Reactive powder concrete

A Seminar Report
Submitted in partial fulfillment of the requirements of the degree of
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING

By
D. Siddhartha(UG101218)



DEPARTMENT OF CIVIL ENGINEERING
NATIONAL INSTITUTE OF TECHNOLOGY, WARANGAL
2013-2014




Table of Contents
Abstract................................................................................................................................. 4
1. Introduction ....................................................................................................................... 5
1.1 Defining Reactive powder concrete ............................................................................. 5
1.2 History and development of RPC ................................................................................. 5
1.3 Scope of RPC .............................................................................................................. 5
2. Composition of RPC .......................................................................................................... 6
2.1 Introduction .................................................................................................................. 6
2.2 RPC components ........................................................................................................ 6
2.2.1 Cement ................................................................................................................. 6
2.2.2 Sand ..................................................................................................................... 6
2.2.3 Quartz powder ...................................................................................................... 7
2.2.4 Silica fume ............................................................................................................ 7
2.2.5 Steel fibers ............................................................................................................ 7
2.2.6 Super plasticizer.................................................................................................... 7
2.2.7 Table showing components of RPC ...................................................................... 7
2.3 Mix proportion of RPC ................................................................................................. 8
3. Properties of RPC ............................................................................................................. 9
3.1 Introduction .................................................................................................................. 9
3.2 Typical properties of RPC 200 ................................................................................... 10
3.3 Typical properties of RPC 800 ................................................................................... 10
3.4 Comparison of RPC and HPC ................................................................................... 11
3.5 Fresh concrete properties .......................................................................................... 11
3.6 Compressive strength ................................................................................................ 12
3.7 Flexural strength ........................................................................................................ 12
3.8 Water absorption ....................................................................................................... 13
3.9 Water permeability ..................................................................................................... 13
3.10 Resistance to chloride ion penetration ..................................................................... 14
4. Factors effecting strength of RPC ................................................................................... 15
4.1 Silica Fume Percentage ............................................................................................. 15
4.2 Quartz Powder........................................................................................................... 15
4.3 Curing Regime........................................................................................................... 15
4.4 Compressive and tensile properties of RPC at elevated temperatures ...................... 15
4.5 Effect of pre-setting pressure ..................................................................................... 15
5. Advantages ..................................................................................................................... 16
6. Limitations ....................................................................................................................... 16
7. Structures built using RPC .............................................................................................. 17
8. Case study ...................................................................................................................... 17
8.1 THE SIDEWALK SYSTEM OF THE QINGHAI-TIBET RAILWAY BRIDGE ................ 17
8.2 Pedestrian bridge in Sherbrooke ............................................................................... 18
9. References ..................................................................................................................... 19


Abstract
Reactive Powder Concrete (RPC) is catching more attention now days because of its high
mechanical and durability characteristics. RPC mainly comprises of cement, silica fume,
silica sand, quartz powder and steel fibers. RPC has been able to produce with compressive
strength ranging from 200 MPa to 800 MPa with flexural strength up to 50 MPa and in some
cases can replace traditional steel reinforcement. RPC will allow the concrete industry to
optimize material use, generates economic benefits, and build structures that are strong and
durable. Present seminar mainly discusses on composition and Mix proportion of RPC,
properties and factors effecting RPC and comparison between High performance concrete
(HPC) and RPC and limitations of RPC and few case studies.

1. Introduction
1.1 Defining Reactive powder concrete
Reactive powder concrete (RPC) is ultra high strength and high ductile composite material
with advanced mechanical properties. Reactive powder concrete is a concrete without
coarse aggregate, but contains cement, silica fume, sand, quartz powder, super plasticizer
and steel fiber with very low water binder ratio. The absence of coarse aggregate was
considered by inventors to be key aspect for the microstructure and performance of RPC in
order to reduce the heterogeneity between cement matrix and aggregate.
1.2 History and development of RPC
The concept of reactive powder concrete was first developed by P. Richard and M. Cheyrezy
and RPC was first produced in the early 1990s by researchers at Bouygues laboratory in
France. The worlds first Reactive Powder Concrete structure, the Sherbrooke Bridge in
Canada, was erected in July 1997. The addition of supplementary material, elimination of
coarse aggregates, very low water/binder ratio, additional fine steel fibers, heat curing and
application of pressure before and during setting were the basic concepts on which it was
developed. Compressive strength of RPC ranges from 200 to 800 MPa, flexural strength
between 30-50 MPa and Youngs modulus up to 50-60 GPa. There is a growing use of RPC
owing to the outstanding mechanical properties and durability. RPC structural elements can
resist chemical attack, impact loading from vehicles and vessels, and sudden kinetic loading
due to earthquakes. Ultra high performance is the most important characteristic of RPC.
RPC is composed of more compact and arranged hydrates. The microstructure is optimized
by precise gradation of all particles in the mix to yield maximum density. It uses extensively
the pozzolonic properties of highly refined silica fume and optimization of the Portland
cement chemistry to produce highest strength hydrates.
1.3 Scope of RPC
RPC will be suitable for pre-stressed application and for structures acquiring light and thin
components such as roofs of stadiums, long span bridges, space structures, high pressure
pipes, blast resistance structures and the isolation and containment of nuclear wastes. In
India the work on RPC has started from last few years. The utility of RPC in actual
construction is minimal or nil in India, it is because of non-availability of sufficient
experimental data regarding production and performance of RPC.
2. Composition of RPC
2.1 Introduction
RPC is composed of very fine powders (cement, sand, quartz powder and silica fume), steel
fibers and super plasticizer. The super plasticizer, used at its optimal dosage, decreases the
water to cement ratio (w/c) while improving the workability of the concrete. A very dense
matrix is achieved by optimizing the granular packing of the dry fine powders. This
compactness gives RPC ultra-high strength and durability. Reactive Powder Concretes have
compressive strengths ranging from 200 MPa to 800 MPa.
Richard and Cheyrezy indicate the following principles for developing RPC:
1. Elimination of coarse aggregates for enhancement of homogeneity
2. Utilization of the pozzolonic properties of silica fume
3. Optimization of the granular mixture for the enhancement of compacted density
4. The optimal usage of super plasticizer to reduce w/c and improve workability
5. Application of pressure (before and during setting) to improve compaction
6. Post-set heat-treatment for the enhancement of the microstructure
7. Addition of small-sized steel fibers to improve ductility
Application of these principles without steel fibers produces a matrix with very high
compressive strength, but with ductility no better than that of conventional mortar. The
inclusion of fibers improves tensile strength, and also makes it possible to obtain the
required level of ductility.
2.2 RPC components
2.2.1 Cement
Cement is binding material for production of primary hydrates. Its particle size ranges from
1m to 100m. Optimum cement properties are C
3
S: 60% C
2
S: 22% C
3
A: 3.8% C
4
AF: 7.4%
2.2.2 Sand
Coarse aggregates are replaced by fine sand. It gives strength to the concrete. Maximum
size of sand is 600m. Size ranges from 150m to 600m. It eliminates mechanical
chemical and thermo mechanical failures.
2.2.3 Quartz powder
Its particle size ranges from 5m to 25m. It must be in crystalline form.
2.2.4 Silica fume
Silica fume is used for filling voids and enhance rheology and for production of secondary
hydrates. Its particle size ranges from 0.1m to 1m .
2.2.5 Steel fibers
It should have good aspect ratio and should be able to improve ductility. Its length ranges
from 13mm to 25mm. It should be straight.
2.2.6 Super plasticizer
A copolymer of acrylic ester (CAE), a polynaphtalene Sulfonate (PNS) and a polymelamine
sulfonate (PMS) are normally employed for the purpose. These admixtures are synthetic
polymers.
2.2.7 Table showing components of RPC

Component



Selection parameter

Function

Particle size
Sand Good hardness
Readily available and
low cost.
Gives strength 150 m to 600 m
Cement C
3
S: 60% C
2
S: 22%
C
3
A: 3.8% C
4
AF: 7.4%
Binding material,
Production of
primary hydrates
1 m to 100 m
Quartz powder Fineness Max. reactivity
during heat-treating
5m to 25m
Silica fume Very less quantity of
impurities
Filling the voids,
Enhance rheology,
Production of
secondary hydrates
0.1m to 1m
Steel fibers Good aspect ratio Improve ductility Length 13mm to 25mm
Dia. 0.15 0.2 mm
Super plasticizer Less retarding
characteristic
Reduce w/c Polyacrylate based

Table 1 Components of RPC
2.3 Mix proportion of RPC
The RPC family includes two types of concrete, designated RPC 200 and RPC 800.
Mix proportion (by weight) given by P. Richard and and M. Cheyrezy.
RPC 200 RPC 800
Non fibered Fibered Silica
aggregates
Steel
aggregates
Portland cement 1 1 1 1 1 1
Silica fume 0.25 0.23 0.25 0.23 0.23 0.23
Sand 1.1 1.1 1.1 1.1 0.5 -
Quartz powder - 0.39 - 0.39 0.39 0.39
Super plasticizer 0.016 0.019 0.016 0.019 0.019 0.019
Steel fibre L=12 mm - - 0.175 0.175 - -
Steel fibre
L=3 mm
- - - - 0.63 0.63
Steel
aggregates<800m
- - - - - 1.49
Water 0.15 0.17 0.17 0.19 0.19 0.19
Compaction pressure - - - - 50 MPa 50 MPa
Heat treatment
pressure (in C)
20 90 20 90 250-400 250-400

Table 2 Mix proportion of RPC

3. Properties of RPC
3.1 Introduction
Comparison of the physical, mechanical, and durability properties of RPC and HPC (High
Performance Concrete) shows that RPC possesses better strength (both compressive and
flexural) and lower permeability compared to HPC.
High-Performance Concrete (HPC) is not just a simple mixture of cement, water, and
aggregates. It contains mineral components and chemical admixtures having very specific
characteristics, which give specific properties to the concrete. The development of HPC
results from the materialization of a new science of concrete, a new science of admixtures
and the use of advanced scientific equipments to monitor concrete microstructure.
HPC has achieved the maximum compressive strength in its existing form of microstructure.
However, at such a level of strength, the coarse aggregate becomes the weakest link in
concrete. In order to increase the compressive strength of concrete even further, the only
way is to remove the coarse aggregate. This philosophy has been employed in Reactive
Powder Concrete (RPC).
Microstructure enhancement of RPC is done by heat curing. Heat curing is performed by
simply heating (normally at 90C) the concrete at normal pressure after it has set properly.
This considerably accelerates the pozzolanic reaction, while modifying the microstructure of
the hydrates that have formed. Pre-setting pressurization has also been suggested as a
means of achieving high strength.
The high strength of RPC makes it highly brittle. Steel fibers are generally added to RPC to
enhance its ductility. Straight steel fibers used typically are about 13 mm long, with a
diameter of 0.15 mm. The fibers are introduced into the mixture at a ratio of between 1.5 and
3% by volume. The cost-effective optimal dosage is equivalent to a ratio of 2% by volume, or
about 155 kg/m
3
.





Mechanical properties for the two types of RPC are given below
3.2 Typical properties of RPC 200
Portland cement 955 kg/m3
Fine Sand (150-400 micron) 1051 kg/m3
Silica fume (18m2/gram) 229 kg/m3
Precipitated silica(35 m2/g) 10 kg/m3
Super plasticizer (polyacrylate) 13 kg/m3
Steel fibers 191 kg/m3
Total water 153 kg/m3
Compressive strength(cylinder) 170-230 MPa
Flexural strength 25-60 MPa
Youngs modulus 50-60 GPa
3.3 Typical properties of RPC 800
Portland cement 1000 kg/m3
Fine Sand (150-400 micron) 500 kg/m3
Ground Quartz (4 microns) 390 kg/m3
Silica fume (18m2/gram) 230 kg/m3
Super plasticizer (polyacrylate) 18 kg/m3
Steel fibers 630 kg/m3
Total water 180 kg/m3
Compressive strength(cylinder) 490-680 MPa
Flexural strength 45-102 MPa
Youngs modulus 65-75 GPa


3.4 Comparison of RPC and HPC
Table 3 shows typical mechanical properties of RPC compared to a conventional HPC of
compressive strength 80 MPa. As fracture toughness, which is a measure of energy
absorbed per unit volume of material to fracture, is higher for RPC, it exhibits high ductility.
Apart from their exceptional mechanical properties, RPCs have an ultra-dense
microstructure, giving advantageous waterproofing and durability characteristics. These
materials can therefore be used for industrial and nuclear waste storage facilities.
Property HPC(80 MPa) RPC 200
Compressive strength 80 MPa 200 MPa
Flexure strength 7 MPa 40 MPa
Modulus of elasticity 40 GPa 60 GPa
Fracture toughness <10 J/m 30*10 J/m

Table 3 comparison of HPC and RPC
RPC has ultra-high durability characteristics resulting from its extremely low porosity, low
permeability, limited shrinkage and increased corrosion resistance. In comparison to HPC,
there is no penetration of liquid and/or gas through RPC. The characteristics of RPC given in
Table 4 enable its use in chemically aggressive environments and where physical wear
greatly limits the life of other concretes.
Abrasive Wear 2.5 times lower
Water Absorption 7 times lower
Rate of Corrosion 8 times lower
Chloride ions diffusion 25 times lower

Table 4 durability of RPC compared with HPC
3.5 Fresh concrete properties
The workability of RPC mixtures (with and without fibers), measured using the mortar flow
table test will be in the range of 120 140%. On the other hand, the workability of HPC
mixtures (with and without fibres), measured using the slump test will be in the range of 120
150 mm. The density of fresh RPC and HPC mixtures was found to be in the range of
2500 2650 kg/m
3
.
3.6 Compressive strength
RPC has higher compressive strength than HPC, as shown in Fig. 1. Compressive strength
at early ages is also very high for RPC. Compressive strength is one of the factors linked
with the durability of a material. In the context of nuclear waste containment materials, the
compressive strength of RPC is higher than required.








Fig 1: Compressive strength of RPC and HPC
(http://www.theconcreteportal.com/reac_pow.html)
The incorporation of fibers and use of heat curing was seen to enhance the compressive
strength of RPC by 30 50%. The incorporation of fibers did not affect the compressive
strength of HPC significantly.
3.7 Flexural strength
Plain RPC was found to possess marginally higher flexural strength than HPC. Here the
increase of flexural strength of RPC with the addition of fibres is higher than that of HPC.
RPC 200 should have an approximate flexural strength of 40 MPa. Fibre reinforced RPC
(with appropriate fibres) has the potential to be used in structures without any additional
steel reinforcement. This cost reduction in reinforcement can compensate the increase in the
cost by the elimination of coarse aggregates in RPC to a little extent.


3.8 Water absorption
Fig. 2 presents a comparison of water absorption of RPC and HPC. A common trend of
decrease in the water absorption with age is seen here both for RPC and HPC. The
percentage of water absorption of RPC, however, is very low compared to that of HPC. This
quality of RPC is one among the desired properties of nuclear waste containment materials.








Fig. 2: Water absorption of RPC and HPC
(http://www.theconcreteportal.com/reac_pow.html)
The incorporation of fibers and the use of heat curing is seen to marginally increase the
water absorption. The presence of fibers possibly leads to the creation of channels at the
interface between the fiber and paste that promote the uptake of water. Heat curing, on the
other hand, leads to the development of a more open microstructure (compared to normal
curing) that could result in an increased absorption.
3.9 Water permeability
A comparison of the surface water permeability of RPC and HPC is shown in Fig. 3.
It can be seen from the data that water permeability decreases with age for all mixtures.
28
th
day water permeability of RPC is negligible when compared to that of HPC (almost 7
times lower). As in the case of water absorption, the use of fibers increases the surface
permeability of both types of concrete.












Fig. 3: Surface Water Permeability of RPC and HPC
(http://www.theconcreteportal.com/reac_pow.html)
3.10 Resistance to chloride ion penetration
Penetration of chloride increases when heat curing is done in concrete. Total charge passed
for normal-cured RPC is negligible compared to the other mixtures. Even though heat-cured
RPC shows a higher value than normal-cured RPC, in absolute terms, it is still extremely low
or even negligible (<100 Coulombs). This property of RPC enhances its suitability for use in
nuclear waste containment structures.
Addition of steel fibres leads to an increase in the permeability, possibly due to increase in
conductance of the concrete. The HPC mixtures also showed very low permeability,
although higher compared to RPC.

4. Factors effecting strength of RPC
4.1 Silica Fume Percentage
It is observed that the compressive strength tends to decrease as the silica fume dosage
increases. The compressive strength is seen to fluctuate in the range of 15 % to 25% of
silica fume regardless of water/binder ratio. As silica fume content increases, mix requires
more super plasticizer to disperse in fresh concrete.
4.2 Quartz Powder
Hydrated cement alone cannot help to elevate the strength of RPC, but other finer materials
also contribute marginally. Quartz powder improves the filler effect in RPC mix. Addition of
quartz powder produce the better result under accelerated curing condition than that of
normal curing condition. The results show that the addition of quartz powder increases the
compressive strength by 20% under the accelerated curing condition.
4.3 Curing Regime
An adequate supply of moisture is necessary to ensure that hydration is sufficient to reduce
the porosity to a level such that the desired strength can be attained. The compressive
strength increased by 10% when cured in hot water as compared to normal curing. This
indicates that curing temperature has a significant effect on the early strength development
of RPC. The increased strength is due to the rapid hydration of cement at higher curing
temperatures of 90C compared to that of 27C. Moreover, the pozzolonic reactions are also
accelerated by the higher curing temperatures.
4.4 Compressive and tensile properties of RPC at elevated temperatures
Cube compressive strength decreases at 100 C, increases at temperatures from 200 to 500
C, and decreases at temperatures above 600 C. Below 300 C, the cube compressive
strength of RPC increases as the fibre content increases, but decreases above 300 C as
the fibre content increases. The tensile strength of RPC with steel fibres decreases at
temperatures below 200 C, increases at temperatures ranging from 200 to 300 C, and
decreases at temperatures above 300 C. 2% steel fibres prevent spalling and significantly
increase mechanical properties.
4.5 Effect of pre-setting pressure
It is observed that application of pre-setting pressure increased compressive strength of the
RPC about twice.
5. Advantages
As fracture toughness is higher, RPC exhibits high ductility.
Since RPC is an Ultra dense micro structure, porosity and permeability is less and
therefore can be used for waste storage holding facility.
RPC has limited shrinkage, increased corrosion resistance and so can be used in
aggressive chemical environments.
Its superior strength combined with higher shear capacity results in significant dead
load reduction and limitless structural member shape.
Its superior strength combined with higher shear capacity results in significant dead
load reduction and limitless structural member shape.
With its ductile tension failure mechanism, RPC can be used to resist all stresses
except direct primary tensile stresses. This eliminates the need for supplemental
shear and other auxiliary reinforcing steel.
RPC improve seismic performance reduces inertia loads with lighter members.
reduced cross sections of members provides higher energy absorption.
Low and non-interconnected porosity reduces mass transfer, making penetration of
liquid/gas or radioactive elements nearly non-existent.

6. Limitations
The least costly components of conventional concrete are basically eliminated or
replaced by more expensive elements.
The fine sand used in RPC becomes equivalent to the coarse aggregate of
conventional concrete
The Portland cement plays the role of the fine aggregate and the silica fume that of
the cement of conventional concrete.
The mineral component optimization alone results in a substantial increase in cost
over and above that of conventional concrete (5 to 10 times higher than HPC)
Applying pressure to mix and applying heat treatment in the field has got
technological difficulties and cost.
RPC should be used in areas where weight savings can be realized
Since RPC is in its infancy, the long-term properties are not yet known.
7. Structures built using RPC
First bridge that used RPC-pedestrian bridge in Sherbrooke, Quebec, Canada.
(230MPa) It was used during the early days of RPC production.
Portugal has used it for seawall anchors
Australia has used it in a vehicular bridge
France has used it in building power plants
Side walk of Qinghai-Tibet Railway Bridge.

8. Case study
8.1 THE SIDEWALK SYSTEM OF THE QINGHAI-TIBET RAILWAY BRIDGE

Fig.4 Qinghai-Tibet Railway Bridge
(http://english.people.com.cn/200607/01/images/railway.jpg)
The Qinghai-Tibet railway lies in the west area of China at an altitude of more than 4,000
meters. The 576-km railway is being built on frozen earth. The bad climate and sandstorms
of the tundra require the concrete of the bridge to have superior mechanical properties and
high durability. By adding portland cement, silica fume, superfine fly ash, and
superplasticizers, reactive powder concrete (RPC) is used in the sidewalk systems of
bridges with compressive strength of 160 MPa.
There are a lot of different problems with conventional concrete sidewalks such as corrosion,
rust of reinforcing steel bars, and breakability of concrete slab. The steel brackets rust in a
conventional concrete sidewalk. As a result, a conventional concrete sidewalk system
requires maintenance every year. Dead weight of the traditional sidewalk system is greater
than that of the RPC sidewalk system, which makes bridges have a bad dynamic
performance.
The sidewalk system made of RPC has such merits as small deadweight, excellent
durability, low cost, and minimum maintenance. Thus, RPC is more suitable for the sidewalk
system of Qinghai-Tibet Railway than conventional concrete.
8.2 Pedestrian bridge in Sherbrooke
Spanning 197 ft ( 60 m), this precast, pre stressed pedestrian/bikeway bridge in Sherbrooke,
Quebec, is a post-tensioned open-web space truss containing no conventional steel
reinforcement. Made up of six prefabricated match-cast segments, it was manufactured
using RPC.
An extensive program monitoring bridge deflections and forces in the pre stressing tendons
has been implemented to Provide information on long-term performance of RPC.

Fig.5 sherbrooke pedestrian bridge
9. References
1. Composition of reactive powder concretes Pierre Richard and Marcel Cheyrezy Cement
and Concrete Research, Vol. 25. No. 7, pp. 1501-1511.1995.
(http://www.sciencedirect.com/science/article/pii/0008884695001442)
2. MICROSTRUCTURAL ANALYSIS OF RPC Pierre Richard and Marcel Cheyrezy Cement
and Concrete Research, Vol. 25, No. 7. pp. 1491-1500.1995.
(http://www.sciencedirect.com/science/article/pii/000888469500143Z)
3. The effect of autoclave pressure, temperature and duration time on mechanical properties
of reactive powder concrete by Halit Yazc, Engin Deniz, Blent Baradan. Construction and
Building Materials, Volume 42, May 2013, Pages 53-63
(http://www.sciencedirect.com/science/article/pii/S0950061813000299)
4. Compressive and tensile properties of reactive powder concrete with steel fibres at
elevated temperatures by Wenzhong Zheng, Baifu Luo, Ying Wang.
Construction and Building Materials, Volume 41, April 2013, Pages 844-851
(http://www.sciencedirect.com/science/article/pii/S0950061813000226)
5. Mechanical performance of low cement reactive powder concrete (LCRPC) by Hseyin
Yiiter, Serdar Aydn, Halit Yazc, Mert Ycel Yardmc. Composites Part B:
Engineering, Volume 43, Issue 8, December 2012, Pages 2907-2914
(http://www.sciencedirect.com/science/article/pii/S1359836812004969)
6. Compressive behaviour of hybrid fiber-reinforced reactive powder concrete after high
temperature by Wenzhong Zheng, Haiyan Li, Ying Wang.
Materials & Design, Volume 41, October 2012, Pages 403-409
(http://www.sciencedirect.com/science/article/pii/S0261306912003275)
7. Compressive stressstrain relationship of steel fiber-reinforced reactive powder
concrete after exposure to elevated temperatures by Wenzhong Zheng, Haiyan Li, Ying
Wang .Construction and Building Materials, Volume 35, October 2012, Pages 931-940
(http://www.sciencedirect.com/science/article/pii/S095006181200387X)
8. Reactive powder concrete change in compressive strength and modulus of elasticity at
high temperature by Tomasz Zdeb, Izabela Hager, Jacek liwiski. Brittle Matrix Composites
10, 2012, Pages 135-143
(http://www.sciencedirect.com/science/article/pii/B978085709988450013X)
9. Assessing drying shrinkage and water permeability of reactive powder concrete produced
in Hong Kong by C.M. Tam, Vivian W.Y. Tam, K.M. Ng. Construction and Building
Materials, Volume 26, Issue 1, January 2012, Pages 79-89
(http://www.sciencedirect.com/science/article/pii/S0950061811002443)
10. Effect of pre-setting pressure applied to mechanical behaviours of reactive powder
concrete during setting phase by Metin Ipek, Kemalettin Yilmaz, Mansur Smer, Mehmet
Saribiyik .Construction and Building Materials, Volume 25, Issue 1, January 2011, Pages 61-
68
(http://www.sciencedirect.com/science/article/pii/S0950061810003053)