mm
Concrete density 2200–2800 kg/m3
Tensile strength at 28 days ≥6 MPa
Water porosity at 90 days ≤9 %
Diffusion coefficient of chloride ions at 90 days ≤0.5 × 10−12 m2/s
Apparent gas permeability at 90 days ≤9.0 × 10−19 m2
The nominal mix design includes:

1 Descriptions and weight of each class of aggregates (dry ingredients), cement, admixtures and additions used in the UHPC.
2 Total water added including in the form of ice, pre-existing water on the surface of the aggregates, water in the admixture, water in
additives and additions.
5. Applications of UHPC
The excellent performance of UHPC offers new opportunities for infrastructure works, building constructions and many niche markets with
increasing number of applications seen in the recent years. According to the market research reported by Grand View Research (GVR), the
UHPC global market size was valued at USD$ 892 million in 2016 and this number is expected to grow by 8.6% to USD$ 1867.3 million in
2025 [3]. UHPC has become a worldwide attention with its commercialization available in many countries, such as Australia and New Zealand
[80], Austria [81], Canada [12,82], US [83,84], Germany [5], France [85], Italy [86], Japan [77], Malaysia [87], Netherlands [88], Slovenia [89], and
South Korea [90]. Within the last two decades, extensive research projects had been conducted by the academics and engineers around the
world in order to industrialize UHPC technology as the future sustainable construction material [91]. A complete search of the literature has
identified more than 200 completed bridges constructed using UHPC in one or more of their components [2]. Other applications of UHPC
can also be seen in buildings, structural strengthening, retrofitting, precast elements and some special applications [15,85]. Both private and
governmental bodies are currently turning their attention and initiative towards utilizing UHPC as the future sustainable construction
material [92,93].
5.1. Infrastructures
First research and development aiming at the application of UHPC in constructions started around 1985 [1]. Since then, different technical
Outline
solutions and UHPC formulations were Download
made available Share
to meet the specific Export
requirements of an individual designs, constructions, and
architectural approaches. Breakthroughs in UHPC application include the very first prestressed hybrid pedestrian bridge over the Magog
River in Sherbrooke, Canada (Table 4) built in 1997 [12], the replacement of corroded steel beams in the aggressive environment of Cattenom
and Civaux nuclear cooling towers in France [29,94] and Bourg-les-Valence bridge made for cars and trucks in France constructed in 2001 [95].
The advanced mechanical properties and durability of UHPC make it possible to reconsider the conventional design methods for many
common bridge components. Many investigations had been conducted on the optimal designs with UHPC elements, resulting in the
development and construction of the UHPC bridges all over the world. In 2002, the Seonyu footbridge in South Korea was constructed using
UHPC with a main span of 120 m and was completed in 2004 (Table 4) [96]. Being the world’s longest span bridge constructed using UHPC,
the construction of Seonyu footbridge structure required only about half the material amount that would have been used in traditional
concrete construction and yet provides equivalent strength properties [48]. In Japan, the 50 m-span Sakata-Mirai footbridge was completed in
2003. The bridge demonstrated how a perforated web in a UHPC superstructure can both reduce the structure’s weight and at the same time
can be aesthetically pleasing [97]. Following to the success of these constructions, UHPC bridges for pedestrian traffic have been constructed
in Europe, North America (US and Canada), Asia and Australia [98].
Table 4. Completed UHPC projects worldwide.
Location Application Year Advantages Image
Sherbrooke, Canada Pedestrian bridge 1997 • 1st UHPC structure
Bourg-les-Valence, France Road bridge 2005 • 90 % reduction on steel reinforcement
• Lighter structure with 66 % weight reduction than CC
Seonyu, Seoul, South Korea Footbridge 2004 • Arch bridge with reduced segments
Mars Hill Bridge, United States Road bridge 2006 • 1st UHPC highway bridge in US
• Simple construction
• No shear reinforcement
Foundation Louis Vuitton, France Cladding UHPC panels 2014 • Innovative design
MUCEM, Marseille, France Column & Façade 2013 • Unique design
• Y-shaped column
• ‘Transparent’ façade
Shawnessy LRT Station, Canada Roof 2004 • Little maintenance
• Light weight
• Easy construction
Jean Bouin Stadium, Paris Roof & Façade 2013 • Precast UHPC elements
• Waterproof roof and façade
• Slender structure with unique design
The first road bridges to be constructed using UHPC technology make its presence in 2005, with four bridges were constructed around the
same time. The Shepherd’s Gully bridge located in Australia [88,99], Bourd-les-Valence bridge in France [100] and Horikoshi C-ramp bridge
in Japan [97]. Mars Hill Bridge in Wapello Country Iowa was the first UHPC road bridge constructed in the US in 2006 (Table 4) [101]. Tokyo
Outline a 40Download
Monorail and Taisei Corporation constructed Share
m-long monorail UHPCExport
girder in 2007 [97]. In 2008, the world’s first segmental UHPC
composite deck road bridge was constructed at Tokyo International Airport making it the largest UHPC road bridge in the world [97].
According to the United States Federal Highway Administration (FHWA) report published in 2013, a total of 55 bridges using UHPC have
been built or are under construction in the US and Canada. There are about 22 UHPC bridges in Europe and 27 UHPC bridges throughout
Asia and Australia [42]. In these applications, UHPC can be used as beams, girders, deck panels, protective layers, field-cast joints between
different components and etc. [[102], [103], [104], [105], [106], [107]]. Compared to traditional reinforced concrete bridges, most bridges built
with the UHPC components or joints exhibit slender appearance with significant reduction in the volume and self-weight, simplified
implementation, and better durability [54]. Most UHPC structures require only half the section depth of the conventional reinforced or pre-
stressed concrete members, which reduces its weight by up to 70% [108]. This lighter weight construction and materials efficiency used in
UHPC structures leads to a sustainable structure through its lower carbon footprints [93].
UHPC was used to manufacture acoustic panels for the Monaco underground train station [109]. The thin and light UHPC panels were cast
with small holes to aid in their acoustic properties. The non-flammable panels are resistant to impact and create an aesthetically pleasing and
bright environment for passengers. Acoustic panels have also been used along a roadway in Châtellerault, France, due to their resistance to car
pollution and deicing salts [109]. Other potentials of UHPC applications are in security infrastructure used as barrier protection systems or as
inherent portions of the critical infrastructure. Extensive researches focusing on security applications were carried out on the mechanical
properties of UHPC subjected to high strain loading rate [[110], [111], [112], [113], [114], [115]], blast resistance [112,[117], [118], [119]] and
penetration resistance [[118], [119], [120]].
5.2. Buildings
In the last decade, UHPC has also gained interest on the field of building components, such as sunshades, cladding, and roof components.
UHPC was selected due to its ability to produce slender, light, durable, and aesthetic structures.
Among the latest buildings adopting UHPC technology is the Foundation Louis Vuitton pour la Creation in Paris as shown in Table 4
[30,121]. Completed in 2014, this project is characterized by its high geometric complexity. The cladding is created from prefabricated UHPC
panels, with each of them uniquely designed through vacuum filling moulds. Another great example is the Museum of European and
Mediterranean Civilizations (MUCEM) [122] as shown in Table 4, located at the port area of Marseille in France. It is the first building in the
world to make such extensive use of UHPC. As mentioned earlier, UHPC can also be used in roofs and canopies as seen in Shawnessy LRT
station in Canada (Table 4). There are other examples of similar applications, such as precast thin curve shells in wastewater treatment plant
constructed in France [123]; roof of Jean Bouin stadium in Paris seen in Table 4 [122]; roof of the Olympic museum in Lausanne, Switzerland
[124]; cladding for the Qatar National Museum [125]; and façade at Terminal 1 of Rabat airport in Morocco [126].
5.3. Non-structural products

Due to its excellent properties, UHPC has been widely used as an overlay to repair existing concrete structures, improving its mechanical and
durability properties for lesser maintenance work [127,128]. The first application on UHPC overlay was reported on a bridge over the La
Morge River in Switzerland [129]. The severely damaged bridge deck and curbs were replaced with UHPC. No cracks were observed on the
prefabricated UHPC curb after 1 year of its application. The successful of these materials in repair and rehabilitation applications paved the
way for similar technology to be used on deteriorated bridges. The hydraulic structures repair and rehabilitation using UHPC was done at the
Hosokawa River Tunnel in Japan [130], Caderousse and Beaucaire Dams in France [131].
UHPC has the potential to be used for special conditions due to its excellent properties of high flexural strength and dense microstructure. It
has been reported that, UHPC was used for cover plates along the high-speed railways in China [132,133], and for the retrofit of the nuclear
reactor containment walls in France [134]. UHPC usage has also been seen in marine areas for its great resistance to the aggressive agents.
Several windmills in the sea have been successfully designed as reported by previous researchers [[135], [136], [137], [138]], and rejuvenation of
maritime signalization structures with UHPC also has been proved to be very effective [116]. In Japan, the Haneda Airport was extended by
using a huge UHPC slab constructed over the sea [97]. To date, this construction is the largest UHPC project realized. The excellent
performance of UHPC is responsible for its large potential in various applications, however many have yet to be discovered to utilize its
increased strength, durability, and flexural capacity. UHPC provides economical and innovative solutions in areas where CC struggles. UHPC
is the future construction material, it is here to stay and will grow continuously throughout the world.
6. Further potential applications

The chloride-induced corrosion has always been the major threat to reinforced concrete structures in marine areas. The high durability and
resistance to chloride of UHPC makes it an ideal material for use in outdoor or severely exposed environment. Using UHPC in marine
structures is one of the solutions to prevent corrosion of the reinforcement because of its excellent durability allowing great resistance to
chloride. Applications of UHPC in marine structures have been reported with promising results [97,116,122]. Most cross-sea bridges built
with UHPC exhibit much lower weight, better durability, lower maintenance, and simplified implementation with less cross-section
members. UHPC also has the potential for construction, overlays, repairing and strengthening of marine structures, such as piers and oil
platforms. Besides chlorides, UHPC also has great resistance to most chemical and physical attacks. This gives the possibilities of UHPC to be
applied in more severe environmental conditions.
The ductile behavior of UHPC makes it possible to be used for buildings and structures in seismic regions [[139], [140], [141]]. It has been
reported that, the reinforced UHPC Outline Download
columns or beams were ableShare Export
to dissipate higher energy compared to normal reinforced concrete during
the earthquakes, preventing it from collapsing. Effort in reducing the high cost of UHPC was done by introducing the usage of hybrid
element, which combines the UHPC with CC or other materials in structures to resist seismic load. The high impact resistance of UHPC was
also studied and the potential of it to be used in piles was investigated; Two H-shaped precast concrete piles were successfully driven into clay
soils and tested under both vertical and lateral loads [15,142].
The excellent workability enables UHPC to be cast into any shapes. Hence, UHPC blocks with different shapes could be precast. These blocks
could be assembled into a structure, just like a jigsaw puzzle. Much time and labor can be saved to build this kind of UHPC structure. Japan
has started the fundamental studies on this concept in the effort to revolutionizing the construction industry [143]. Since UHPC shows very
good application prospects, more and more innovative UHPC applications will be seen in the near future.
7. Challenges
In the last two decades, UHPC has been used for both structural and non-structural precast components in many countries. However, this
outstanding technology has struggled to become a mainstream technology for everyday use due to its high initial costs and the lack of design
codes. Moreover, the high UHPC material cost and high energy consumption makes it hard to compete with CC designs thus restricting its
application. Researches on reducing the cost and improving the sustainability of UHPC are what is needed to allow its future wider
implementation. Several studies were performed to modify the material mixtures with the use of local raw materials and waste products in
the effort of reducing the amount of Portland cement, steel fiber and SP [144]. With a lower cost and impact on the environment, UHPC will
be much easier to be accepted by the infrastructure market and arouse the interests from the infrastructure owners.
Another issue concerning the cost is the life cycle cost of UHPC structures. One of the primary advantages of UHPC is its excellent durability.
Structures made with UHPC will have much longer service life with lower maintenance and repair cost in the future compared to CC or HPC
structures [145]. With the applications of UHPC in the past few years, empirical skills and knowledge on the design and construction of
UHPC structures have been gained. However, for some reasons they may not be easily shared [85]. The dissemination of this information is
extremely important to encourage its applications. Guidelines for design and construction of UHPC structures must be developed based on
the previous experiences and knowledge obtained from the field, experimental researches, and scientific computations. International
recommendations are difficult to be produced due to a significant variety of UHPC experience in the different countries [85]. Due to the
growing interest and applications on UHPC, countries like France, Japan, China, German, and Switzerland have made standardization efforts.
In mid-2016, France published their first national standard on UHPC [73].
The design and construction methods for the UHPC structures are different from the traditional provisions for conventional reinforced
concrete. To date, the number of skilled architects, engineers, and experts in the UHPC design and construction is still limited. Since wide
application prospect can be seen for UHPC, skilled teams which are familiar with UHPC technology and specific design issues are needed
[85]. At present, only around five major players for global UHPC market could be identified, with products mainly distributed in Europe and
North America [133]. In Malaysia, only one locally blend UHPC are commercialized under the name Dura® since 2006 [48]. Although this
product has successfully been used in local bridge construction, more studies are required for material optimization in producing locally
blends UHPC to further improve its properties and to reduce its cost and minimize the environmental impact. The researchtrend on UHPC
is now related to nanotechnology. Experimental explorations have been performed to modify its properties using nano-particles such as
nano-silica and nano-fibers. Moreover, some researchers have tried to study the structure of hydration products in UHPC at nano-scale level
[146]. Nanotechnology might be a solution to the drawbacks of UHPC, such as the shrinkage problem, and thus may improve the general
performance of UHPC.
8. Conclusions
UHPC is a fascinating new material featuring outstanding properties with extraordinary strengths and excellent durability achieved through
homogeneity and packing density improvements. Since its introduction in the early 1990s, a great accumulation of knowledge on the
material, design, and construction of UHPC structures have been gained with various countries having attempted to introduce it to building
and bridge applications. Technical recommendations have been published in France, Japan, Germany, and Switzerland. Two French national
standards were published in 2016 for UHPC to replace the technical guidelines and professional recommendations that have been generally
referred in designing UHPC. These new standards allow clear and codified specifications, which is anticipated to help further acceptance of
UHPC at the international level. Some applications in Europe, North America and Asia have shown proven benefits on UHPC technology
focusing on the sustainability and service life. Over 10 years journey of UHPC constructions in Malaysia, more than 90 bridges have been
constructed, with another 20 at various stages of tender, design, and construction.
Successful achievements on the application of UHPC can be seen throughout the world. However, UHPC is seeing slow with barriers limiting
its applications. High initial cost, limited codes, design difficulties, and complex fabrication technique together with the limited available
resources severely hampered its commercial development and application in modern construction industry, especially in the developing
countries. In order to make use of the large potential of UHPC, the industry should cooperate in a much better way with academic
institutions, governmental bodies, owners and end users. The knowledge and practical experiences on this new material should be laid on the
table and shared between all parties. Due to the material sensitivity of UHPC, local recommendations and design standards should be
established. More studies on the development of sustainable and cost-effective UHPC using alternative materials with similar functions to
substitute the expensive composites of UHPC and to minimize the environmental impact are needed for greater UHPC acceptance.
Designers, architects and engineers should be more open to this new material and technology. With all these efforts mentioned, UHPC may
turn to be the construction materialOutline Download
for both present Shareexploitation
uses and future Export with more complete solution for sustainable constructions.
Conflict of interest
The authors declare no conflict of interest.
Funding
The authors would like to acknowledge Universiti Teknologi PETRONAS, Malaysia for sponsoring this research work.
Recommended articles Citing articles (14)
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