Abstract
Ultra-high-performance concrete (UHPC) represents the next generation of concrete, with a strength 3-4 times greater than traditional concrete (100-120 MPa as opposed to 30-40 MPa). However, most of the commercial UHPC mixes are proprietary and expensive. In this project, we document the development of nonproprietary, cost-effective UHPC mixes primarily using locally sourced or pre-qualified materials in Illinois. The research utilizes the modified Anderson and Andreasen packing model to establish a new parameter: “packing factor” that has a significant influence on the design and performance of multi-binder UHPC mixes. Initially, 19 UHPC mixes without fibers are analyzed for their rheological, mechanical, and durability properties, demonstrating promising results. Specifically, we obtain self-flowing capabilities with minimal HRWR usage (<1% by wt.%), a turnover time of 7–10 minutes, and a significant reduction in cement content (47% Type IL and the remaining 53% SCMs by volume) while maintaining superior compressive strengths (~120–150 MPa, 17.2–21.8 ksi @ 28 days). Then, optimal mixes, particularly M18 and M19, are evaluated with fibers, achieving compressive strengths exceeding 150 MPa (21.8 ksi) at 28 days and exhibiting open porosity under 2%, and have shrinkage rates below the target threshold (<800µξ @ 91 days). Finally, effective particle packing resulted in UHPC mixes costs of ~$400/m3 (~$308/yd3) without steel fibers and ~$590/m3 (~$454/yd3) with steel fibers, enabling cost-effective, optimal UHPC for deployment by the Illinois Department of Transportation.
Published Version
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