Ultra-high performance concrete (UHPC) is a novel cement-based material with exceptional mechanical and durability properties. Silica fume, the primary supplementary cementitious material (SCM) in UHPC, is expensive in North America, so it is often substituted with inexpensive class F fly ash. However, future availability of fly ash is uncertain as the energy industry moves toward renewable energy, which creates an urgent need to find cost-effective and environmentally friendly alternatives to fly ash. This study investigated replacing cement, fly ash, and silica fume in UHPC mixtures with ground granulated blast-furnace slag (GGBFS), metakaolin, and a natural pozzolan (pumicite). To identify acceptable UHPC mixtures (28-day compressive strength greater than 120 MPa), workability, compression, and flexural tests were conducted on all mixtures. Then, durability properties including shrinkage, frost resistance, and chloride ion permeability (rapid chloride permeability and surface resistivity tests) were evaluated for the acceptable UHPC mixtures. Results showed that 75, 100, and 40% of fly ash in the control mixture could be replaced with pumicite, metakaolin, and GGBFS, respectively, while still producing acceptable strengths. Flexural strengths were greater than 14.20 MPa for all mixtures. For durability, UHPC mixtures had shrinkage strains no greater than 406 μstrain, durability factors of at least 105, and “very low” susceptibility to chloride ion penetration, indicating that these SCMs are suitable candidates to completely replace fly ash and partially replace silica fume in non-proprietary UHPC.

While ultra-high performance concrete (UHPC) offers numerous advantages, it also presents specific challenges, primarily due to its high cost and excessive cement content, which can pose sustainability concerns. To address this challenge, this study aims to develop cost-effective and sustainable UHPC mixtures by incorporating ground granulated blast furnace slag (GGBFS) and limestone powder (LP) as partial replacements for portland cement. Eight fiber-reinforced UHPC mixtures were investigated, with a water-to-cementitious materials (w/cm) ratio of 0.15. In four of the UHPC mixtures, 25% of the cement was replaced with GGBFS, and further, LP was added as a mineral filler, partially substituting up to 20% of the cement. In the remaining four mixtures, cement was replaced with only LP up to 20% (without GGBFS). The 28-day compressive strength of the UHPC mixture with 25% GGBFS and 20% LP was 149 MPa, 3.50% lower than the mixture without GGBFS. Its 28-day flexural strength decreased by 30%. Increasing LP replacement reduced drying and autogenous shrinkage, with a 29% shrinkage reduction at 20% LP replacement. Moreover, UHPC mixtures with GGBFS exhibited lower shrinkage compared to those without GGBFS for all LP replacements up to 20%. For evaluating the sustainability of UHPC mixtures, the cement composition index (CCI) and clinker to cement ratio (CCR) were determined. For 20% LP replacement with 25% GGBFS, CCI was 3.6 and the CCR was 0.5, 38% decrease from the global clinker to cement ratio. Overall, 20% LP replacement UHPC mixtures with and without GGBFS can produce UHPC class performance and reduce the environmental impact.

The development of non-proprietary Ultra-High Performance Concrete (UHPC) is one way to reduce the initial cost of construction. However, workability is a major issue for which such mixtures are not practical in field conditions. Ultra-high performance cannot be achieved in field conditions if the concrete is not placed, finished, and compacted properly during placement. In this research, six UHPC mixtures were developed (three with steel fibers and three without fibers) using materials which are readily available on the local marketplace with water-to-cementitious materials ratios ranging between 0.17 to 0.30. The workability was determined using standard ASTM flow table apparatus, and specimens were prepared to determine compressive strength, splitting tensile strength, and permeable porosity. Flow table test exhibited flow values greater than 250 mm. Such high workability of the mixtures was achieved by optimizing the silica fume content and water reducing admixture dosage. These mixtures exhibited compressive strengths greater than 120 MPa and splitting tensile strengths greater than 5.10 MPa in both ambient and elevated curing temperatures. Results indicated that UHPC can be produced with a water-to-cementitious materials ratio as high as 0.30. Steel fibers helped to increase splitting tensile strength due to fiber-matrix interactions. Very low permeable porosity (1.7–16.7%) was observed which indicates superior durability due to the significant reduction of ingress of deleterious ions.