Optimizing Concrete Mix Designs for Ultra-High-Performance Concrete

(UHPC) Using Nano-Silica

Final Year Project Proposal

M. Umar Khokhar 2K21-CIVE-13

Hanan Asgher 2K21-CIVE-10
Alishba Awan 2K21-CIVE-24

Supervisor
Engr. Saulat Jillani

Civil Engineering Department

NFC Institute of Engineering & Technology, Multan
Abstract:
Ultra-High-Performance Concrete (UHPC) represents a significant advancement in the field of
construction materials, offering exceptional strength, durability, and resilience. However,
optimizing its mix design to achieve these enhanced properties requires innovative approaches.
This paper focuses on the use of nano-silica as a key additive in UHPC mix designs to improve
mechanical performance and durability. Nano-silica enhances the microstructure of the concrete
by refining the pore size distribution and promoting pozzolanic reactions, which increase
compressive strength, reduce permeability, and improve resistance to chemical attack.
The study investigates the effects of incorporating various percentages of nano-silica into UHPC
formulations, analyzing parameters such as water-to-cement ratio, binder content, and aggregate
proportions. Experimental results reveal that optimal nano-silica content significantly enhances
UHPC's compressive strength, flexural strength, and durability compared to traditional UHPC
formulations. Additionally, the use of nano-silica improves particle packing density, reduces
voids, and leads to better dispersion of cementitious materials.
Through systematic optimization of the concrete mix, this research demonstrates that nano-silica
is a highly effective additive for producing UHPC with superior properties, offering potential
applications in infrastructure projects requiring high-performance materials. The findings
provide practical guidelines for engineers and researchers to develop sustainable and cost-
effective UHPC mix designs.

Introduction:
Ultra-high-performance concrete (UHPC) is an enhanced fibrous and cementitious concrete with
high compressive strength (120–250 MPa), particle packing density (0.825–0.855), tensile
strength (15–20 MPa), and extraordinary durability. UHPC has 300 times the ductility and
energy absorption of high-performance concrete (HPC) and three to sixteen times the
compressive strength of regular concrete. Because of its outstanding mechanical qualities as well
as its superior ductility and toughness under tension, UHPC is often regarded as the material of
choice when it comes to seismic design reasons. UHPC is a feasible option for enhancing the
long-term viability of buildings and infrastructure facilities.
UHPC is produced with a low water/cement (w/c) ratio. Given the low water content,
superplasticizer agents are required to improve the packing of the composite material’s particles,
which results in increased fluidity and workability of the mixture. In most UHPC manufacturing
scenarios, silica fume (SF) and ordinary Portland cement (OPC) are used as cementitious
binders. During the period 2018–2022, the global UHPC market is expected to develop at a
multifactorial annual growth level of close to 7%. The demand of UHPC has grown in recent
years; as the large carbon footprint of OPC has become a worldwide concern, the need for more
environment friendly cementing binders has increased considerably.
The mechanical properties of UHPC makes it a perfect material for applications where strength
is a primary design criterion and concrete structural element sizes can be lowered to make them
smaller, thinner, and more aesthetically acceptable. It is commonly composed of Portland
cement, fine aggregate, SF, a water reducing additive with a high range of effectiveness, and
fibers. UHPC may be a suitable material for concrete constructions that are exposed to harsh
environments. UHPC is widely used in bridge engineering, ultra-high-rise building, and long-
span objects. In an outdoor or severe climate-exposure situation, the better endurance and
longevity of UHPC improves service life and lowers maintenance cycles. It is possible to achieve
high tensile ductility and ultra-high compressive strength in concrete materials by employing the
use of synthetic fibers in UHPC. Although the technology and development of UHPC have been
thoroughly explored and established from micro to macro level, its extensive promotion remains
challenging because of complex manufacturing process and high cost. The complicated
manufacturing process is mostly because too many components are used, resulting in difficult
handling and high costs. UHPC technology introduces a novel product that enables infrastructure
developers to expand their product and service offerings. The fundamental tenet of this
technology is introducing systematic solutions to overcome inherent flaws in conventional
concrete. This novel concrete is the better choice as it exhibits better ductile behavior, with a
high capacity to distort and support tensile and flexural loads even after early cracking patterns.
The higher performance properties of UHPC are the result of upgraded mineral matrix
microstructural features and optimization of the bonding between concrete matrix components.
Since more than 20 years ago, UHPC has received growing interest from the construction sector,
with the focus on the following: construction bridges, unique architectural designs, skyscrapers,
damaged concrete components, vertical elements (e.g., wind turbines and windmills towers),
facilities related to gas and oil industry applications, offshore constructions, hydraulic structures,
and overlay materials. The usage of UHPC is prominent in all these applications and in addition
to bridge and road construction. UHPC is particularly well suited for bridge building in tough
conditions because its composites possess high strength and the need for rehabilitation during
service life is low. UHPC is also a desirable choice for bridge construction in high-traffic areas as
it provides long and stronger spans and thus creates additional space available for use. The
quality of used materials and manufacturing precision have a substantial influence on the
performance of UHPC though. The high cement content of UHPC is another aspect that
contributes to carbon dioxide (CO2) emission, which increases the concerns on environment
issues. As a cement replacement, SF incorporating fillers (such as quartz powder and limestone)
can tremendously improve the workability of ultra-high-performance fiber-reinforced concrete
(UHPFRC) and enhance the effectiveness of steel fibers in the material. Furthermore, the use of
fillers can reduce the amount of micro silica required, which is important for UHPFRC in terms
of cost, energy, and environmental impact. SF has a wide variety of physical and chemical
properties depending on its sources, so further research and standardization are warranted.

Problem Statement:
Ultra-High-Performance Concrete (UHPC) is widely recognized for its exceptional strength,
durability, and enhanced resistance to environmental factors. However, achieving the optimal
mix design to maximize these properties remains a significant challenge. Traditional UHPC
formulations often rely on high cement content and supplementary cementitious materials,
leading to issues such as increased cost, higher carbon emissions, and difficulties in achieving
consistent performance. The introduction of nano-silica as an additive offers a potential solution,
but its optimal integration into UHPC mix designs has not been fully explored. The problem lies
in identifying the optimal nano-silica dosage and corresponding mix parameters to achieve a
balance between cost, material performance, and sustainability. This research aims to address the
challenge of optimizing concrete mix designs for UHPC using nano-silica to improve strength,
durability, and workability, while also considering the economic and environmental impacts.

Research Objectives:
The research objectives are mentioned below:
1. To investigate the effects of nano-silica on the mechanical properties of UHPC.
2. To optimize the nano-silica content in UHPC mix designs.
3. To study the impact of nano-silica on the durability characteristics of UHPC.
4. To assess the influence of nano-silica on the microstructure of UHPC.
5. To develop sustainable and efficient UHPC mix designs using nano-silica.
6. To provide practical guidelines for the implementation of nano-silica in UHPC
production.

Link with Sustainable Development Goals (SDGs):

The SDGs linked with our project work are:
 Decent Work and Economic Growth (SDG-08).
 Industry, Innovation, and Infrastructure (SDG-09).
 Sustainable Cities and Communities (SDG-11).
 Responsible Consumption and Production (SDG-12).
 Climate Action (SDG-13).

Literature Review:
Ultra-High-Performance Concrete (UHPC) has gained considerable attention in recent years due
to its remarkable mechanical properties, including its high compressive strength (exceeding 150
MPa), excellent durability, and enhanced toughness. UHPC differs from traditional concrete in
its composition, which typically includes fine aggregates, low water-to-cement ratios, and the use
of supplementary cementitious materials (SCMs) like silica fume, fly ash, or slag. These
properties make UHPC ideal for applications in high-performance infrastructure, such as bridges,
high-rise buildings, and other structures requiring long-term resilience and minimal maintenance.
However, the optimization of UHPC mix designs remains a critical area of research. Achieving
the desired performance often requires the use of high cement content and advanced additives,
which increases costs and environmental impacts. One promising solution is the use of nano-
silica, a material that can enhance UHPC’s performance by refining its microstructure and
promoting chemical reactions at the nanoscale.
Sikora et al. (2016) highlight that nano-silica reacts with calcium hydroxide (CH) during the
hydration process to form additional calcium silicate hydrate (C-S-H) gel, the primary strength-
contributing phase in concrete. This reaction helps reduce the porosity of the cement matrix and
improves mechanical properties. Studies such as those by Zhu et al. (2014) and Nazari and
Riahi (2011) have demonstrated that nano-silica's ultra-fine particles improve particle packing
density in UHPC, which reduces voids and enhances the compressive and tensile strength of
concrete. Additionally, nano-silica can accelerate the early stages of cement hydration, leading to
improved strength development at earlier ages.
Liu et al. (2017) found that incorporating nano-silica in UHPC significantly improves
compressive strength, particularly when used in conjunction with silica fume. They observed that
an optimized dosage of nano-silica, typically ranging from 1-3% by weight of cement, resulted in
a more homogeneous microstructure with reduced microcracks. Quercia et al. (2012) found
similar results, reporting that nano-silica increased the flexural strength of UHPC by refining the
transition zone between cement paste and aggregates.
Zhu et al. (2018) showed that nano-silica particles contribute to the bridging and healing of
microcracks, preventing crack propagation and improving the material’s fracture resistance. This
property is critical for UHPC used in applications where high tensile forces and dynamic loads
are expected. Ghafari et al. (2015) found that nano-silica reduced the permeability of UHPC,
leading to better resistance against chloride ion penetration and sulfate attack. This is particularly
important for structures exposed to marine environments or de-icing salts.
Shi et al. (2015) examined the effect of nano-silica on UHPC’s freeze-thaw resistance. The
researchers concluded that nano-silica improves resistance to freeze-thaw cycles by densifying
the pore structure, thus minimizing the ingress of water, which is the primary cause of freeze-
thaw damage. Other studies, such as Mohammad and Ghaffar (2016), further demonstrate that
nano-silica helps mitigate alkali-silica reaction (ASR), a common durability issue in traditional
concrete.
Hou et al. (2020) pointed out that the cost of nano-silica remains a limiting factor for widespread
adoption in large-scale construction projects. Gao et al. (2018) also noted potential issues with
shrinkage in UHPC mixes containing high levels of nano-silica. While nano-silica improves
strength, it may contribute to early-age cracking due to increased autogenous shrinkage.