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How to Make Ultra High Performance Concrete

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How to Make Ultra High Performance Concrete
Step 1
Calculate how much concrete you will need for your job. Measure the surface area (length and width) of the area where you will be pouring concrete, and also determine how thick you need your concrete to be. Input these figures into a concrete calculator (see Resources below) to determine exactly how much concrete is required to complete your job.
Step 2
Purchase the amount of cement recommended by the calculator. Portland cement is the standard that should be used when making ultra high performance concrete. If you have difficulty obtaining enough Portland cement to cover your job, you may also mix in other cementitious materials, such as slag cement or fly ash.
Step 3
Determine how much coarse aggregate and fine aggregate you need for your mixture. Making concrete is a delicate balance, particularly if you are going to make ultra high performance concrete. The standard ratio is 11 percent Portland cement, 41 percent coarse aggregates (such as gravel or crushed stone) and 26 percent fine aggregates, such as sand. The remaining 22 percent is a combination of air and water (6 percent air and 16 percent water) in most concrete, but in ultra high performance concrete you need to use less water. Use these figures to calculate how much aggregate material you need to acquire.
Step 4
Mix your coarse aggregate with silica fume. Pour the course aggregate into your cement mixer and add just enough water to get the stones damp. Turn on the mixer and begin to slowly add the silica fume. The amount of silica should be roughly 4 to 5 percent (by weight) of the amount of course aggregate. So if you are using 100 lbs. of course aggregate, you will want to add 4 to 5 lbs. of silica fume. The use of the silica fume alone will increase the strength of your concrete to 15,000 psi. Mix the course aggregate and silica fume for 1 1/2 to 2 minutes.
Step 5
Add your Portland cement to the mix. Pour in your dry Portland cement and then continue mixing for an additional 1 1/2 to 2 minutes. The cement will not become active until the water is added, so at this point you are basically mixing dry ingredients.
Step 6
Add your fine aggregate and the polypropylene fibers. The amount of polypropylene fibers should be roughly equal to the amount of silica fume that was added to the mix. For example, if you added 5 lbs. of silica fume, you should add around 5 lbs. of fiber. Adding the fibers will double the strength of the concrete. Mix these items for 1 1/2 to 2 minutes.
Step 7
Add the water to your concrete mixer. Water is the key ingredient that activates Portland cement. In traditional concrete mixes, the overall mixture is approximately 16 percent water. Since you are making ultra high performance concrete and have already added silica fume and polypropylene fibers, less water is needed. Reduce the amount of water to equal 8 to 10 percent of the overall volume of the concrete mix.
Step 8
Mix the final solution. Mix all ingredients for 5 minutes to blend the water. Allow the concrete to sit for 3 minutes after this initial mixing so that the water has a chance to penetrate all of the ingredients. Mix the ingredients for another 5 minutes and then you are done. You have now made ultra high performance concrete with strength of approximately 30,000 psi.
Mechanical characteristic of UHPC compared to HPV and normal concrete
Normal concrete NPC  concrete UHPC concrete
Compressive strength kg/cm2 200-400 400-1000 1500-25000
Creep ratio Cu 3.35 1.6-1.9 0.2-0.8
 Porosity % 20-25 10-15 2-6
Tensile strength of seperation (Brazilian experiment)kg/cm2 25-32 - 70-250
Young's modulus 140000-420000 320000-560000 560000-630000
Ingredients range of UHPC mixing
Ingredients Value (kg)
Portland cement 630-900
Microsilides 200-250
Quartz Powder 180-250
Silica sand 800-1100
Steel Fibers 150-200
Super liquefaction 25-30
Water 150-180
Water-to-cement ratio 0.18-0.25
Parameters for durability
Normal concrete HPS UHPC
Carbonation depth (mm) after 3 years 7 4 1.5
Depth of penetration of  chlorine ion emission 23 8 1
Resistance to frost cycle 1500 150 20-50
Water absorption factor 60 11 1
Mixing scheme for UHPC with local materials mixing
Cement 730 kg
Silica sand passing through sieve with mesh grade 50 1010 kg
Quartz powder from sieve with mesh grade 200 210 kg
Microsilides 230 kg
Super liquefaction 28 kg
Water-to-cement ratio 0.21