REACTIVE POWDER CONCRETE

SEMINAR REPORT
On

“REACTIVE POWDER CONCRETE”

A DEVELOPING ULTRA HIGH STRENGTH CONCRETE

SUBMITTED
TO

VIVESWARAIAH TECHNOLOGICAL UNIVERSITY

BELGAUM

FOR THE PARTIAL FULFILLMENT OF M-TECH

(STRUCTURAL ENGINEERING)

BY
DIVAKAR.Y
Reg. No: -
1st Semester M-Tech Structures

Under The Guidance of:

Prof. K.JAYARAM
Prof. & Head
Department of Civil Engineering

BANGALORE INSTITUTE OF TECHNOLOGY

(Affiliated To Visveswaraiah Technological University)
Bangalore-560004

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BANGALORE INSTITUTE OF TECHNOLOGY

BANGALORE -560004

CERTIFICATE

This is to certify that Mr. DIVAKAR.Y bearing university USN

has submitted the seminar report on “REACTIVE POWDER
CONCRETE A DEVELOPING ULTRA HIGH STRENGTH
CONCRETE” in partial fulfillment of the 1 st semester M-Tech
course in structural engineering as prescribed by the
Visveswaraiah Technological University during the academic year
2006-2007, under the guidance of Prof. K. JAYARAM

Prof. K.JAYARAM
Prof. & Head
Department of Civil Engineering

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ACKNOWLEDGEMENT

I express my deep sense of gratitude to PROF. K.JAYARAM

professor & Head, Department of Civil Engineering, BIT, for his
guidance and help through out this seminar work.

I will remain thankful to all the faculty members of Department

of Civil Engineering, BIT for their support during the course of this
work.

Finally I express gratitude to my family and friends.

DIVAKAR.Y
st
1 Semester M-TECH (STRUCTURES)
BANGALORE INSTITUTE OF TECHNOLOGY

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CONTENTS

1. INTRODUCTION

2. COMPOSITION OF RPC

3. MECHANICAL PERFORMANCE AND

DURABILITY OF RPC

4. MIXTURE DESIGN OF RPC AND HPC

5. RESULTS
5.1 Fresh Concrete Properties
5.2 Compressive Strength
5.3 Flexural Strength
5.4 Water Absorption
5.5 Resistance to Chloride Ion Penetration
5.6 Water Permeability

6. THE BENEFITS

7. STATUS

8. LIMITATIONS OF RPC

9. DISCUSSIONS

10. CONCLUSIONS

11. PHOTOGRAPHS
12. REFERENCES

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REACTIVE POWDER CONCRETE

A DEVELOPING ULTRA HIGH STRENGTH
CONCRETE
ABSTRACT
Concrete is a versatile and critical material for the construction of
infrastructure facilities throughout the world. A new developing material
known as reactive powder concrete (RPC) is available that differs
significantly from traditional concretes. RPC has no large aggregates, and
contains small steel fibres that provide additional strength and in some
cases can replace traditional steel reinforcement. Reactive powders
concrete (RPC) will allow the concrete industry to optimize material use,
generates economic benefits, and build structures that are strong and
durable. A comparison of the physical mechanical and durability
properties of RPC and high performance concrete (HPC) shows that RPC
possesses better (both compressive and Flexural strength) and lower
permeability compared to HPC. HPC leads the way to the achievement of
the maximum compressive strength of the order of say 120-150 MPa or
so. 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 coarser aggregate. This
philosophy has been employed in what is today known as reactive powder
concrete

1 INTRODUCTION

RPC with trade name ‘DUCTAL’ was developed in France by

researchers Mr.Richard and Mr. Cheyrezy in the early 1990s at
Bouygues, laboratory in France. The world’s first RPC structure, the
Sherbrooke Bridge in Canada, was constructed in July 1997. RPC is an
ultra high-strength and high ductility cementitious composite with
advanced mechanical and physical properties. It is a special concrete
where the microstructure is optimized by precise gradation of all particles
in the mix to yield maximum density. It extensively uses the pozzolanic
properties of highly refined silica fume and optimization of the Portland
cement chemistry to produce the highest strength hydrates.

RPC was nominated for the 1999 nova awards from the construction
innovation forum. RPC has been used successfully, for isolation and

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containment of nuclear wastes in Europe due to its excellent

impermeability.

This new material demonstrates greatly improved strength and durability

characteristics compared with traditional or even high-performance
concrete. Classified as Ultra-High Performance Concrete (UHPC), or
Reactive Powder Concrete (RPC). The improved properties of RPC are
obtained by improving the homogeneity of the concrete by eliminating
large aggregates, increasing compactness of the mixtures by optimizing
packing density of fine particles, and using fine steel fibres to provide
ductility

The HPC used for nuclear waste containment structures of Indian

concrete power plants are having moderate compressive strength,
moderate E value, uniform density, good workability, and high durability.
There is a need to evaluate RPC regarding its strength and durability to
suggest its use for nuclear waste containment structures.

2 COMPOSITION OF RPC
RPC is composed of very fine powders (cement, sand, quartz
powder, steel aggregates and silica fume), steel fibres (optimal) and a
superplasticizer. The superplasticizers, used at its optimal dosage,
decrease 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 810 MPa

Mr. Richard and Mr. Cheyrezy indicate the following principles for
developing RPC.

1. Enhancement of homogeneity by elimination of coarser

aggregates.
2. Enhancement of compacted density by Optimization of the
granular mixture.
3. Enhancement of the microstructure by Post-set heat-treatment
4. Enhancement of ductility by addition of small-sized steel fibres
5. Application of pressure before and during setting to improve
compaction
6. Utilization of the pozzolanic properties of silica fume.
7. The optimal usage of superplasticizer to reduce w/c and
improve workability

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Table1 (Mr. Dili and Mr. Santhanam, Indian concrete journal,

April 2004) lists salient properties of RPC, along with suggestions
on how to achieve them

Table 1 - Properties of RPC enhancing its homogeneity and

strength
Property of Description Recommended Types of
RPC Values Failure eliminated

Reduction Coarser aggregates are Maximum size Mechanical,

in replaced by fine sand with a of the fine sand chemical &
Aggregate reduction in the size of the is 600microns thermo-
size coarsest aggregate by a factor mechanical
of about 50
Enhanced Improved mechanical Young’s Disturbance of
mechanica properties of the paste by the modulus mechanical stress
l addition of silica fume values in 50-75 field
Properties GPa range
Reduction Limitations of sand content Volume of the By any external
in paste is at least source (Eg: Form
aggregate 20% greater work
to matrix than the voids
ratio index of non-
compacted
sand

Table 2 Describes the different ingredients of RPC and their selection

parameters.

The mixture design of RPC primarily involves the creation of a dense

granular skeleton. Optimization of the granular mixture can be achieved
either by the use of packing models or by particle size distribution
software such as LISA .For RPC mixture design, an experimental method
has been preferred. The major parameter that describes the quality of the
mixture is its water demand (quantity of water for minimum flow of
concrete). In fact the voids index of the mixture is related to the sum of
water demand and entrapped air.

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Table 2- Selection parameters for RPC components

Function Types
Components Selection Particle
parameters
Good
hardness Gives Strength
150µm to Natural
Sand Readily as
600µm crushed
available at Aggregate
low cost
C3 S: 60%
Binding material OPC
C2S: 22% 1µm to
Cement production of medium
C3A: 3.8% 100µm
primary hydrates fineness
C4AF:7.4%
Maximum
5µm to
Quartz Fineness reactive during Crystalline
25µm
heat-treating
Filling the voids,
enhances Procured
Very less rheology (flow from Ferro-
0.1µm to silicon
Silica fume quantity of ability), 1µm industry
impurities production of (highly
secondary refined)
hydrates
L:3-25mm
Good aspect
Steel fibre Improve ductility Dia:0.15- Straight
ratio
0.2mm
Less
Super- Polycrylat
retarding Reduce w/c ------
Plasticiser e based
characteristic

After selecting a mixture design according to minimum water demand,

optimum water content is analyzed using the parameter of relative density
(Do / Ds). Here Do and Ds represent the density of the concrete and the
compacted density of the mixture (no water or air), respectively. Relative
density indicates the level of packing of the concrete and its maximum
value is one. For RPC, the mixture design should be such that the packing
density is maximized.

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Heat curing does microstructure enhancement of RPC. Heat curing is by

simply heating (normally at 90 C) the concrete at normal pressure after it
has set properly. This considerably accelerates the pozzolanic 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 micro fibres are
generally added to RPC to enhance its ductility. Straight steel fibre used
typically are about 13mm long, with a diameter of 0.15mm.The fibre are
introduced into the mixture at a ratio of between 1.5 and 3 percent by
volume. The cost-effective optimal dosage is equivalent to a ratio of 2
percent by Volume.

Table 3 Comparison of oxide composition of different pazzalonic

material, we can notice that Sio2 presence in silica fumes is very
high

Table 3 - Oxide composition of Cementations Materials

(Concrete Technology by M.L.Ghambir page 36)

Oxide
Portland Silica Fly Blast Furnace
Composition, %
Cement Fume Slag
by Weight

CaO 63.0 4.15 2.5 42.4

SiO2 20.0 93.0 52.5 32.3
AL2O3 6.3 0.2 28.2 13.3
Fe2 O3 3.6 0.05 10.5 0.3
MgO 2.4 0.51 1.6 6.4
SO3 1.5 0.05 0.2 2.1
Na2O 0.15 0.2 0.04 -
K2O 0.5 0.22 0.9 -

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3 MECHANICAL PERFORMANCE AND DURABILITY

OF RPC

The RPC family includes two types of concrete, designated RPC 200 and
RPC 800, which offer interesting implicational possibilities in different
areas. Mechanical properties for the two types of RPC are given in Table
4(Mr. Dili and Mr.Santhanam, 2004). The high flexural strength of RPC
is due to the addition of steel fibres.

Table -4 Comparison of RPC 200 and RPC 800

RPC RPC 800

200
Compressive strength (using Quartz sand) MPa 170-230 490-680
Compressive strength (using Steel aggregate) ------- 650-810
MPa
Flexural strength MPa 30-60 45-141
Heat-Treating 20-90 250-400

Table 5- Shows mechanical properties of RPC compared to a

conventional HPC having compressive strength of 80 MPa. (Bickley J.A
and Mitchell D, 2001). 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.

Table 5 Comparisons of HPC (80 MPa) and RPC 200

HPC RPC 200

(80MPa)
Compressive strength MPa 80 200
Flexural strength MPa 7 40
Modulus of elasticity GPa 40 60
Fracture toughness J/m2 <103 30x103

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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 (Mr. Dauraic C, May 9,1997). The characteristics of
RPC given in table 6 (Mr. Bickley J.A and Mr. Mitchell D, 2001) enable
its use in chemically aggrasive environments and where physical wear
greatly limits the life of other concretes.

Table 6- Durability of RPC compared to HPC

Abrasive wear 2.5 times lower

Water absorption 7 times lower
Rate of corrosion 8 times lower
Chloride ions diffusion 25 times lower

4 MIXTURE DESIGN OF RPC AND HPC

The process of mixture selection of RPC and HPC is given below.

1. Considerable numbers of trial mixtures were prepared to obtain good

RPC and HPC mixture proportions.
2. Particle size optimization software, LISA (Elkem website) was used
for the preparation of RPC and HPC trial mixtures.
3. The selection of best mixture proportions was on the basis of good
workability and ideal mixing time.
4. Finalized mixture proportions of RPC and HPC are shown in Table 8
(Mr. Dili and Mr. Santhanam, 2004)

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Table 7- Mixture proportions of RPC and HPC

Materials Mixture proportions

RPC RPC- HPC HPC-Fibre
Fibre
Cement 1.00 1.00 1.00 1.00
Silica fume 0.25 0.25 0.12 0.12
Quartz powder 0.31 0.31 --- ---
Standard sand 1.09 1.09 --- ---
grade 2
Standard sand 0.58 0.58 --- ---
grade 3
River sand 2.40 2.40
20mm aggregate 1.40 1.40
10mm aggregate 1.50 1.50
30mm steel fibre 0.20
36mm steel fibre 0.20
Water 0.25 0.25 0.4 0.4

Workability and density were recorded for the fresh concrete mixtures.
Some RPC specimens were heat cured by heating in a water bath at 90 0 C
after setting until the time of testing. Specimens of RPC and HPC were
also cured in water at room temperature

The performance of RPC and HPC were monitored over time with respect
to the following parameters.

1. Compressive strength (as per IS 516 on 50mm cubes for RPC,

100mm cubes for HPC), flexural strength (as per IS 516 on
40x40x160 mm prisms for RPC, 100x100x500 cm beams for HPC)
2. Water absorption (on 150 mm cubes for both RPC and HPC),
confirming to BS 1881:122-1983
3. Non destructive water permeability test using German instruments
(on 150mm cubes for both RPC and HPC),
4. Resistance to chloride ions penetration test (on discs of diameter
100mm and 50mm as per ASTM C 1202)

5 RESULTS

The laboratory experiment conducted by Mr. Dili and Mr. Santhanam

(2004), based on the mix proportions given in table 6 has obtained the
following results.

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5.1 Fresh Concrete Properties

The workability of RPC mixture (with and without fibre) measured using
the mortar flow table test as per ASTM C 109 was in the range of 120-
140 mm. On the other hand, the workability of HPC mixture (with and
without fibre), measured using the slump test as per ASTM C 231,was in
the range of 120-150mm.The density of fresh RPC and HPC mixtures
was found to be in the range of 2500-2650 kg/m3.

5.2 Compressive Strength

The compressive strength test shows that RPC has higher compressive
strength than HPC 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. The maximum compressive strength of
RPC obtained from this study is high as 200 MPa, while the maximum
strength obtained for HPC is 75 MPa. The incorporation of fibre and use
of heat curing was seen to enhance the compressive strength of RPC by
30 to 50 percent. The incorporation of fibre did not affect the compressive
strength of HPC significantly.

Fig-1 Compressive Strength of RPC & HPC

5.2 Compressive Strength
5.3 Flexural Strength

Plain RPC was found to possess marginally higher flexural strength than HPC.Table
9 clearly explains the variation in flexural strength of RPC and HPC with
RPC-F Hot the addition
water curing
200
of steel fibres. Here the increase of flexural strength of RPC with RPC-F
the addition
Normalof fibre
curing

is higher than that 180

of HPC. RPC Hot water curing
RPC Normal curing

160
Table 9 Flexural
Mpa
strength (as per IS 516) at 28 days, MPa
HPC Hot wat er curing
HPC Normal curing
ngth 140
RPC 120
Stre RPC-Fibre HPC HPC-Fibre
NC
ve HWC NC HWC NC HWC
100
11
essi 12 18 22 8 10
mpr 80
CoNC-Normal60Cured; HWC-Hot water curing
40
0 7 14 21 28 35
According to Mr. Blais P.Y (1994) literature view RPC should have an
approximate flexural strength of 40 MPa. The reasons for low flexural
strength is due to theTime
fibre used
days(30mm) were long and their diameters
were relatively very higher. Fibre reinforced RPC (with appropriate fibre)
has the potential to be used in structures without any addition of steel
reinforcement. This cost reduction in reinforcement can compensate the

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increase in the cost by the elimination of coarse aggregates in RPC to

some extent
ent
perc
n
rptio
abso
5.4 Water Absorption
er
Wat
Fig 2 represents a comparison of water absorption of RPC and HPC. A
common trend of the water absorption with age is seen for both 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.

5.4. Water absorption

The incorporation of fibres and use of heat curing are seen to marginally
increase the water absorption. The presence of fibre possibly leads to
creation of channels at the interface between the fibre and paste HPC-F that
Normal curing
promote the3.5uptake of water. Heat curing, on the other hand, leads
HPC to the
Normal curing
development of a more open microstructure (compared to normal curing)
RPC-F Hot water curing
3 in an increased absorption.
that could result RPC-F Normal curing
RPC Hot wat er curing
2.5
5.5 Resistance to Chloride Ion Penetration RPC Normal curing
2
Penetration of chloride increases when heat curing is done in concrete.
Even though 1.5heat cured RPC shows a higher value than normal-cured
RPC, it is still
1 extremely low or even negligible (<100 coulombs). This
property of RPC enhances its suitability for use in nuclear waste
containment0.5structures. The addition of steel fibre leads to an increase in
the permeability,
0 possibly due to increase in conductance of the concrete.
The HPC mixture also showed very low permeability, although higher
compared to RPC. 0 7 14 21 28
Time days
Fig 2 Water absorption of RPC &HPC

5.6 Water Permeability

The non-destructive assessment of water permeability using the German
instrument equipment actually only measures the surface permeability
and not the bulk permeability like in conventional test methods. A

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comparison of the surface water permeability of RPC and HPC is shown

in Fig 3.

5.6 - Water permeability

c
se 3.5
m/
m 3
01
00 2.5 14th
0. day
, 2
ity 28th
bil 1.5 day
1
ea
m
r 0.5
pe
er 0
at RPC Fibered RPC HPC Fibered HPC
W
Type of concrete

Fig3 Surface water permeability of RPC and HPC

It can be seen from the fig 3 the water permeability decreases with age.
The 28-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 fibre increases the surface permeability of both types of
concrete.

6 THE BENEFITS
The Benefits of Reactive Powder Concrte are as follows.
1. RPC is a better alternative to High Performance Concrete and has
the potential to structurally compete with steel.
2. Its superior strength combined with higher shear capacity results in
significant dead load reduction and limitless structural member
shape.
3. With its ductile tension failure mechanism, RPC can be used to
resist all but direct primary tensile stresses. This eliminates the
need for supplemental shear and other auxiliary reinforcing steel.
4. RPC provides improve seismic performance by reducing inertia
loads with lighter members, allowing larger deflections with
reduced cross sections, and providing higher energy absorption.

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5. Its low and non-interconnected porosity diminishes mass transfer

making penetration of liquid/gas or radioactive elements nearly
non-existent. Cesium diffusion is non-existent and Tritium
diffusion is 45 times lower than conventional containment
materials.

7 STATUS

The firm HDR Engineering Inc. is responsible for the development

and promotion of RPC in North America. An application of RPC can
be seen in the Pedestrian Bridge 197m span, 3.3m wide, 3.0m deep,
30mm thick slab, in the city of Sherbrooke, Quebec, Canada. Seonyu
foot Bridge ,120m span, 4.4m wide, 1.3m deep, 30mm thick slab, in
Seoul, Korea, Sakata Mirai footbridge, in Japan and Canopy at
Shawnessy Light Rail Transit Station, Calgary, Canada. RPC has also
been used for isolation and containment of nuclear waste of several
projects in Europe and also for Producing Sewer, Culvert and
Pressure Pipes in Army engineer waterways experiment station, Vicksburg MS.,
This product was nominated for the 1999 Nova Awards from the
Construction Innovation Forum

8 LIMITATIONS OF RPC

In a typical RPC mixture design, the least costly components of

conventional concrete are basically eliminated or replaced by more
expensive elements. In terms of size scale, 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. 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). RPC should
be used in areas where weight savings can be realized and where some
of the remarkable characteristics of the material can be fully utilized.
Owing to its high members where durability issues are at stake (for
example, in marine condition). Since RPC is in its infancy,

the long-term properties are not yet known. Applying pressure to mix
and applying heat treatment in the field has got technological
difficulties and cost.

9 DISCUSSIONS

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A laboratory investigation carried out by Mr. Dili and Mr. Santhanam

gave the following conclusion.
1. A maximum compressive strength of 198 MPa was obtained. This
is in the RPC 200 range (175 MPa -225 MPa)
2. The maximum flexural strength of RPC obtained was 22 MPa,
lower than the values quoted 40 MPa. A possible reason for this
could be the higher length and the diameter of fibre used in this
study.
3. A comparison of the measurements of the physical, mechanical
and durability properties of RPC and HPC shows that RPC shows
better strength (both compressive and flexural) and lower
permeability compared to HPC,
4. The extremely low levels of water and chloride ion permeability
indicate the potential of RPC as a good material for storage of
nuclear waste. However, RPC needs to be studied with respect to
its resistance to the penetration of heavy metals and other toxic
wastes emanating from nuclear plants (such as Cesium 137 ion in
alkaline medium) to qualify for use in nuclear waste containment
structures.

10 CONCLUSIONS
RPC is an emerging technology that lends a new dimension to the term
“high performance concrete”. It has immense potential in construction
due to superior mechanical and durability properties than conventional
high performance concrete, and could even replace steel in some
applications. The development of RPC is based on the application of
some basic principles to achieve enhanced homogeneity, very good
workability, high compaction, improved microstructure and high
ductility. RPC has an ultra-dense microstructure, giving advantageous
waterproofing and durability characteristics. It could, therefore be a
suitable choice for industrial and nuclear waste storage facilities.

11. PHOTOGRAPHS

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Section RPC X- Steel PSC RCC

parameters Shaped
Section depth 360 mm 360 mm 700 700
mm
Flexural Strength or Fracture Energy ? mm
Weight 130 kg 110 kg 470 kg 530kg
Impact Resistance
– Drop Hammer Test -

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Impact resistance of:

Reactive Powder Concrete (RPC)

Impact resistance of:

Reactive Powder Concrete (RPC)

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 REACTIVE POWDER CONCRETE

Pedestrian Bridge,
Sherbrooke, Canada.

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 REACTIVE POWDER CONCRETE

Shawnessy Light Rail Transit Station,

Calgary, Canada

12. REFERENCES:
RICHARD P and CHEYREZY M “Composition of Reactive Powder
Concrete, Cement and Concrete Research”, 1995, Vol 25

AICTIN P.C. “Cements of yesterday and today: Concrete of tomorrow,

Cement and Concrete Research”, 2000, Vol 30.

BLAIS P.Y and COUTURE M. “Precast, Prestressed pedestrian bridge-

World’s first Reactive Powder Concrete structure, PCI journal” 1999,
Vol 44

DAURAIC C “Special concrete may give steel stiff competition:

Building concrete. The seattle Daily Journal of Commerce”, May 9,
1977.

BASU P.C “Performance requirements of HPC for Indian NPP

structure. The Indian

BONNEAU O, VERNET C, MORANVILLE M. and AITCIN P C

“Characterization of granular packing and percolation threshold of
Reactive Powder Concrete, Cement and Concrete Research” 2000 ,

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Vol 30

GOLTERMANN P, JOHNSAN V and PALBOL L “Packing of

aggregates: An alternate tool to determine the optimal aggregate mix,
ACI Materials Journal”, September – October 1997.

MATTE V and MORANVILLE M “Durability of reactive powder

composites: Influence of silica fume on the leaching properties of very
low w/b pastes, Cement and Concrete Composites”, 1999,
Vol 21.

STAQUET S and EPISON B “Influence of cement and silica fume type

on compressive strength of reactive powder concrete, 6th International
Sympoium on HPC,University of Brussels ,Belgium”, 2000.

BICKLEY J.A and MITCHELL D “A state of art review of high

performance concrete structures built in Canada”, 1990-2000(2001)

Dili and Santhanam,”The Indian concrete journal”, April 2004

Website on Reactive powder concrete

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