DEVELOPMENT IN HIGH PERFORMANCE CONCRETE TECHNOLOGY

Marijan Skazlic1, Dubravka Bjegovic2, Mladen Jambresic3

1
Faculty of Civil Engineering, University of Zagreb, Kaciceva 26, 10000 Zagreb, Croatia,
E-mail: skazle@grad.hr
2
Faculty of Civil Engineering, University of Zagreb, Kaciceva 26, 10000 Zagreb, Croatia,
E-mail: dubravka@grad.hr
3
Faculty of Civil Engineering, University of Zagreb, Kaciceva 26, 10000 Zagreb, Croatia,
E-mail: jmladen@grad.hr

Received ; accepted

Abstract. Development of new materials based on cement binder, and improvement of properties of existing
materials have made great advances over the last few decades. All this can be achieved only if development of
concrete microstructure, concrete technology and concrete performance are closely related. The modern, innovative
types of concrete are expected to have outstanding durability properties, should be environmentally friendly, cost-
effective, and readily used in construction.
High performance concrete (HPC) has been a promising material for many decades. Development of new high
performance concrete types has a great success within the last few years. One type of such innovative concrete types
are ultra high performance concrete types (UHPC), the development of and researches on which started late in the
20th century. UHPC exhibit a very high compressive (even above 200 MPa) and flexural strengths and possess
outstanding properties such as high durability etc. Beside that, high performance concretes with the strength range
between 100 and 200 MPa are already integrating because of their lower price related to UHPC.
This paper deals with the development of new high performance concrete types. The experimental results of testing
mechanical and durability properties of different high performance concrete types (ordinary HPC, ultra high
performance fibre reinforced concrete (UHPFRC), high performance fibre reinforced self compacting concrete
(HPFRSCC), and high performance sprayed concrete (HPSC)) are presented. Advantage and disadvantage of these
concrete types are critically commented with the aim to find the optimum practical application of different high
performance concrete types.

Keywords: concrete, durability, high performance concrete, high strength, mechanical properties, HPFRSCC, HPSC,
ultra high strength, UHPC, UHPFRC

1. Introduction classes up to C50/60. HSC correspond to concrete

Increasing demands for construction of new, modern
buildings and repair of deteriorated constructions in the
last few decades led to invention, development and
application of new concrete types high performance
concretes (HPC). HPC is material based on cement binder
with higher strength and at least one improved property
than of normal strength concrete (NSC) [1]. Its high
performance properties can be achieved only by
improving and correlating concrete microstructure,
concrete technology and performance in a proper way [2].
Development of HPC technology started in the
middle of the 20th century with the invention of high
strength concretes (HSC). According to existing Croatian
standards NSC are concrete types of compressive strength
compressive strength classes from C55/67 to C100/115
[3]. If HSC has other improved properties beside
compressive strength, than it is called HPC.
Concretes with compressive strength higher of
compressive strength class C100/115 are called ultra high
strength concretes (UHSC). The development of UHSC
started late in the 20th century by modifying some of the
existing rules for designing concrete composition and
selecting materials in HSC types. Beside ultra-high
compressive strength (even above 200 MPa), UHSC also
have considerably improved tensile strength, stiffness and
durability compared to other concrete types. Therefore,
they are also called ultra high performance concretes
(UHPC) [4].
 In this paper experimental results of testing adhesion of fibres and cement matrix, and the quality of
mechanical and durability properties of different high the cement matrix itself [6].
performance concrete types (ordinary HPC, ultra high
performance fibre reinforced concrete (UHPFRC), high
performance fibre reinforced self compacting concrete
(HPFRSCC), and high performance sprayed concrete
(HPSC)) are presented. Advantage and disadvantage of
these concrete types are critically commented with the
aim to present the optimum practical application of
different high performance concrete types.

2. HPC and UHPC mix design

The mix design and production of HPC is more

complicated than design of NSC. By increasing of
compressive strength the concrete properties are in
correlation not only with water/cement (w/c) ratio, as it is
in design of NSC, but also with several other parameters
(especially porosity of concrete) [5].
To achieve higher strengths or to improve other
properties, special attention should be given to the
selection and compatibility of components (cement,
superplasticizer, aggregate, mineral additives, fibres, etc.)
and technology (production, placement, curing, transport,
and quality control).
In comparison to NSC, HPC are much more
homogenous and less porous. Strength and other
properties of HPC grow with the higher number of
contacts among particles, reduced porosity and defects
within the structure. Considering that HPC contain high
quantities of binders, the size of maximum aggregate
grain size should be also reduced. Reduction of porosity
is achieved by using a low water/binder (w/b) ratio,
adding superplasticizer (providing sufficient workability
in fresh state), and replacing a portion of cement with
pozzolanic additives. Less water in the composition of
HPC than in NSC reduces the space between cement
grains and mineral additives in the fresh state. In this way
capillary porosity is also reduced and so is the space to be
filled with the products of hydration [4, 5].
A reduction in water/binder ratio and the use of
mineral additives have a positive effect on an
improvement in the interface between cement matrix and
aggregates as the weakest link in the concrete structure.
The most efficient admixture to cement is silica fume.
Because of its very small grains (about 10 times smaller
than a cement grain) and large specific area, silica fume
has a positive effect on an increase in density of the area
surrounding cement particles and, because of higher
reactivity, on accelerated hydration. Furthermore, silica
fume reacts with free lime - the poorest component of
cement thereby making CSH gel [2].
Concrete brittleness grows with the increase of its
compressive strength. Therefore HSC/HPC are much
more brittle than those exhibiting less strength. By using
fibres in this weak, brittle matrix, ductility of the cement
matrix can be improved (Figure 1). The degree of
improvement resulting from fibre reinforcement varies
depending on the amount and kind of fibres admixed,
Fig 1. Improving ductility of HPC by using hybrid steel fibres
Fig 2. Multiple cracking of UHPFRC due to higher ductility
Besides taking into account the facts mentioned
above, to obtain UHSC/UHPC the concrete designer
should adhere to the basic principles as follows:
o increase of homogeneity by completely or
partially eliminating coarse aggregate,
o increase of density of the placed concrete by
optimizing grain size distribution in such a way
to achieve maximum packing of particles,
o improvement to the structure of placed concrete
by heat treatment,
o water quantity in concrete is maximally reduced
and, because of this, its quantity is insufficient
for cement hydration; this principle results in the
reduced quantity of free water, which can result
in the formation of micro cracks because of
desiccation; non-hydrated cement acts as
reactive micro aggregate of high modulus of
elasticity that can hydrate subsequently,
o improvement to ductility by adding higher
quantity of fibres.
By adhering to the first four principles high
compressive strengths can be achieved, while by adding
fibres tensile strength and ductility are improved. This has
an effect on the ductility of the cross-section and
structural elements, thereby ensuring deformation and
redistribution of cutting forces and prevention of brittle
failure of the structure or the test element [6].
 High performance fibre reinforced self compacting
concrete (HPFRSCC) has to have, beside properties of Table 1. Compositions of the mixtures tested
normal self compacting concrete (filling and passing Mix components UHP
HPC HPFRSCC HPSC
(kg/m3) FRC
ability, resistance to segregation, prevention of blowholes Water/binder
making on the surface), higher mechanical (e.g. ductility) 0.35 0.16 0.22 0.25
(w/b) ratio
and durability properties. This can be obtained by Max. aggregate
16 0.5 11 4
modifying composition of ordinary HPC by using: size (mm)
o higher volumes of superplasticizers, cement, and Aggregate/binder
4.2 0.8 2.4 1.3
(a/b) ratio
silica fume, Amount of silica
o higher quality cement, 7.5 15.2 9.8 15
fume (% mcem)
o lower aggregate/binder (a/b) ratio, Superplasticizer
o steel fibres, amount 0.7 2.9 0.8 1.1
(% mcem+sil)
o higher quality aggregate (e.g. diabase), and
CEM I 42,5 400 - -
o larger content of fine aggregate. CEM I 52,5 - 1115 600 875
HPSC can be obtained using the basic principles of Silica fume 30 169 59 131
high performance fibre reinforced shotcrete technology Fine aggregate
918.5 - - -
laid down at the end of the 20th century. Specifically, (dolomite)
Coarse aggregate
HPSC is obtained by modifying shotcrete composition by (dolomite)
882.5 - - -
using: Fine aggregate
o smaller maximum aggregate size (up to 4 mm), - - 943.5 1122
(diabase)
o higher quality aggregate (e.g. quartz sand or Coarse aggregate
- - 647.6 -
igneous sand), (diabase)
Quartz sand - 1073 - -
o shorter fibres and larger volumes of steel fibres Water 150.5 204 145 215
(even up to 2 vol.%), and Superplasticizer 3 37 5.2 11
o larger volumes of cement, silica fume and Steel fibres
- 39 - -
superplasticizers. 6/0.15, flat
The use of these components greatly reduces Steel fibres
40
10/0.2, curved
rebound during application, and makes it possible for Steel fibres
HPSC to be applied in a thick layer without falling off - 117 - -
13/0.15, flat
[6]. Steel fibres
40
35/0.55, curved
Steel fibres
3. Experimental work - 78 - -
40/0.5, curved
Steel fibres
In the laboratory of the Department of Materials at - - 67 -
30/0.8, curved
the Faculty of Civil Engineering, University of Zagreb, Steel fibres
- - 33 -
experimental researches have been conducted into above 60/1.0, curved
mentioned new types of concrete. These researches have
been carried out by investigating, in parallel, properties Silica fume used, was in dry state and packed in
and technology of concrete. The aim of the researches bags. It had following characteristics:
was to get new types of concrete that exhibit improved o specific surface 18 595 cm2/g, and
mechanical and durability properties in relation to other o content of total SiO2 93,02 %.
concrete types. At the same time, they also needed to
fulfil the condition that the obtained concrete types can be Table 2. Mineralogical composition of cements used
Mineral content (%)
prepared at the existing concrete production plants. The Cement
C3S C2S C3A C4AF
preceding researches yielded the components for these CEM II/B-S 42,5 37,7 12,2 11,1 13,4
concretes which were used in the subject researches [2, CEM I 52,5 70,7 3,5 8,2 9,1
7]. In order that the production price of the new concretes
is as favourable as possible the components available in All mixtures had plastic consistency in fresh state. In
the Croatian market were used. hardened state, they were tested for the following
Table 1 shows the compositions of the mixtures of properties (according to existing Croatian standards):
HPC, UHPFRC, HPFRSCC, and HPSC tested. The o Compressive strength (HRN EN 12390-3)
design of the compositions of mentioned mixtures, (Figure 3)
selection of their components and production were o Flexural strength (HRN EN 12390-5 or HRN EN
governed by the principles described in previous chapter. 196-1)
Two types of cement were used, CEM II/B-S 42,5 for o Static modulus of elasticity (HRN.U.M1.025)
HPC and CEM I 52,5 for other three concrete types. o Toughness (ASTM C1609)
Mineralogical compositions of cements used in o Gas permeability (EN 993-4)
experimental work, calculated by Bogue formula o Capillary water absorption (HRN.U.M8.300)
according to the results of chemical analysis, are shown o Diffusion of chloride ions (ASTM C 1202)
in Table 2.
 The results of testing mechanical and durability
properties are shown in Table 3. Statistical analysis of the
results obtained by the single-parameter model of analysis
of variance showed that they are repeatable for all four
concrete types.

Table 3. Test results

Property HPC UHPFRC HPFRSCC HPSC
Compressive
71.5 211.3 141.7 73.9
strength (MPa)
Flexural strength
7.1 40.1 13.3 16.8
(MPa)
Static modulus of
34.4 48.7 40.8 32.4
elasticity (GPa)
Coefficient of gas
1.310-17 1.310-19 1.310-18 -
permeability (m2)
Fig 3. Compressive strength testing of HPSC Coefficient of
capillary water
Due to size effect in high performance concretes, absorption
0.138 0.023 0.06 -
samples taken, for mechanical properties tests, were of (kg/m2h1/2)
different sizes depending on each concrete type. For HPC Diffusion of
and UHPFRC compression strength testing cube samples chlorine ions 766 150 416 -
(Coulomb)
of 15x15x15 cm dimension were used. Cubes of 4x4x4
cm dimension were used for compression strength testing
By comparison of the test results of mechanical
of HPFRSCC.
properties given in Table 3, it can be seen that concrete
Samples for compression testing of HPSC were
cylinders of 5/10 cm dimension, cored from test panels
types UHPFRC and HPFRSCC have much better
mechanical properties than the ordinary HPC and HPSC.
(Figure 1). Test panels had plan dimensions of 60x60 cm
Except increased values of compressive strengths in
and thickness of 20 cm. Dimensions of test panels as well
comparison with the other three concrete types, UHPFRC
as spraying of HPSC were according to EFNARC
has also high flexural strength and toughness owing to
European specifications for sprayed concrete (Figure 4).
high quantities of steel fibres contained in its
Dimensions of samples (prisms) for flexural strength
composition. With the increase in concrete homogeneity,
testing were 10x10x40 cm (for HPC and HPFRC) and
their stiffness grows too. As for the values of static and
4x4x16 cm (for HPFRSCC and HPSC) (Figure 5).
dynamic modulus of elasticity, Table 3 shows that
UHPFRC and HPFRSCC have also higher values of
modulus of elasticity compared to HPC and HPSC. Figure
6 shows that UHPFRC has much higher toughness than
other three concrete types, while HPSC and HPFRSCC
have similar toughness curves. Furthermore, it can be
seen that ordinary HPC performs like brittle material
because it has no fibres in its composition.

80

70

60

50
fo rce (kN)

40

Fig 4. Placing of HPSC test panels 30

UHPFRC
20

10 HPC HPFRSCC
HPSC
0
0 1 2 3 4 5 6 7 8
displacement (mm)

Fig 6. Diagrams showing toughness of concrete types tested

Results of testing durability properties show that the

Fig 5. UHPFRC samples taking for flexural strength tests UHPFRC exhibits the best durability properties, and then
follow HPFRSCC and HPC in this order (Table 3). HPSC
was not tested on durability properties. Such results are
primarily due to significantly reduced capillary and total
porosity of UHPFRC compared to the other two concrete
types.
4. Possible structural applications of tested high
performance concretes
Presently, ordinary HPC is mainly used in precast or
in situ constructions of load bearing elements of viaducts
and bridges, as well as for high-rise building columns.
HPC is also used in construction of concrete pavements
(e.g. highways, airports) and for repair of damaged
concrete structures.
The use of UHPFRC for structures allows the
designer to reduce the sizes of structural elements.
Modulus of elasticity of these concrete types does not
raise proportionally to the strength values. High flexural
strength of UHPFRC, in certain applications, makes
possible to eliminate ordinary reinforcement and to only
pre-stress cross-sections of structural elements. As a
result, structural engineers have gained freedom in
structural shaping of load-bearing elements. For this
reason, in structural application of high-strength and
ultra-high strength concretes, slim cross-sections are used
[4].
On the basis of the above facts, it can be concluded
that UHPFRC can be used for high-building construction,
for bridge construction, and for the construction of slim
and lightweight structures such as thin-walled roof
structures for roofs having wide spans or for girders of
low self-weight intended for building additional storey or
rising.
Considering all properties of UHPFRC, this concrete
type could also be used for precast segments of secondary
tunnel linings, impact protection panels against missiles
and explosion, containers intended for storage of
radioactive and other non-degradable waste, waste water
pipes, vaults in which valuable things are kept safely, etc.
Due to the fact that HPFRSCC contains fine
particles which make the structure of a material
especially fine, and with the possibility for admixing
colour pigments and replacing steel fibres with polymer
ones, fabrication of more complicated architectural
elements is possible.
Furthermore, HPFRSCC is more cost-effective than
UHPFRC, and its compressive strength and other
mechanical properties are sufficient for the majority of
similar structural applications.
HPSC can be successfully applied as a shotcrete in
placing of primary tunnel lining. In this manner the
thickness of the placed HPSC would be reduced thus
ensuring flexibility of the primary tunnel support. Rapid
growth in strengths would allow it to immediately take
over a large portion of load; additionally, because of a
large binder quantity, rebound, i.e. the loss of material
during installation would be reduced. HPSC can also be
applied in rock masses of poorer quality with reasonable
certainty that in time such concrete will not lose its
durability properties, which could result in the collapse of
a tunnel [8]. By using fibres in this concrete type, it gains
high ductility and energy absorption along with small
self-weight. Therefore, this kind of concrete can also be
used for strengthening and repairs of existing structures.
5. Conclusion
Described high performance concretes exhibited
much better mechanical and durability properties than
other concrete types. Outstanding characteristics of these
materials enable their structural application in various
fields of civil engineering.
Excluding ordinary HPC which is in use for a longer
time, other three tested concrete types (UHPFRC,
HPFRSCC and HPSC) have been applied for the last five
to ten years. However, the first structures built of these
concrete types were test structures aimed primary to
monitoring material and structure behaviour with time. So
it can be generally said that the real structural application
is yet to take hold. The properties and production
technology of these concretes should further be improved
with the aim to use them in the structures in which the
properties of material will be used optimally.
Experimental work performed at the Faculty of Civil
Engineering in Zagreb was one valuable step to increase
future applications of these materials.
References
1. Nawy, E. Fundamentals of high-performance concrete. 2nd
Edition, New York: John Wiley & Sons Inc, 2001.
2. Skazlic, M. High performance hybrid fibre reinforced
concrete. Masters Thesis, Zagreb: Faculty of Civil
Engineering, University of Zagreb, 2003. (in Croatian).
3. Radic, J. Concrete structures handbook, Zagreb: Faculty
of Civil Engineering, University of Zagreb, 2006., p. 922-
1000 (in Croatian).
4. Skazlic, M., Bjegovic, D. Perspectives of designing with
new concrete types. Zagreb: Annual 2005 of the Croatian
Academy of Engineering, 2005., p. 167-178.
5. Aitcin, P. C. High-performance concrete, London: E&FN
SPON, 1998.
6. Skazlic, M. Precast fibre reinforced segments of secondary
tunnel lining. Dissertation, Zagreb: Faculty of Civil
Engineering, University of Zagreb, 2005. (in Croatian).
7. Skazlic, M., Bjegovic, D. High strength concretes,
Gradjevinar 56 (2004) 2, p. 289-299. (in Croatian)
8. Skazlic, M., Skazlic, Z., Majer, J. Application of high
performance fibre reinforced shotcrete for tunnel primary
support, Proceedings of the 10th International Conference -
Shotcrete for Underground Support, Whistler, 2006. p. 206-
214.