REACTIVE POWDER CONCRETE
advanced mechanical and chemical
Atri Agrawal and Nirav B. Thakkar
Reactive powder concrete is a
developing composite material that will
allow the concrete industry to optimize
material use, generate economic
benefits, build structure that are strong,
durable and sensitive to environment. A
comparison of the physical, mechanical
and durability properties of RPC and
high performance concrete shows that
RPC possesses better strength and lower
permeability compared to HPC.
Introduction
RPC is not just a simple mixture of
cement, water and aggregates. Quite
often, it contains mineral components
and chemical admixtures having very
specific characteristics, which impart
specific properties to the concrete.
HPC leads the way to the achievement
of the maximum compressive strength of
the order 120-150 MPa. 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 what is today known
as Reactive Powder Concrete.
RPC is an ultra high strength and high
ductility cementitious composite with
.
properties. It consists of special concrete
where the micro structure 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 Portland cement
chemistry to produce the highest
strength hydrates
The concept of RPC was first developed
by P. Richard and M. Cheyrezy and RPC
was first produced in the early 1990’s by
researchers at Bouygues laboratory in
France and the world’s first RPC
structure, the Sherbrooke Bridge in
Canada was constructed in July 1997.
RPC was nominated for the 1999 Nova
awards from the Construction Innovation
Forum. RPC has been used successfully
for isolation and containment of nuclear
wastes in Europe due to its excellent
impermeability
Reactive powder concrete can lead to
new horizon for the civil engineering
field in India. Booming infrastructure
development in India demands new
technologies to be implemented to make
structures stronger and highly durable.
Reactive powder concrete provides ultra
high strength and high durability which
meets the present as well as future
demand for the infrastructure
development.
.
COMPOSITION OF RPC
Materials
a) Cements
Cements were selected for their wide
compositional range. Their C3A content,
determined by quantitative XRD
(internal standard), varies from 1% up to
8%.Their Blaine fineness ranges from
320 m2 /kg to 430 m2 /kg . Their soluble
alkali content is very low and is
comprised between 0.16% and 0.38%.
b) Silica fumes
Their pozzolanic potential is measured
through the quantity of reacted CaO
during a Chapelle test. Their specific
surfaces are in range 11to12 m2 /g. The
ions in solution given by silica fume
particles were measured by inductively
coupled plasma (ICP) with water to solid
ratio of one.
c) Sand
Sand should be of good hardness, readily
available and low cost. Its particle size
ranges from 0.15mm to 0.6 mm. The
type of sand generally used is natural
and crushed.
d) Quartz powder
It is maximum reactive during heat
treatment. Its particle size ranges from
0.005mm to 0.025mm.
It should be crystalline in nature.
Table 1
Composition of RPC
Cement Silica fume Quartz flour
730 240 220
All quantities are in kg/ m3
e) Steel Fibers
It should have good aspect ratio and
should be able to improve ductility. Its
length ranges from 13mm 25mm. It
should be straight.
f) Water
It should be clean from all the organic
impurities as well as other dust particles.
It should not be saline in nature.
g) Super plasticizers
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. CAE contains carboxylic
(COOÿ) instead of sulfonic (SO3ÿ)
anionic groups present in PNS and PMS
polymers. The molar ratio of anionic
groups per organic monomer unit:
acrylic group (CAE), naphthalene
(PNS), melamine (PMS) is 1 for PNS
and PMS, and is much lower than 1 for
CAE copolymer. To obtain a good
workability and minimal secondary
effects, the SP dosage were optimized
with a rheometer, which is specially
designed for RPC.The dosage is
expressed as the mass percentage of the
solids of the SP related to the mass of
cement used.
Sand water superplasticizer
1040 150 15
PRINCIPLES FOR DEVELOPING
RPC
a) Elimination of coarse aggregate for
enhancement of homogeneity
b) Utilization of pozzolanic properties of
silica fume.
c) Optimal usage of super plasticizer to
reduce W/C and at the same time
improves compaction
d) Post- set heat treatment for
enhancement of the microstructure
e) Addition of small sized steel fibers to
improve ductility.
PROPERTIES
a) Fresh concrete properties
Workability of RPC mixtures measured
using the mortar flow table test is in the
range of 120 to 140 %. On the other
hand, workability of HPC mixtures using
slump test is in the range of 120 to 150
mm. Density of fresh RPC and HPC
mixtures in the range of 2500 to 2650
kg/m3.
b) Compressive strength
The compressive strength of RPC is
usually higher than HPC. 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 is in the range of 150 to 200 Mpa,
while the maximum strength for HPC is
75 Mpa. The incorporation of fibers did
not affect the compressive strength of
HPC significantly.
c) Flexural strength
Plain RPC is found to possess
marginally higher flexural strength than
HPC. The increase of flexural strength
of RPC with the addition of steel fibers
is higher than that of HPC.
RPC with compressive strength 200 Mpa
should have an approximate flexural
strength of 40 Mpa. The reason for low
flexural strength can be due to long
fibers and their relatively higher
diameter. Fiber reinforced RPC has the
potential to be used in structures without
any additional steel reinforcement. This
cost reduction in reinforcement can
compensate the increase in cost by
elimination of coarse aggregates in RPC
to some extent.
d) Water absorption and permeability
The percentage of water absorption of
RPC is very low compared to that of
HPC. This quality of RPC is one among
the desired properties of nuclear waste
containment materials. The
incorporation of fibers and use of heat
curing are seen to marginally increase
the water absorption. The permeability
of RPC is almost 7 times lower than that
of HPC
.
INFLUENCE OF FLY ASH AND
SLAG CONTENT ON
COMPRESSIVE STRENGTH OF
STEAM CURED SPECIMENS

The hydration of the cement compounds

proceeds more rapidly but the hydration
reactions are basically the same.
However, this higher rate of hydration
will lead to a lower ultimate strength.

The reactions of pozzolans are also

accelerated by the higher curing Furthermore, using 80% FA as a cement
temperatures. Fig. shows the influence replacement, caused disintegration
of FA content on compressive strength of during steam curing period. The
steam cured (90 C) and standard cured compressive strength of 6 days and 12
specimens. It can be seen from the figure days steam cured specimens are more
that, the increasing amount of FA than that of standard cured specimens in
content up to 60% replacement level, water during 28 days at all FA
generally caused an increase in replacement levels.
compressive strength at all curing
conditions. After 12 days of steam
curing, compressive strength of control FA, which has high lime content, used
specimens, FA20, FA40 and FA60 with SF and generally mechanical
mixtures are 154, 152, 159 and 155MPa, properties were improved by FA
respectively. replacement under steam curing possibly
due to the hydration reactions between
extra lime released from FA and SF
Fig. shows the influence of PS content compressive strength after 12 days steam
on compressive strength of steam cured curing.
(90 C) and standard cured mortars. It can
be seen from the figure that, with the
increasing amount of PS content up to
60% replacement level, generally an
increase in compressive strength is
observed at all curing conditions. After
12 days of steam curing, compressive
strength of control specimens, PS20,
PS40 and PS60 mixtures are 154, 150,
156 and 145 MPa, respectively.

Although, using 80% PS as a cement

replacement caused large reduction in
compressive strength for standard
curing, this mixture showed 134Mpa.
INFLUENCE OF DIFFERENT hydration process especially with
CURING CONDITIONS ON combined mineral admixtures.
COMPRESSIVE STRENGTH

APPLICATIONS

a) It can be used in nuclear waste

containment structures due to
lower water absorption and low
permeability.
b) It can be used for heavily loaded
structures like bridges due to its
ultra high strength and durability.
c) It can also be used for marine
structures due to high sulphate
Depending on the FA content, the
resistance.
compressive strength of steam cured (12
d) As no reinforcement is needed
days 90 1C) specimens relative to the
for fibred RPC it minimizes
high-pressure steam cured specimens (8
overall cost.
h, 2MPa, and 210 1C) is shown in Fig.
In steam curing, 60% FA replacement
and 80% PS replacement enabled greater
ADVANTAGES
compressive strength than the high-
pressure steam curing. Fig. shows the
a) As fracture toughness is higher,
effectiveness of steam curing and high-
RPC exhibits high ductility.
pressure steam curing with respect to the
b) Since RPC is an Ultra dense
standard curing. It can be concluded
micro structure, porosity and
from the figure; compressive strength at
permeability is less and therefore
all mixtures after high-pressure steam
can be used for waste storage
curing (8 h) is greater than the strength
holding facility.
of water cured specimens.
c) RPC has limited shrinkage,
increased corrosion resistance
Furthermore, the effectiveness of steam
and so can be used in aggressive
curing increases with increasing PS
chemical environments.
content, while this situation is not valid
for increasing FA replacement. Similar
trend is also observed with steam curing.
LIMITATIONS
In other words, 12 days of steam curing
improved the compressive strength of all
a) In RPC mix design low cost
mixtures with respect to the standard
component of conventional
curing. These findings can be explained
concrete are replaced by more
by the superior inter-reactions of the
expensive elements
ingredients (FA, PS, SF and cement). It
b) Since RPC is in its infancy, a
is clear that steam curing provides
long term properties are not yet
perfect conditions for complete and
known.
accelerated hydration media for
REACTIVE POWDER CONCRETE
USED IN THE SIDEWALK SYSTEM
OF THE QINGHAI-TIBET
RAILWAY BRIDGE
1. Introduction
The Qinghai-Tibet railway lies in
Qinghai-Tibet plateau in the west area of
China, at an altitude of more than 4,000
meters and in a high intensity earthquake
region. The 576-km railway is being
built on frozen earth. The climate
conditions are harsh in that area: low air
temperature, concentrated rain and snow,
and heavy sandstorms. The area also has
complicated geology conditions, and
groundwater causes corrosion. The
conditions mentioned above require the
concrete used for the bridges to have
superior mechanical properties and high
durability. As the subsidiary facility of
the railway bridge, the sidewalk system
needs to support the load from the
passersby and from some small
machines and equipment for
maintenance of the bridge. The
traditional sidewalk system of the
railway bridge is composed of angle
steel brackets and a concrete flat. The
traditional sidewalk system will be prone
to be out of order due to low durability
of concrete and angle steel bracket and
thus needs a great deal of maintenance to
keep it in service.
To adapt to severe conditions on the
Qinghai-Tibet plateau and to meet the
requirements of railway developments,
reactive powder concrete (RPC) has
been developed by the common
production process workflow with
national material in this research. RPC
has high strength and high durability,
including excellent impermeability of
chloride and frost-resistance. At the
same time, the structure members of
sidewalk system for the Qinghai-Tibet
railway, including flats, brackets, and
rails, have been manufactured.
2. Material and mechanics function of
the reactive powder concrete
2.1. Material preparation
This research concerns 42.5# Portland
cement, active mineral powder,
including high-quality silica fume whose
ratio surface exceeds 200,000 cm3/g,
low-need water superfine fly ash, super
plasticizers that have good compatibility
with cement, whose rate of reducing
water is above 32 percent, and quartz
sands whose grain size are 0.16 to 0.315
mm, 0.315 to 0.63 mm, 0.63 to 1.0 mm,
and that make up the most close-grained
preparation. It is detected that grain size
of the two materials is very different,
and they form discontinuous preparation
in the course of arranging cementitious
property and aggregates. Therefore,
higher mineral powder whose grain size
is between cementitious properties and
aggregates has been produced.
2.2. Mechanics function of the reactive
powder concrete
In order to study the influence of the
different mixture ratio on the RPC
material function, the following has been
studied: the influence of w/b ratio,
admixture of mineral additive,
compounding between different
preparation aggregates and cementitious
property, admixture of additive,
admixture of steel fibers, curing
temperature, and curing system. Through
hundreds of mixture ratio
experimentation, the optimal mixture
ratio, whose w/b ratio is 0.16, whose
curing temperature is 75°C and whose
mechanics function, is confirmed on the
basis of routine agitating and moulding
technology. It is known that concrete’s
28-day compressive strength is 168.6
MPa, bending strength is 20.6 MPa, and
elastic modulus is 46.8 Gpa,
3. Durability of Reactive Powder
Concrete
In such severe conditions as on the
Qinghai-Tibet plateau, the durability,
security, and service life of structures
will be distinctly reduced due to the
reasons such as the initial flaw of the
concrete cast in-suite in a low
temperature, subjectivity of the concrete
to frosting and thawing, and erosion
caused by groundwater brine. Chloride
impermeability is the ability of concrete
to resist high-pressed liquid such as
water penetrating the concrete. The
wearing off of concrete, either physical
or chemical, is concerned with water
penetration. So, impermeability of
chloride almost becomes the core
problem of durability of most concrete.
3.1. Chloride impermeability
There was no water leakage when
hydraulic pressure varies from 0.1 to 1.6
MPa with increase of 0.1 MPa/8h. When
hydraulic pressure was taken away, there
was only 2.7-mm penetration. As a
result, the conclusion can be reached that
RPC has excellent chloride
impermeability, caber-resistance, and
corrosion-resistance.
3.2. Frost resistance
These specimens were dropped in 20oC
water for 4 days. The temperature
ranged from negative 17oC to negative
13oC, while another from 4 oC to 8 oC,
and every cycle lasted 4 hours. After 800
cycles of freezing and thawing, relative
modulus of elasticity of RPC was still
100%, whereas the lost weight ratio was
0, and the durability ratio was 2.67.
From the results, the conclusion can be
reached that RPC has excellent frost-
resistance. Therefore, RPC is more
suitable for the bridges of Qinghai-Tibet
Railway than conventional concrete.
4. Study on the RPC Sidewalk System
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. To
improve the conventional sidewalk
system, RPC sidewalk system has been
developed in Beijing Jiao tong
University. An RPC sidewalk system
composed of pre-cast slabs, brackets,
and rails is assembled in-situ. RPC,
based on optimal mixture ratio, meets
the design requirements of sidewalk that
the compressive strength should be
greater than 120 MPa, and the split
tensile strength should be greater than 12
MPa. The slump of RPC is greater than
180 mm. With an excellent workability,
RPC can meet the requirements of
construction. 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.
CONCLUSIONS
1). Elimination of coarse aggregates
combined to optimization of the granular
mixture allows the obtention of an
homogenous and dense cementitious
matrix that exhibits high mechanical
performance
5). Helene Zanni, Marcel Cheyrezy,
Vincent Maret, Samuel Philippot and
Pedro Nieto, Investigation of hydration
and pozzolanic reaction in reactive
powder concrete, 1995

2). Application of a confining pressure to

the fresh concrete combined to excess
water removal further improves the
density. Induced micro cracking does not
impede compressive strength
enhancement.

3). Addition of small size steel fibers

gives RPC a ductile behavior.

ACKNOWLEDGEMENT

The authors would like to thank Prof

U.V.Dave for his guidance and support.

REFERENCES

1). A.S Dili and Manu Santhanam,

Investigations on concrete powder
concrete: A developing ultra high-
strength technology, 2004.

2). Halit Yazici, The effect of curing

conditions on compressive strength of
ultra high strength concrete with high
volume mineral admixtures, 2006.

3). Pierre Richard and Marcel Cheyrezy,

Composition of Reactive powder
concretes, 1995

4). Ching- Tsung Liu and Jong- Shing

Huang, Highly flowable reactive powder
mortar as a repair material, 2007