Development and Performance Evaluation of UHPC and HPC Using Eco-Friendly Additions as Substitute Cementitious Materials with Low Cost

Ultra-high-performance concrete (UHPC) and high-performance concrete (HPC) are widely used in construction engineering applications. The quality and economy of this type of concrete are the main challenges in real construction systems due to their expensive cost. In the present investigation, the performances of UHPC and HPC were improved using eco-friendly additives from natural sources or industrial wastes. Accordingly, different kinds of concrete mixtures were prepared with the addition of various eco-friendly materials, such as metakaolin (10, 15, and 20%), silica fume (2.5, 5, 10, and 15%), cement kiln dust (CKD) (0, 5, and 10%), and 1 vol.% of steel and polypropylene fibers. All of these materials were subjected to efficient treatment and purification processes. The results indicated that the prepared UHPC was characterized by high compression and flexural strengths. The prepared UHPC (sample CR-2) with metakaolin (10%), CKD (10%), and 1 vol.% of steel fibers provided the highest compressive strength of 135 MPa at 28 days. Moreover, the results showed that reducing the cement amounts to 750, 500, and 250 kg/m³ provided concrete with efficient structural requirements and specifications and can be characterized as UHPC and HPC. Also, the mixture (sample CM15) with a metakaolin addition of 15%, CKD of 100 kg/m³, and 1 vol.% of steel fibers showed the highest flexural strength of 19.14 MPa at 28 d. Moreover, the highest splitting tensile strength of the prepared UHPC cylinders was 9.6 MPa at 28 d for the MSS1000 sample, which consisted of 15% metakaolin, a cement content of 1000 kg/m³, silica fume of 10%, and steel fibers of 1% vol. The prepared UHPC mixtures will reduce the amount of consumed cement and the production cost, with a high performance in comparison to classical concrete. Finally, it was clear that the prepared UHPC and HPC concrete with green additions can serve efficiently in specific construction applications, with high performance, economic feasibility, and safe environmental impacts.

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