Research Articles | Challenge Journal of Concrete Research Letters

Design of reactive powder concrete mortar mixes through high strength and durability

Yousry B. I. Shaheen, Zeinab A. Etman, Hanan Lotfy Sabiha


DOI: https://doi.org/10.20528/cjcrl.2025.03.004
View Counter: Abstract | 43 times | ‒ Full Article | 7 times |

Full Text:

PDF

Abstract


This research investigates the characteristics of reactive powder concrete (RPC) through comprehensive analysis. The primary methodology involved evaluating both fresh (uncured) and hardened RPC specimens. The initial phase incorporated silica fume (SF) as a cement replacement at concentrations of 5, 10, 15, 20, and 25%, fly ash (FA) substitution at levels of 5, 10, 20, 25, and 30% of the cement content, plus binary combinations where SF constituted 10% cement replacement while FA proportions ranged from 10 to 30%. Material behavior was assessed through slump flow testing procedures. Hardened concrete evaluation encompassed dry density measurements, compressive strength analysis conducted at 7, 28, 56, and 90-day intervals, along with tensile splitting strength and flexural strength determination at 28 days. Results demonstrate that FA substitution alone provides superior workability compared to SF+FA combinations and pure SF, whereas SF replacement individually exhibits enhanced compressive, tensile splitting, and flexural strength performance relative to standalone FA and binary SF+FA mixtures. The subsequent investigation phase examined the influence of nano-silica (NS) on fresh and hardened RPC characteristics. NS replaced cement at 1, 2, 3, 4, and 5% levels, combined with 10% SF and 20% FA. Findings revealed that increased NS content diminishes workability due to elevated water demand for hydration and mixing processes as particle fineness increases. Regarding hardened properties, the optimal composition comprises 10% SF, 20% FA, and 3% NS, attributed to NS’s effective interaction with calcium hydroxide generated during cement hydration, which facilitates additional C-S-H formation through enhanced pozzolanic reactions. This mechanism results in improved mixture performance and strength development.


Keywords


reactive powder concrete; blast furnace slag cement; silica fume; fly ash; nano silica

References


Aïtcin PC (2000). Cements of yesterday and today. Cement and Concrete Research, 30(9), 1349-1359.

Aïtcin PC (2016). Supplementary cementitious materials and blended cements. In: Aïtcin PC, Flatt RJ, editors. Science and Technology of Concrete Admixtures. Elsevier, Amsterdam, Netherlands, 53-73.

Albakry BA, Abbas ZK (2025). Evaluation of reactive powder concrete strength using various curing methods. Engineering, Technology & Applied Science Research, 15(2), 21685-21690.

ASTM C1017 / C1017M – 13 (2013). Standard specification for chemical admixtures for use in producing flowing concrete. ASTM International, West Conshohocken, PA, USA.

ASTM C109 / C109M – 20b (2020). Standard test method for compressive strength of hydraulic cement mortars (using 2-in. or [50-mm] cube specimens). ASTM International, West Conshohocken, PA, USA.

ASTM C348 – 21 (2021). Standard test method for flexural strength of hydraulic-cement mortars. ASTM International, West Conshohocken, PA, USA.

ASTM C496 / C496M – 17 (2017). Standard test method for splitting tensile strength of cylindrical concrete specimens. ASTM International, West Conshohocken, PA, USA.

ASTM C618 – 19 (2019). Standard specification for coal fly ash and raw or calcined natural pozzolan for use in concrete. ASTM International, West Conshohocken, PA, USA.

ASTM C642 – 13 (2013). Standard test method for density, absorption, and voids in hardened concrete. ASTM International, West Conshohocken, PA, USA.

ASTM C1116 / C1116M – 10a (2010). Standard specification for fiber-reinforced concrete. ASTM International, West Conshohocken, PA, USA.

ASTM C1339 / C1339M – 08 (2008). Standard specification for thin bonded overlays for bridge decks using hydraulic cement concrete. ASTM International, West Conshohocken, PA, USA.

Bahmani H, Mostofinejad D (2022). Microstructure of ultra-high-performance concrete (UHPC) – A review study. Journal of Building Engineering, 50, 104118.

Balapour M, Joshaghani A, Althoey F (2018). Nano-SiO₂ contribution to mechanical, durability, fresh and microstructural characteristics of concrete: A review. Construction and Building Materials, 181, 27-41.

Chandra S, Berntsson L (1996). Use of silica fume in concrete. In: Chandra S, Berntsson L, editors. Waste Materials Used in Concrete Manufacturing. Elsevier, Amsterdam, Netherlands, 554-623.

Danha LS, Khalil WI, Al-Hassani HM (2013). Mechanical properties of reactive powder concrete (RPC) with various steel fiber and silica fume contents. Engineering and Technology Journal, 31(16), 3090–3108.

E.S.S. 1109 (2008). Aggregates for concrete. Egyptian Organization for Standardization and Quality (EOS), Cairo, Egypt.

E.S.S. 4756-1 (2013). Plain and reinforced concrete – Part 1: Specifications, performance, production and conformity. Egyptian Organization for Standardization and Quality (EOS), Cairo, Egypt.

E.S.S. 5129-1 (2006). Products and systems for the protection and repair of concrete structures – Definitions, requirements, quality control and evaluation of conformity – Part 1: Definitions. Egyptian Organization for Standardization and Quality (EOS), Cairo, Egypt.

Ge W, Wang A, Zhang Z, Ge Y, Chen Y, Li W, Jiang H, Shuai H, Sun C, Yao S, Qiu L (2023). Study on the workability, mechanical property and water absorption of reactive powder concrete. Case Studies in Construction Materials, 18, e01777.

Golewski GL (2018). An assessment of microcracks in the interfacial transition zone of durable concrete composites with fly ash additives. Composite Structures, 200, 515-520.

Hefni Y, Zaher YA El, Wahab MA (2018). Influence of activation of fly ash on the mechanical properties of concrete. Construction and Building Materials, 172, 728-734.

Ju Y, Tian K, Liu H, Reinhardt HW, Wang L (2017). Experimental investigation of the effect of silica fume on the thermal spalling of reactive powder concrete. Construction and Building Materials, 155, 571-583.

Keshavarzian F, Saberian M, Li J (2021). Investigation on mechanical properties of steel fiber reinforced reactive powder concrete containing nano-SiO₂: An experimental and analytical study. Journal of Building Engineering, 44, 102601.

Kong D, Du X, Wei S, Zhang H, Yang Y, Shah SP (2012). Influence of nano-silica agglomeration on microstructure and properties of the hardened cement-based materials. Construction and Building Materials, 37, 707-715.

Kurdowski W (2014). Mineral additions for cement production. In: Kurdowski W, editor. Cement and Concrete Chemistry. Springer Netherlands, Dordrecht, Netherlands, 533-583.

Malheiro R, Camões A, Meira G, Pinto J (2020). Durability of fly ash eco-friendly cement mortars in severe environment. Procedia Manufacturing, 46, 122-130.

Moffatt EG, Thomas MDA, Fahim A (2017). Performance of high-volume fly ash concrete in marine environment. Cement and Concrete Research, 102, 127-135.

Neville AM (2005). Properties of Concrete (4th and final edition). Pearson Education Limited, Harlow, England.

Ranjan M, Kumar S, Sinha S (2024). Nanosilica’s influence on concrete hydration, microstructure, and durability: A review. Journal of Applied Engineering Sciences, 14(2), 322-335.

Rashad AM (2014). A comprehensive overview about the effect of nano-SiO₂ on some properties of traditional cementitious materials and alkali-activated fly ash. Construction and Building Materials, 52, 437-464.

Richard P, Cheyrezy M (1995). Composition of reactive powder concretes. Cement and Concrete Research, 25(7), 1501-1511.

Rupasinghe M, Mendis P, Ngo T, Nguyen TN, Sofi M (2017). Compressive strength prediction of nano-silica incorporated cement systems based on a multiscale approach. Materials & Design, 115, 379-392.

Sadrekarimi A (2004). Development of a light weight reactive powder concrete. Journal of Advanced Concrete Technology, 2(3), 409-417.

Sarika S, Elson J (2015). A study on properties of reactive powder concrete. International Journal of Engineering Research & Technology, 4(11), 110-113.

Shen M, Zhou L, Chen Z, Shen Y, Huang B, Lv J (2022). Effects of basalt powder and silica fume on ultra-high-strength cementitious matrix: A comparative study. Case Studies in Construction Materials, 17, e01397.

Sultan HK, Zinkaah OH, Rasheed AA, Alridha Z, Alhawat M (2022). Producing sustainable modified reactive powder concrete using locally available materials. Innovative Infrastructure Solutions, 7(6), 342.

Tan H, Yuan P, Sun D, Fan X, Wang C, Liu J (2025). Ratio of water to cement and supplementary cementitious materials on mechanical and impact resistance properties of reactive powder concrete. Scientific Reports, 15(1), 7480.

Ullah R, Qiang Y, Ahmad J, Vatin NI, El-Shorbagy MA (2022). Ultra-high-performance concrete (UHPC): A state-of-the-art review. Materials, 15(12), 4131.

Wang BM (2011). Influence of nano-SiO₂ on the strength of high performance concrete. Materials Science Forum, 686, 432-437.

Yazıcı H, Yardımcı MY, Aydın S, Karabulut AŞ (2009). Mechanical properties of reactive powder concrete containing mineral admixtures under different curing regimes. Construction and Building Materials, 23(3), 1223-1231.

Yu R, Spiesz P, Brouwers HJH (2015). Development of an eco-friendly ultra-high performance concrete (UHPC) with efficient cement and mineral admixtures uses. Cement and Concrete Composites, 55, 383-394.

Zhang L, Ma N, Wang Y, Han B, Cui X, Yu X, Ou J (2016). Study on the reinforcing mechanisms of nano silica to cement-based materials with theoretical calculation and experimental evidence. Journal of Composite Materials, 50(29), 4135-4146.

Zhang Y, Wang J, Wang J, Qian X (2022). Preparation, mechanics and self-sensing performance of sprayed reactive powder concrete. Scientific Reports, 12(1), 7787.


Refbacks

  • There are currently no refbacks.