Ultra-high performance concrete and fiber reinforced concrete: achieving strength and ductility without heat curing

Ultra-high performance concrete (UHPC) and ultra-high performance fiber reinforced concrete (UHP-FRC) were introduced in the mid 1990s. Special treatment, such as heat curing, pressure and/or extensive vibration, is often required in order to achieve compressive strengths in excess of 150 MPa (22 ksi). This study focuses on the development of UHP-FRCs without any special treatment and utilizing materials that are commercially available on the US market. Enhanced performance was accomplished by optimizing the packing density of the cementitious matrix, using very high strength steel fibers, tailoring the geometry of the fibers and optimizing the matrix-fiber interface properties. It is shown that addition of 1.5% deformed fibers by volume results in a direct tensile strength of 13 MPa, which is 60% higher than comparable UHP-FRC with smooth steel fibers, and a tensile strain at peak stress of 0.6%, which is about three times that for UHP-FRC with smooth fibers. Compressive strength up to 292 MPa (42 ksi), tensile strength up to 37 MPa (5.4 ksi) and strain at peak stress up to 1.1% were also attained 28 days after casting by using up to 8% volume fraction of high strength steel fibers and infiltrating them with the UHPC matrix.     

Dynamic impact factors of strain hardening UHP-FRC under direct tensile loading at low strain rates

Enhanced matrix packing density and tailored fiber-to-matrix interface bond properties have led to the recent development of ultra-high performance fiber reinforced concrete (UHP-FRC) with improved material tensile performance in terms of strength, ductility and energy absorption capacity. The objective of this research is to experimentally investigate and analyze the uniaxial tensile behavior of UHP-FRC under various strain rates, ranging from 0.0001 to 0.1 1/s. A direct tensile test set up is used. The experimental parameters encompass three types of steel fibers, each in three different volume fractions at four different strain rates resulting in 36 test series. Elastic and strain hardening tensile parameters, such as, cracking stress, elastic and strain hardening modulus, composite tensile strength and strain, energy absorption capacity, and crack spacing of the UHP-FRC specimens, are recorded and analyzed. Explanation of the material’s strain rate sensitivity is mainly based on the inertia effect of matrix micro cracking. Potential contributions of other mechanisms include viscosity of water within nanopores and confinement effects. Dynamic impact factor (DIF) formulas are provided based on the experimental data to illustrate the relationship between DIF and strain rate for UHP-FRC.     

Effect of loading rates on pullout behavior of high strength steel fibers embedded in ultra-high performance concrete

In this paper single fiber pull-out performance of high strength steel fibers embedded in ultra-high performance concrete (UHPC) is investigated. The research emphasis is placed on the experimental performance at various pullout rates to better understand the dynamic tensile behavior of ultra-high performance fiber reinforced concrete (UHP-FRC). Based on the knowledge that crack formation is strain rate sensitive, it is hypothesized that the formation of micro-splitting cracks and the damage of cement-based matrix in the fiber tunnel are mainly attributing to the rate sensitivity. Hereby, different pull-out mechanisms of straight and mechanically bonded fibers will be examined more closely. The experimental investigation considers four types of high strength steel fibers as follows: straight smooth brass-coated with a diameter of 0.2 mm and 0.38 mm, half end hooked with a diameter of 0.38 mm and twisted fibers with an equivalent diameter of 0.3 mm. Four different pull out loading rates were applied ranging from 0.025 mm/s to 25 mm/s. The loading rate effects on maximum fiber tensile stress, use of material, pullout energy, equivalent bond strength, and average bond strength are characterized and analyzed. The test results indicate that half-hooked fibers exhibit highest loading rate sensitivity of all fibers used in this research, which might be attributed to potential matrix split cracking. Furthermore, the effect of fiber embedment angles on the loading rate sensitivity of fiber pullout behavior is investigated. Three fiber embedment angles, 0°, 20°, and 45°, are considered. The results reveal that there is a correlation between fiber embedment angle and loading rate sensitivity of fiber pullout behavior.     

Preparation of C200 green reactive powder concrete and its static–dynamic behaviors

In this paper, a new type of green reactive powder concrete (GRPC) with compressive strength of 200 MPa (C200 GRPC) is prepared by utilizing composite mineral admixtures, natural fine aggregates, short and fine steel fibers. The quasi-static mechanical properties (mechanical strength, fracture energy and fiber–matrix interfacial bonding strength) of GRPC specimens, cured in three different types of regimes (standard curing, steam curing and autoclave curing), are investigated. The experimental results show that the mechanical properties of the C200 GRPC made with the cementitious materials consisting of 40% of Portland cement, 25% of ultra fine slag, 25% of ultra fine fly ash and 10% of silica fume, 4% volume fraction of steel fiber are higher than the others. The corresponding compressive strength, flexural strength, fracture energy and fiber–matrix interfacial bonding strength are more than 200 MPa, 60 MPa, 30,000 J/m² and 14 MPa, respectively. The dynamic tensile behavior of the C200 GRPC is also investigated through the Split Hopkinson Pressure Bar (SHPB) according to the spalling phenomena. The dynamic testing results demonstrate that strain rate has an important effect on the dynamic tensile behavior of C200 GRPC. With an increase of strain rate, the peak stress rapidly increases in the dynamic tensile stress–time curves. The C200 GRPC exhibits an obvious strain rate stiffening effect in the case of high strain rate. Finally, the mechanism of excellent static and dynamic properties gains of C200 GRPC is also discussed.     

Properties of strain hardening ultra high performance fiber reinforced concrete (UHP-FRC) under direct tensile loading

Enhanced matrix packing density and tailored fiber-to-matrix interface bond properties have led to the recent development of ultra-high performance fiber reinforced concrete (UHP-FRC) with improved material tensile performance in terms of strength, ductility and energy absorption capacity. The objective of this research is to experimentally investigate and analyze the uniaxial tensile behavior of the new material. The paper reviews and categorizes a variety of tensile test setups used by other researchers and presents a revised tensile set up tailored to obtain reliable results with minimal preparation effort. The experimental investigation considers three types of steel fibers, each in three different volume fractions. Elastic, strain hardening and softening tensile parameters, such as first cracking stress and strain, elastic and strain hardening modulus, composite strength and energy dissipation capacity, of the UHP-FRCs are characterized, analyzed and linked to the crack pattern observed by microscopic analysis. Models are proposed for representing the tensile stress–strain response of the material.     

钢纤维超高强混凝土动态力学性能

采用分离式霍普金森压杆装置对不同纤维体积率的钢纤维超高强混凝土进行不同应变率的冲击压缩试验,结果表明钢纤维超高强混凝土是应变率敏感材料,并测出其应变率敏感阀值,当应变率超过阀值后,钢纤维超高强混凝土的强度、韧度与弹性模量都随纤维体积率的增加而显著提高,在高应变率下,超高强混凝土基体成粉碎性破坏,而钢纤维超高强混凝土呈现出“裂而不散”的破坏形态。     

Fracture energy of UHP-FRC under direct tensile loading applied at low strain rates

This research investigates the fracture energy of ultra-high performance fiber reinforced concretes (UHP-FRC) under direct tensile loading applied at relatively low strain rates. Nine UHP-FRC series incorporating three types of steel fibers (straight, end-hooked, and twisted fibers), each in three different fiber volume fractions, are tested under uniaxial tensile loading at four different strain rates, ranging from 0.0001 s⁻¹ to 0.1 s⁻¹. Particular attention is given to clearly distinguish between the dissipated energy during the strain hardening and softening portions of the loading regime. The test results show that: 1) the fracture energy is mainly influenced by a parameter, termed fiber factor, which is a function of the fiber volume fraction and slenderness, and 2) all three types of UHP-FRCs exhibit increases in fracture energy with increasing strain rates. The observed strain rate sensitivity of the fracture energy suggests it is likely associated with the strain sensitive micro-cracking that occurs during fiber pull-out.     

Effects of coarser fine aggregate on tensile properties of ultra high performance concrete

This experimental research investigates the mechanical properties and shrinkage of ultra high performance concrete (UHPC) incorporating coarser fine aggregates with maximum particle size of 5 mm. To adequately design UHPC mixtures using various sizes of solid constituents, particle packing theory was adopted. UHPC mixtures containing either dolomite or basalt, and four fiber volume fractions up to two volume percent were investigated. Uniaxial tension test was performed to evaluate the first cracking tensile strength, ultimate tensile strength, tensile strain capacity and cracking pattern. The UHPC mixtures with dolomite and steel fibers with more than one volume percent achieved more than 150 MPa of compressive strength at the age of 56 days, and showed strain hardening behavior and limited decrease in tensile strength compared to typical UHPC without coarser fine aggregates. The experimental results highlight the potential of dolomite used as coarser fine aggregate in UHPC.     

High strain rate effects on direct tensile behavior of high performance fiber reinforced cementitious composites

Direct tensile behavior of high performance fiber reinforced cementitious composites (HPFRCCs) at high strain rates between 10 s⁻¹ and 30 s⁻¹ was investigated using strain energy frame impact machine (SEFIM) built by authors. Six series of HPFRCC combining three variables including two types of fiber, hooked (H) and twisted (T) steel fiber, two fiber volume contents, 1% and 1.5%, and two matrix strengths, 56 MPa and 81 MPa, were investigated. The influence of these three variables on the high strain rate effects on the direct tensile behavior of HPFRCCs was analyzed based on the test results. All series of HPFRCCs showed strongly sensitive tensile behavior at high strain rates, i.e., much higher post cracking strength, strain capacity, and energy absorption capacity at high strain rates than at static rate. However, the enhancement was different according to the types of fiber, fiber volume content and matrix strength: HPFRCCs with T-fibers produced higher impact resistance than those with H-fibers; and matrix strength was more influential, than fiber contents, for the high strain rate sensitivity. In addition, an attempt to predict the dynamic increase factor (DIF) of post cracking strength for HPFRCCs considering the influences of fiber type and matrix strength was made.     

Flexural performance of fiber-reinforced ultra lightweight cement composites with low fiber content

This paper presents an experimental study on flexural performance of ultra lightweight cement composites (ULCC) with 0.5 vol% fibers. Low density of the ULCC is achieved by using cenospheres from coal-fired power plants as micro aggregates. Effects of shrinkage reducing admixture (SRA) and fiber types on compressive strength and flexural performance of the ULCC are investigated. ULCC with density of 1474 kg/m³, compressive strengths of 68.2 MPa, flexural strength of 8 MPa, and deflection hardening behavior can be produced. Such good performance could be attributed primarily to the SRA which reduced entrapped air in paste matrix and densified fiber–matrix interface. The improvement on the flexural performance of the ULCC depends on fibers used and bond between fibers and matrix. Improvement of the flexural performance of the steel fiber (coated with brass) reinforced ULCC due to the densification effect by SRA was more significant than that of the PE fiber reinforced ULCC.     

Material and bond properties of ultra high performance fiber reinforced concrete with micro steel fibers

For investigating the effect of fiber content on the material and interfacial bond properties of ultra high performance fiber reinforced concrete (UHPFRC), four different volume ratios of micro steel fibers (V_f = 1%, 2%, 3%, and 4%) were used within an identical mortar matrix. Test results showed that 3% steel fiber by volume yielded the best performance in terms of compressive strength, elastic modulus, shrinkage behavior, and interfacial bond strength. These parameters improved as the fiber content was increased up to 3 vol.%. Flexural behaviors such as flexural strength, deflection, and crack mouth opening displacement at peak load had pseudo-linear relationships with the fiber content. Through inverse analysis, it was shown that fracture parameters including cohesive stress and fracture energy are significantly influenced by the fiber content: higher cohesive stress and fracture energy were achieved with higher fiber content. The analytical models for the ascending branch of bond stress-slip response suggested in the literature were considered for UHPFRC, and appropriate parameters were derived from the present test data.     

Rate-dependent tensile behavior of high performance fiber reinforced cementitious composites

High Performance Fiber Reinforced Cementitious Composites (HPFRCC) show strain hardening behavior accompanied with multiple micro-cracks under static tension. The high ductility and load carrying capacity resulting from their strain hardening behavior is expected to increase the resisting capacity of structures subjected to extreme loading situations, e.g., earthquake, impact or blast. However, the promise of HPFRCCs for dynamic loading applications stems from their observed good response under static loading. In fact, very little research has been conducted to investigate if their good static response translates into improved dynamic response and damage tolerance. This experimental study investigates the tensile behavior of HPFRCC using High strength steel fibers (High strength hooked fiber and twisted fiber) under various strain rates ranging from static to seismic rates. The test results indicate that the tensile behavior of HPFRCC using twisted fiber shows rate sensitivity while that using hooked fiber shows no rate sensitivity. The results also show that rate sensitivity in twisted fibers is dependent upon both fiber volume fraction and matrix strength, which influences the interface bond properties.     

Synergy assessment in hybrid Ultra-High Performance Fiber-Reinforced Concrete (UHP-FRC)

Ultra-High Performance Fiber-Reinforced Concretes (UHP-FRC) subjected to uniaxial tensile loads are investigated in the present paper. The study comprises a new procedure to assess the effectiveness of the hybridization, herein obtained by reinforcing UHP-FRC with micro and macro steel fibers. A comprehensive experimental campaign is also performed on monofiber and hybrid UHP-FRC. In all the concretes, the distance between the cracks and the minimum fiber volume fraction, which produces strain hardening response and multiple cracking, are theoretically and experimentally evaluated. If the bond parameter of the macro-fibers is properly calculated, the results of the analytical model, in terms of crack-spacing vs. fiber volume fraction, are in good agreement with the test data. Moreover, to increase the number of the cracks, and to reduce crack spacing, the hybridization is suitable only when the amount of macro-fibers is within a well-defined range.     

Strain rate dependent properties of ultra high performance fiber reinforced concrete (UHP-FRC) under tension

The results of an experimental investigation of UHP-FRC tensile response under a range of low strain rates are presented. The strain rate dependent tests are conducted on dogbone specimens using a hydraulic servo-controlled testing machine. The experimental variables are strain rate, which ranges from 0.0001 1/s to 0.1 1/s, fiber type, and fiber volume fraction. Five different types of fibers are considered including straight and twisted fibers with different geometric properties. The rate sensitivity of the composite material in tension is evaluated in terms of its first cracking strength, post-cracking strength, energy absorption capacity, strain capacity, elastic modulus, fiber tensile stress and number of cracks. The test results show pronounced rate effects on post-cracking strength and energy absorption capacity. Further, post cracking strength varies linearly with the fiber reinforcing index and energy absorption capacity varies linearly with the product of the fiber length and the reinforcing index, as predicted from the theory for fiber reinforced concrete.     

Flexural behavior of geopolymer composites reinforced with steel and polypropylene macro fibers

Like ordinary Portland cement concrete, the matrix brittleness in geopolymer composites can be reduced by introducing appropriate fiber reinforcement. Several studies on fiber reinforced geopolymer composites are available, however there is still a gap to understand and optimize their performance. This paper presents the flexural behavior of fly ash-based geopolymer composites reinforced with different types of macro steel and polypropylene fibers with higher aspect ratio. Three types (length-deformed, end-deformed and straight) of steel fibers and another type of length-deformed polypropylene fiber with optimum fiber volume fraction of 0.5% are studied. The effects of different geometries of the fibers, curing regimes (ambient cured and heat cured at 60 °C for 24 h) and concentration of NaOH activator (10 M and 12 M) on the first peak strength, modulus of rupture and toughness of the geopolymer composites are investigated. The quantitative effect of fiber geometry on geopolymer composite performance was also analyzed through a fiber deformation ratio. The compressive strength, splitting tensile strength and flexural toughness are significantly improved with macro fibers reinforcement and heat curing. The results also show that heat curing increases the first peak load of all fiber-reinforced geopolymers composites. End-deformed steel fibers exhibit the most ductile flexural response compared to other steel fibers in both heat and ambient-cured fiber reinforced geopolymer composites.     

Design of a new Ni-free austenitic stainless steel with unique ultrahigh strength-high ductility synergy

A conceptual approach was used to design a new Ni-free austenitic stainless steel with a unique combination of ultrahigh strength and ductility. The concept was based on the alloying of the 0.05C–18Cr–12Mn (wt.%) steel by 0.39%N and heavy warm rolling (84% reduction) at 1173 K (900 °C) to achieve the yield strength of minimum 1 GPa and high tensile strength and elongation due to a proper stability of the austenite as a result of the optimized stacking fault energy (SFE). The yield strength of 1010 MPa, tensile strength of 1150 MPa and high fracture strain of 70% were measured for the steel designed. Dislocation and solid solution hardening mechanisms are introduced as the main contributors for the ultrahigh yield strength of the steel. The strain hardening is gradual and the hardening rate reaches a high level of ∼2400 MPa at a high true strain of 40% due to slow α′-martensitic transformation and mechanical twinning. Consequently, the ductility of the designed steel is excellent.     

Strain rate effects on tensile deformation behavior of Fe-3.5Mn-0.3C-5Al ferritic based lightweight steel

Tensile deformation behavior of Fe-3.5Mn-0.3C-5Al ferritic based lightweight steel was studied in a large range of strain rate (0.001 s⁻¹–1200 s⁻¹). Microstructures of the steel before and after tension were observed. The results show that Fe-3.5Mn-0.3C-5Al lightweight steel has a good strength (820 MPa) and plasticity (40 %) and exhibits excellent combinations of specific strength and ductility (>32000 MPa %) at the strain-rate of 0.001 s⁻¹ after annealing at 850 °C for 5 minutes then directly quenching into water. The austenite in the steel tested was transformed into α′-martensite during the tensile deformation process. With an increase in strain rate from 0.001 s⁻¹ to 1200 s⁻¹, tensile strength of the steel investigated increased from 820 MPa to 932 MPa, while its elongation first decreased from 40 % to 15 %, and then increased from 15 % to 29 %. At the strain rate of 1200 s⁻¹, adiabatic heating resulted in temperature rising in matrix, suppressed the transformation of austenite to α′-martensite. Comparing with transformation induced plasticity steel, the austenite in 3.5Mn lightweight steel is obviously unstable and cannot provide progressive phase transition.     

Development of engineered cementitious composites with limestone powder and blast furnace slag

Nowadays limestone powder and blast furnace slag (BFS) are widely used in concrete as blended materials in cement. The replacement of Portland cement by limestone powder and BFS can lower the cost and enhance the greenness of concrete, since the production of these two materials needs less energy and causes less CO₂ emission than Portland cement. Moreover, the use of limestone powder and BFS improves the properties of fresh and hardened concrete, such as workability and durability. Engineered cementitious composites (ECC) is a class of ultra ductile fiber reinforced cementitious composites, characterized by high ductility, tight crack width control and relatively low fiber content. The limestone powder and BFS are used to produce ECC in this research. The mix proportion is designed experimentally by adjusting the amount of limestone powder and BFS, accompanied by four-point bending test and uniaxial tensile test. This study results in an ECC mix proportion with the Portland cement content as low as 15% of powder by weight. This mixture, at 28 days, exhibits a high tensile strain capacity of 3.3%, a tight crack width of 57 μm and a moderate compressive strength of 38 MPa. In order to promote a wide use of ECC, it was tried to simplify the mixing of ECC with only two matrix materials, i.e. BFS cement and limestone powder, instead of three matrix materials. By replacing Portland cement and BFS in the aforementioned ECC mixture with BFS cement, the ECC with BFS cement and limestone powder exhibits a tensile strain capacity of 3.1%, a crack width of 76 μm and a compressive strength of 40 MPa after 28 days of curing.     

Fabrication and mechanical properties of Cu-coatedwoven carbon fibers reinforced aluminum alloy composite

Cu-coatedwoven carbon fibers/aluminum alloy composite (C_f/Al) was prepared by spark plasma sintering. Microstructure and mechanical properties of the composite were investigated. Microstructure observation indicates that the interface reaction is evidently inhibited by Cu coating. Woven carbon fibers are adhered to the matrix alloy by anchor locking effect of matrix alloy immersing into the interstices between carbon fibers. Under the quasi-static and dynamic compressive conditions, the composite exhibits excellent ductility even when the strain reaches 0.8. Adding carbon fibers into ZL205A alloy has no obvious influence on compressive flow stress of the composite. The compressive true stress–true strain curves show that the composite is a strain rate insensitive material. During the tensile tests, the elongation of the composite shows a sharp increase from 4.5% to 13.5% due to the adding of woven carbon fibers. Meanwhile, the tensile strength of the composite is increased slightly from 168 MPa to 202 MPa compared to that of ZL205A alloy. The good ductility of the composite is ascribed to the cracks deflection, fibers pulling out, debonding and breakage mechanisms.     

钢纤维对超高性能混凝土抗弯力学性能的影响

为研究长、短钢纤维对超高性能混凝土（UHPC）受弯力学性能的影响,设计并制作了13组标准养护条件下的UHPC试件,其中3组为掺单一型短钢纤维,其他组均为掺混杂型钢纤维,对其进行立方体抗压及四点抗折试验。结果表明：对于掺加单一型短钢纤维的钢纤维/UHPC,钢纤维体积掺量为5vol%时,抗折强度最大,为19.98 MPa,继续增加钢纤维掺量,抗折强度反而降低;掺混杂型钢纤维的UHPC比单一型的抗折强度高,并且当长、短钢纤维体积掺量分别为2vol%和1vol%时,抗折强度达到最大,为23.55 MPa;钢纤维/UHPC的抗弯力学性能主要受长纤维的影响,短纤维影响较小;长纤维掺量对钢纤维/UHPC的抗折强度、延性以及抗弯韧性有一定影响,但是主要取决于长、短纤维的搭配,长、短纤维体积掺量最优搭配为2vol%和1vol%。