MATEC Web of Conferences 120, 03014 (2017) DOI: 10.

1051/ matecconf/201712003014
ASCMCES-17

Use of alternative waste materials in producing

ultra-high performance concrete
Shamsad Ahmad *
Civil & Environmental Engineering Department, King Fahd University of Petroleum & Minerals,
Dhahran-31261, Saudi Arabia

Abstract. In a corrosive environment similar to that of the Arabian Gulf,

use of high-performance concrete is one of the options to ensure a target
service life of concrete structures. However, in absence of good quality
coarse aggregates, it is a challenging task to produce high-performance
concrete. Recently, the possibility of producing ultra-high-performance
concrete (UHPC) has been widely reported in the literature. UHPC is
produced without coarse aggregates at very low water to cementitious
materials ratio, high amounts of cement, mineral admixtures, and
superplasticizer along with fine quartz sand as aggregate, quartz powder as
micro-filler, a nd steel fibres for fracture toughness. In the present work,
an effort was made to utilize local waste materials as alternative mineral
admixtures and local dune sand as aggregate in producing different UHPC
mixtures without addition of quartz powder. The mechanical properties,
shrinkage, and durability characteristics of the UHPC mixtures were studied.
Test results indicate that it is possible to produce UHPC mixtures using
alternative waste materials, which would have targeted flow, strength,
toughness, and resistance against reinforcement corrosion. The information
presented in the paper would help in optimum selection of a mixture of
UHPC considering the availability of local materials, exposure conditions
and structural requirements.

1 Introduction
In recent years, the possibility of producing ultra-high-performance concrete (UHPC) has
been widely reported in the literature. UHPC is produced without coarse aggregates at very
low water to cementitious materials ratio, high cementitious materials content, and quartz
fine sand, quartz powder as micro-filler, silica fume or any other suitable mineral admixture,
steel or polymer fibres, and high dosage of superplasticizer. UHPC is reported to possess
very high strength, elastic modulus, ductility (i.e., fracture toughness), and excellent
durability characteristics. The mechanical properties of UHPC typically reported in literature
are: compressive strength > 150 MPa, flexural tensile strength > 25 MPa, modulus of
elasticity > 50 GPa, and fracture energy > 20000 J/m2 [1-4].

*
Corresponding author: [email protected]

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative
Commons Attribution License 4.0 (http://creativecommons.org/licenses/by/4.0/).
MATEC Web of Conferences 120, 03014 (2017) DOI: 10.1051/ matecconf/201712003014
ASCMCES-17

The mixtures of UHPC are developed based on four principles: (i) reduction in porosity
through close packing of raw materials and reduction in water/cementitious materials ratio
with the help of superplasticizer; (ii) improvement in microstructure through close packing
of solid materials, facilitating hydration and pozzolanic reactions, and improving the
interfacial transition zone between aggregates and cementitious products; (iii) enhancement
in homogeneity by eliminating coarse aggregate and using fine raw materials; (iv) increase
in toughness by using fibres. Besides selection of suitable raw materials and mixture design,
the mixing methods and curing regimes also significantly affect the quality of UHPC [5].
The specifications regarding ingredients, mix design, mixing methods, and curing of
UHPC, as reported in literature, are briefly described in the following sub-sections along with
the objectives and significance of the present work.

1.1 Ingredients
Fine quartz sand having particles in the size range of 150 to 600 μm is used as the only
aggregate because coarse aggregate is eliminated from UHPC [2, 3, 5]. Quartz powder having
particle size distribution in the range of 0.1 to 100 μm is used as micro-filler [2, 3, 5]. If very
fine quartz sand is available, the UHPC can be produced without the quartz powder [6].
Ordinary Portland cement with low C 3 A content, low alkali content, and low to medium
fineness is used as primary binder [2, 3, 5]. Silica fume, a byproduct from ferro-silicium
industries with particle size distribution ranging from 0.1 to 1.0 μm is generally used as
mineral admixture [2, 3, 5]. Polycarboxylates are used as most effective superplasticizer for
UHPC to achieve the desirable fluidity [7]. Steel fibers having length of 13 mm and diameter
of 0.2 mm are often used in UHPC mixtures [5].
In addition to cement, silica fume is primarily used as supplementary cementitious
materials in UHPC. However, the use of silica fume may not be economical, particularly if
it is not available locally at a low price. The partial replacement of cement by locally available
cementitious materials would be economical and environment-friendly. The silica fume may
be partially or fully replaced and cement may be partially replaced (without compromising
with the quality of UHPC) by locally available supplementary cementitious materials such
as ground granulated blast furnace slag, fly ash, metakaolin, limestone powder, rice husk,
steel slag powder, cement kiln dust, nanomaterials (nano-SiO 2 , nano-CaCO 3 , nano-Fe 2 O 3 ,
nano-TiO 2 ), etc. [5, 8-14].

1.2 Design of UHPC mixtures

Particle size distribution, cement content, supplementary cementitious material content,
water/cementitious materials ratio, dosage of superplasticizer, and fiber content are the
parameters that are optimally selected to satisfy the requirements of UHPC in fresh and
hardened states [1, 15-16].
The particle size ranges of cement, supplementary cementitious materials (such as silica
fume), fine quartz sand and quartz powder should be selected in such a way that the grading
curve for the mixture of granular materials would match with the optimum grading curves,
reported in literature, for example optimum grading curve given by Schmidt and Fehling [17]
and particle size distribution model for optimization of the composition of mixture of
granular materials used for UHPC [18-19].
The values of the mix design parameters can be selected within their ranges as reported
in literature [20], as follows: water to total binder ratio 0.15-0.24, cement content 800-1100
kg/m3, silica fume content 150-300 kg/m3, silica fume to cement ratio 0.15-0.35, cement and
silica fume content 950-1400 kg/m3, quartz and sand 1000-1400 kg/m3, steel fiber content
190-250 kg/m3.

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MATEC Web of Conferences 120, 03014 (2017) DOI: 10.1051/ matecconf/201712003014
ASCMCES-17

In order to obtain an optimum mixture design satisfying the intended fresh and hardened
properties of UHPC, various trial mixtures should be considered by choosing different sets
of mixture design parameters within their reported ranges satisfying the absolute volume
equation, i.e. the sum of absolute volumes of all the ingredients including air content should
be equal to the total volume of UHPC considered for mixture design for example 1 m3. After
mixture design, the UHPC mixtures should be prepared and tested for flow. The dosage of
superplasticizer should be adjusted to keep the flow as 200 ± 20 mm. Once the required flow
for each of the trial mixtures is achieved, the mixtures should be tested for their hardened
properties. An optimum mixture of UHPC, out of various trial mixtures considered, should
be finally selected based on the high performance at low consumption of cement. UHPC with
lower cement content would be economical and environment-friendly because of reduced
carbon dioxide footprint.

1.3 Preparation and curing of UHPC mixtures

UHPC mixtures are prepared by mixing the ingredients in a proper sequence. First cement,
supplementary cementitious materials, sand and filling powder are mixed in dry state for
about 10 minutes and then the mixture of water and superplasticizer is added in steps over a
period of about 5 to 10 minutes till appropriate flow ability of the mortar matrix is achieved.
Finally, the fibers are added [5]. The porosity of an UHPC mixture can be reduced enhancing
its hardened properties by using vacuum mixing [21-22]. Various curing regimes reported
for producing UHPC include standard room temperature curing for 28 days, heat curing
under atmospheric pressure, and autoclave curing [5].

1.4 Objective and significance of the present work

The main objective of the present work was to explore the possibility of producing UHPC
mixtures utilizing dune sand and several industrial waste materials such as micro silica,
natural pozzolana, fly ash, limestone powder, cement kiln dust, and pulverized steel slag,
locally available in Saudi Arabia. The outcomes of the present work would be useful in
producing UHPC mixtures by concrete industries in Saudi Arabia with a wider range of
options regarding the use of readily available raw materials and meeting out the intended
strength and durability requirements.

2 Experimental work

2.1 Materials

The ingredients used to prepare different mixtures of UHPC are listed in Table 1 along with their
specific gravities. Locally available dune sand having fine quartz particles was used in its
naturally-graded form in all the mixtures. The particle size distribution of the dune sand used in
this study is given in Table 2. Due to very fine size range of the dune sand, the quartz powder was
not used. A liquid superplasticizer (commercial name: Glenium 51) was used to obtain the
desired flow. Glenium 51 is a polycarboxylic ether (PCE) based superplasticizer with 65%
water content by weight that does not contain chlorides and complies with ASTM C494
Types A and F. Varying dosage of this superplasticizer was used to obtain a flow of 200 ±
20 mm for all the mixtures. Micro copper-coated steel fibres of 0.22 mm diameter and 13
mm length with an aspect ratio, l/d, of 59 were utilized. Fibres are made up of high strength
steel (tensile strength greater than 2850 MPa). Locally available supplementary cementitious
materials namely micro silica, natural pozzolana, limestone powder, cement kiln dust, and

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MATEC Web of Conferences 120, 03014 (2017) DOI: 10.1051/ matecconf/201712003014
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pulverized steel slag were used. The CaO and SiO 2 contents of all cementitious materials
used in the present study are presented in Table 3.
Table 1. List of ingredients used for producing UHPC mixtures.

Ingredient Specific gravity

Basic ingredients of UHPC
Water 1.00
Cement (Type I conforming to ASTM C150) 3.15
Dune sand 2.53
Superplasticizer (Glenium® 51) 1.09
Steel fibers 7.85
Micro silica 2.25
Waste materials used to partially replace micro silica and sand
Natural pozzolana 3.00
Fly ash 2.25
Limestone powder 1.60
Cement kiln dust 2.79
Pulverized steel slag 3.75
Table 2. Particle size distribution of dune sand used.
Sieve opening, mm Cumulative % retained
4.75 0
2.4 0
1.2 0
0.6 3.8
0.3 38.6
0.15 78.1
0.075 99.0
Table 3. CaO and SiO 2 contents of the cementitious materials used.
Cementitious material CaO content (%) SiO 2 content (%)
Cement (Type I) 64.35 22.00
Micro silica 0.48 92.50
Natural pozzolana 8.06 42.13
Fly ash 8.38 45.30
Limestone powder 45.70 11.79
Cement kiln dust 49.30 17.10
Pulverized steel slag 40.80 16.47

2.2 Design of mixtures

Design of several trial mixtures of UHPC was carried out considering various design
variables, such as water to cementitious material (w/cm) ratio, micro silica content, sand
content, and fiber content. Each trial mixtures of UHPC were prepared and tested for flow
before casting to test for compressive strength after 28-days of moist curing. Based on a
maximum flow of 230 mm and a maximum 28-day compressive strength of 161 MPa, a basic
optimum mixture of UHPC (designated as M0) having mixture proportion as follows: w/cm
ratio = 0.145 (by mass); cement content = 900 kg/m3; micro silica content = 220 kg/m3; sand
content = 1005 kg/m3; water content = 162.4 kg/m3; superplasticizer content = 40.3 kg/m3
(3.6% of the mass of cementitious materials); and steel fiber content = 157 kg/m3, was
selected.

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MATEC Web of Conferences 120, 03014 (2017) DOI: 10.1051/ matecconf/201712003014
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Taking the basic mixture of UHPC (M0) as a benchmark, various trial mixtures of UHPC
were considered by partially replacing micro silica and dune sand using different
permutations and combinations of the five waste materials, listed in Table 1, keeping
everything same as of mixture M0. These trial mixtures were prepared and tested for flow
and 28-day compressive strength and based on adequate flow and maximum 28-day
compressive strength, a total of seven optimum mixtures of UHPC with partial replacement
of silica fume and dune sand were selected. The details of eight optimally selected UHPC
mixtures for detailed study (i.e., M0 without replacement by waste materials and M1 to M7
with replacement by waste materials) are presented in Table 4.
Table 4. Details of eight optimally selected UHPC mixtures for detailed study
Optimally fixed parameters for all 8 mixtures: w/cm ratio = 0.145 (by mass); Cement content = 900
kg/m3; Mineral admixture content = 220 kg/m3; Water (w) content = 162.4 kg/m3; Superplasticizer
content = 40.3 kg/m3 (3.6% of the mass of cementitious materials); Steel fiber content = 157 kg/m3
Mixtur Optimum use of Waste materials (kg/m3)
MS Sand
e ID waste materials in NP FA LSP CKD PSS
(kg/m3) (kg/m3)
addition to MS
M0 Only MS 220 - - - - - 1005
M1 40% MS and 60% 88 132 - 1042
NP - - -
M2 40% MS and 60% 88 - - 1005
FA 132 - -
M3 80% MS and 20% 176 - - 985
LSP - 44 -
M4 80% MS and 20% 176 - - 1015
CKD - - 44
M5 10% sand replaced 220 - 87 - 868
by LSP - -
M6 5% sand replaced 220 - - 962
by CKD - - 48
M7 5% sand replaced 220 - 48 972
by PSS - - -
MS: Micro Silica; NP: Natural Pozzolana; FA: Fly Ash; LSP: Lime Stone Powder; CKD: Cement
Kiln Dust; PSS: Pulverized Steel Slag

2.3 Tests

Flow test was conducted on each of the eight selected mixtures of UHPC in accordance to
ASTM C1437 and subsequently test specimens were prepared to conduct tests for
determining their compressive strength, flexural strength, fracture toughness, drying
shrinkage, water absorption, DIN water penetration depth, chloride permeability, electrical
resistivity, and reinforcement corrosion rate. The details of specimens and test methods used
for determining various hardened properties of UHPC mixtures are given in Table 5.

3 Results and discussion

The summary of test results are presented in Table 6. It can be seen from Table 6 that almost
all mixtures have satisfied the flow requirements (required range of flow is 180 mm to 220
mm).
All eight mixtures possess compressive strength above 150 MPa. The compressive and
flexural tensile strengths and fracture toughness of the UHPC mixtures developed under this

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MATEC Web of Conferences 120, 03014 (2017) DOI: 10.1051/ matecconf/201712003014
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work are comparable to that of a patented UHPC mixture with a proprietary name Ductal®
[24].
Except few mixtures, the shrinkage is in the same range as that for the normal concrete
mixtures.
The water absorption for these UHPC mixtures is found to be around one-tenth of the
permissible limits for normal concrete. Water penetration depth is zero in all cases indicating
negligible water permeability. Chloride permeability and electrical resistivity values for all
eight mixtures of UHPC are indicating “very low” to “negligible” risk of reinforcement
corrosion. Very low corrosion current densities measured for all the UHPC mixtures (around
one-tenth of the threshold value) have confirmed that they are highly corrosion- resistant.
Table 5. Details of specimens and test methods used to determine hardened properties.
Property Specimen shape and size Specimens Test method
per
mixture
1. Compressive strength 50 mm cube 3 ASTM C 109
2. Flexural tensile strength
40 u 40 u 160 mm prism 3 ASTM C 78
(using 3 point bend test)
40 u 40 u 160 mm prisms Jenq and Shah
3. Fracture Toughness 3
(notched) [23]
4. Drying shrinkage 25 u 25 u 275 mm prism 3 ASTM C 356
5. Water absorption 75 u 150 mm cylinder 3 ASTM C 642
6. Water penetration depth 100 mm cube 3 DIN 1048
7. Rapid chloride
100 u 200 mm cylinder 3 ASTM C 1202
permeability
Two probe
8. Electrical resistivity 75 u 150 mm cylinder 3
Wenner method
A centrally embedded rebar in Linear
9. Reinforcement corrosion
75 u 150 mm concrete 3 polarization
rate
cylinder resistance method
Table 6. Summary of test results of eight optimally selected UHPC mixtures
28-d Compressive strength

exposure to chloride for six

permeability (Coulombs)
Water penetration depth
Drying shrinkage strain
28-d fracture toughness

after around 6 months

Water absorption (%)

28-d flexural strength

Corrosion rate after

Electrical resistivity

months (μA/cm2)
Rapid chloride
Mixture ID

Flow (mm)

(MPa ξ‫)ܕ‬

(microns)

-cm)
(MPa)

(MPa)

(mm)

M0 230 161 31 8.0 450 0.43 0 9 179.6 0.038

M1 195 154 29 5.2 845 0.62 0 66 205.8 0.038
M2 210 158 32 6.5 446 0.40 0 75 110.6 0.017
M3 255 152 31 4.0 594 0.40 0 37 245.1 0.020
M4 220 153 25 4.4 585 0.35 0 78 182.1 0.033
M5 215 163 29 4.0 867 0.32 0 35 313.0 0.029
M6 180 153 26 4.0 1147 0.40 0 75 176.8 0.039
M7 210 161 24 4.5 718 0.41 0 49 215.4 0.026

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MATEC Web of Conferences 120, 03014 (2017) DOI: 10.1051/ matecconf/201712003014
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4 Conclusions
Based on the results of the present study, following conclusions can be drawn:

1. The local dune sand and several waste materials available in abundance in Saudi
Arabia have potential to produce UHPC mixtures.
2. The local dune sand was found to be naturally well graded cutting the need for quartz
powder. Arranging quartz powder for producing UHPC is a big hassle and consumes
a lot of time, energy and money.
3. The developed mixtures of UHPC having strength and durability several times more
than the normal concrete could be utilized alternatively in special structural members,
such as long span bridge girders, large-diameter concrete pipes, heavy-duty tanks,
high-rise buildings, precast concrete members etc., and for repairing the deteriorated
concrete structures.

The author gratefully acknowledges the financial support received from King Abdulaziz City for
Science and Technology (KACST), Saudi Arabia, through King Fahd University of Petroleum &
Minerals (KFUPM), Saudi Arabia, for carrying out this project under the National Science, Technology
and Innovation Plan (NSTIP) funding (Project No. AM-08-2009, Code Number: 09-ADV751-04). The
technical support received from the Civil & Environmental Engineering Department and the Center for
Engineering Research at the Research Institute, KFUPM, are also acknowledged.

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