Guide Specification for PCI-UHPC Materials

(Appendix to PCI TR-9-22 incorporating March 2023 errata)

Preface
This guide specification is intended to be used as a basis for the preparation of
specifications for a specific application. It must be edited to fit the conditions of use.
Particular attention should be given to the deletion of inapplicable provisions or inclusion of
appropriate requirements. The specifications must be coordinated with the information
shown on the project design plans and other contract document requirements to avoid
duplication or conflicts.

This guide specification has been developed for use in connection with the structural
design of precast, prestressed concrete beams for both building and transportation
structures. A typical specification based on the MasterFormat, as may be used for
American Institute of Architects (AIA) or Naval Facilities Engineering Command (NAVFAC)
structures, may consist of three parts: Part 1—General, Part 2—Products, and Part 3—
Execution. A transportation agency may have separate related documents: an Ultra-High-
Performance Concrete (UHPC) Materials Specification and a Precast UHPC Element
Fabrication Specification. Each of these transportation agency documents will typically
consist of three or more parts, which most commonly include the following: Section 1—
Description, Section 2—Materials, and Section 3—Construction. It is intended that the
sections of this guide specification may be inserted into the applicable sections of either
specification type, as recommended in Table A-1.

This guide specification addresses the materials and production of PCI-UHPC class materials
for use in structural precast, prestressed components. It does not address structural design
or erection requirements, and it excludes the following: structural performance
requirements, connection materials and details, anchorage and other hardware
requirements, fire resistance ratings, reinforcing materials (except fibers) and
reinforcement fabrication, welding, finishes, delivery, storage and handling of UHPC
members, erection, and cleaning.
Table A-1 Recommended guide specification section to be used in different
specification sections

Section in this guide Recommended Recommended

specification MasterFormat transportation agency
specification section specification section
1 Scope Part 1—General: Summary Precast UHPC Element
Fabrication Specification
Section 1—Description;
revise as necessary to suit
scope of individual
document.
2 Terms and Definitions May be added as part of Part Relevant terms may be
1—General included in UHPC Materials
Specification Section 1—
Description or in Precast
UHPC Element Fabrication
Specification Section 1—
Description; or entire list
may be included in overall
project specifications.
3 General
3.1Reference May be added as part of Part Relevant standards may be
Standards 1—General included in UHPC Materials
Specification Section 1—De-
scription or in Precast UHPC
Element Fabrication
Specification Section 1—
Description; or entire list may
be included in overall project
specifications.
3.2Submittals Part 1—General: Submittals Include the Material Identity
Card and material test
reports in UHPC Materials
Specification Section 2—
Materials.
Include the Material Identity
Card and field quality control
tests in Precast UHPC
Element Fabrication
Specification Section 3—
Construction.
4 Materials
4.1 UHPC Materials Part 2—Products: Materials UHPC Materials Specification
Section 2—Materials
4.2 UHPC Materials Part 2—Products: Materials UHPC Materials Specification
Section 3—Construction
5 Fabrication
5.1Forms Part 2—Products: Fabrication UHPC Materials
Specification Section 3—
Construction
5.2Concrete Part 2—Products: Concrete Precast UHPC Element
Fabrication Specification
Section 3—Construction
5.3Tests and Part 2—Products: Source
Inspection Control
These text sections between horizontal lines are notes to the specification writer. Delete
prior to issuing specification.

1. Scope
A. This section applies to UHPC intended for use in structural precast, prestressed components. The
work performed under this section includes all labor, material, equipment, related services, and
supervision required for the manufacture of the structural precast and precast, prestressed UHPC
work shown on the contract drawings.

Adjust list below to suit project. Delete the paragraph below if not listing type(s) of
members.
B. This section includes the following:

1. <Insert applicable members>

2. Terms and Definitions

A. The following definitions apply to terms in this section.

1. Acceptance testing: Testing performed during production to verify that the UHPC complies
with the requirements of the project specifications and other contract documents. Acceptance
testing considers the specific lot of materials, batch proportions, batching procedures, and
production methods used to produce the UHPC member.

2. Batch: A volume of materials placed into a mixer and uniformly blended, then discharged.

3. Binder: The combination of hydraulic cement, supplementary cementitious materials, and

mineral fillers included in a UHPC mixture.

4. Flexural strength: The maximum tensile stress value sustained by a test specimen due to
bending when tested in accordance with ASTM C1856.

a. First-peak (first-crack) flexural strength: The stress value obtained at the first point on
the flexural load-deflection curve where the slope is zero; this typically corresponds to
the stress value at the time of first cracking.

b. Peak flexural strength: The maximum engineering stress value obtained in a flexural
test, computed using simple bending theory for linear elastic materials and gross
(uncracked) section properties.

c. Residual flexural strength: The engineering stress value obtained, after cracking, at a
specified net deflection (for example, L/150, where L is span length in test) in a
flexural test. Residual flexural strength is computed using simple bending theory for
linear elastic materials and gross (uncracked) section properties.

5. Flow spread: The distance of lateral flow of UHPC during a flow test conducted in
accordance with ASTM C1437 using modifications described in ASTM C1856.

6. Informational testing: Testing that is not required by project specifications but is performed
to obtain additional information about material properties or durability characteristics of the
UHPC.

7. Material Identity Card: A manufacturer’s document that provides the details of the
 constituent materials, mixture proportions, mixing instructions, curing methods (including
thermal treatment, if used), and resulting hardened properties of a specified UHPC mixture.

8. Mineral filler: A finely divided inorganic material, usually derived from quarried stone that
may be used in UHPC to improve certain properties.

9. Preblend: A uniform mixture of powder constituents into which water and admixtures are
added during batching. Fibers may or may not be included in the preblend.

10. Qualification testing: Testing performed prior to production to characterize the performance of
a UHPC mixture and to demonstrate that the material can meet all Project requirements.
Qualification testing considers the mixture components, proportions, mixing procedures, curing,
and thermal treatment intended to be used for the Project.

11. Thermal treatment: A process of heating the UHPC to an elevated temperature, above normal
heat of hydration, in the presence of high relative humidity, holding the elevated temperature for
a period of time to promote the hydration process, and then slowly cooling to ambient
temperature. If used, thermal treatment is applied after the initial curing process (that is, post
cure) and is generally applied after the precast UHPC element has been removed from its
formwork.

12. Total water: The combination of the batched water and ice, free moisture added from (or
removed by) the aggregates, and the liquid water portion of all chemical admixtures and silica
fume slurry.

13. Ultra-high-performance concrete (UHPC): A fiber-reinforced cementitious material

character- ized by highly refined microstructure, post-cracking ductility, high tensile strength,
high compressive strength, and excellent durability properties.

14. Water-binder ratio w/b: The weight of total water in a UHPC mixture divided by the
weight of total binder.

15. Working time: The period of time after the introduction of water during mixing, over
which a UHPC mixture maintains a flow spread of at least 8 in. (200 mm). Working time
will vary with ambient conditions, concrete temperature, mixing procedures, and transport
methods.
3. General
3.1 Referenced Standards
American Association of State Highway and Transportation Officials (AASHTO)

AASHTO R 72-16—Standard Practice for Match Curing of Concrete Test Specimens

AASHTO T 217-14—Standard Method of Test for Determination of Moisture in Soils by Means of a Calcium
Carbide Gas Pressure Moisture Tester.

AASHTO T 255-00—Standard Method of Test for Total Evaporable Moisture Content of Aggregate by
Drying

American Petroleum Institute (API)

SPEC 10A—Specification for Cements and Materials for Well Cementing, 25th edition (includes addendum)

ASTM International

ASTM A820/A820M-16—Standard Specification for Steel Fibers for Fiber-Reinforced Concrete

ASTM C31/C31M-21a—Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C33/C33M-18—Standard Specification for Concrete Aggregates

ASTM C39/C39M-21—Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C138/C138M-17a—Standard Test Method for Density (Unit Weight), Yield, and Air Content
(Gravimetric) of Concrete

ASTM C144-18—Standard Specification for Aggregate for Masonry Mortar

ASTM C150/C150M-21—Standard Specification for Portland Cement

ASTM C157/C157M-17—Standard Test Method for Length Change of Hardened Hydraulic-Cement

Mortar and Concrete

ASTM C191-19—Standard Test Methods for Time of Setting of Hydraulic Cement by Vicat Needle

ASTM C192/C192M-19—Standard Practice for Making and Curing Concrete Test Specimens in the
Laboratory

ASTM C469/C469M-14e1—Standard Test Method for Static Modulus of Elasticity and Poisson’s Ratio of
Concrete in Compression

ASTM C494/C494M-19—Standard Specification for Chemical Admixtures for Concrete

ASTM C512/C512M-15—Standard Test Method for Creep of Concrete in Compression

ASTM C566-19—Standard Test Method for Total Evaporable Moisture Content of Aggregate by Drying

ASTM C595/C595M-21—Standard Specification for Blended Hydraulic Cements

ASTM C618-19—Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in
Concrete

ASTM C642-13—Standard Test Method for Density, Absorption, and Voids in Hardened Concrete

ASTM C666/C666M-15—Standard Test Method for Resistance of Concrete to Rapid Freezing and Thawing
 ASTM C989/C989M-18a—Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM C1012/C1012M-18b—Standard Test Method for Length Change of Hydraulic-Cement Mortars

Exposed to a Sulfate Solution

ASTM C1064/C1064M-17—Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement

Concrete

ASTM C1116/C1116M-10a(2015)—Standard Specification for Fiber-Reinforced Concrete

ASTM C1202-19—Standard Test Method for Electrical Indication of Concrete’s Ability to Resist Chloride
Ion Penetration

ASTM C1218/C1218M-20—Standard Test Method for Water-Soluble Chloride in Mortar and Concrete

ASTM C1240-20—Standard Specification for Silica Fume Used in Cementitious Mixtures

ASTM C1437-20—Standard Test Method for Flow of Hydraulic Cement Mortar

ASTM C1556-11a(2016)—Standard Test Method for Determining the Apparent Chloride Diffusion
Coefficient of Cementitious Mixtures by Bulk Diffusion

ASTM C1602/C1602M-10—Standard Specification for Mixing Water Used in the Production of Hydraulic
Cement Concrete

ASTM C1609/C1609M-19a—Standard Test Method for Flexural Performance of Fiber-Reinforced Concrete

(Using Beam with Third-Point Loading)

ASTM C1778-20—Standard Guide for Reducing the Risk of Deleterious Alkali-Aggregate Reaction in
Concrete

ASTM C1797-17—Standard Specification for Ground Calcium Carbonate and Aggregate Mineral Fillers
for Use in Hydraulic Cement Concrete

ASTM C1856/C1856M-17—Standard Practice for Fabricating and Testing Specimens of Ultra-High

Performance Concrete

ASTM D4944-18—Standard Test Method for Field Determination of Water (Moisture) Content of Soil by the
Calcium Carbide Gas Pressure Tester

ASTM D7508/D7508M-20—Standard Specification for Polyolefin Chopped Strands for Use in Concrete

Precast/Prestressed Concrete Institute (PCI)

PCI MNL-116—Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete
Products
3.2 Submittals

Retain the test reports paragraph below if submittal is required. Edit the list to suit project.
3.2.1 Material Identity Card
A. Submit a Material Identity Card for each mixture to be used in the Project. The properties listed in the
material identity card shall demonstrate, at a minimum, compliance with all project material property
requirements.

B. The material identity card shall include the following:

1. The type and source of each constituent material.

2. The mixture proportions.

3. Mixing procedures.

4. Curing procedures, including thermal treatment procedures (if used).

Revise the section references in the paragraph below as needed.

5. The properties of the PCI-UHPC in accordance with Subsections 4.2.2 and 4.2.3.

a. Reported properties shall include, at a minimum, all properties indicated in Table 4.2.4-1 as
“Qualification” and “Informational (mandatory)” tests.

a. Additional properties and performance characteristics listed as “Informational (optional)”

in Table 4.2.4-1 may be reported for informational purposes. Informational (optional) test
results may be included in project submittals but are not required for approval.

b. Include the date of testing; the temperature, flow spread, and unit weight (density) of each
batch produced for qualification purposes; the number of tests; the mean result of all tests; the
standard deviation of results for each test; and the name, address, and contact information of
the laboratory where the testing was performed.

C. An updated Material Identity Card, based on data no older than two years, shall be prepared and submit-
ted to the Engineer of Record for approval every two years.

3.2.2 Strength Test Records

A. Submit documentation indicating that the proposed mixture proportions will produce average com-
pressive and flexural strengths equal to or greater than the required average compressive and flexural
strengths, respectively.

1. The minimum required average compressive and flexural strengths shall be determined as defined
in Subsection 4.2.4.C based on the standard deviation of test results and the specified strengths.

B. Documentation shall consist of strength test records as defined in Section 4.2.4.

C. When strength and performance data exist for established concrete mixture proportions, the mixture
proportions may be used on the basis of past test results if no more than two years has passed since
testing, the concrete is made from the same material sources, and the same mixing, curing, and thermal
treatment procedures will be used for the Project.
3.2.3 Material Test Reports
A. Mill or suppliers’ test certificates or compliance test reports shall be submitted for the following materials:

1. Cementitious materials.

2. Mineral fillers.

3. Aggregates.

4. Water (for concrete batching).

5. Chemical admixtures.

6. Fibers.

7. Other components specified in Contract Documents with applicable standards.

3.2.4 Quality Control Test Reports

A. Submit quality control test reports as described in Section 5.3.1.

4. Materials
4.1 UHPC Materials
A. Use the same type, brand, and mill source for all materials throughout the UHPC production. Changes in
the type or source of cementitious materials, mineral fillers, aggregates, admixtures, or fibers require the
submittal and approval of an updated Material Identity Card (Section 3.2.1) for the modified UHPC
mixture produced with the alternative material type(s) or source(s).

Retain materials in this article that are required. Revise to suit Project.
B. Hydraulic cement: ASTM C150, ASTM C595, or API SPEC 10A.

C. Supplementary cementitious materials and mineral fillers:

Consult local fabricators prior to selecting mineral or cementitious materials from the six
subparagraphs below. These materials may affect UHPC appearance, workability, setting
times, strength, and cost.
1. Fly ash: ASTM C618, Class C or F.

2. Raw or calcined natural pozzolan: ASTM C618, Class N.

3. Silica fume: ASTM C1240.

4. Slag cement: ASTM C989.

5. Ground calcium carbonate and aggregate mineral fillers: ASTM C1797.

6. Other supplementary cementitious materials or mineral fillers: Demonstrate suitable

mechanical and durability performance when used in UHPC. Suitability to be determined at
the discretion of the engineer of record.

D. Fine aggregates: ASTM C33 or ASTM C144.

1. Fine aggregates do not need to comply with the grading requirements in ASTM C33 or
ASTM C144.
 2. Aggregates that are potentially expansive by alkali-silica reaction, as defined by
ASTM C1778, shall not be used without mitigation.

3. Aggregates that are potentially expansive by alkali-carbonate reaction, as defined by

ASTM C1778, shall not be used.

E. Water and ice: Potable municipal water or other water for concrete and water used to make ice
shall comply with chemical limits of PCI MNL-116 or ASTM C1602.

F. Chemical admixtures: Certified by manufacturer to be compatible with other admixtures and do not
contain calcium chloride, or more than 0.15% chloride ions by weight of admixture.

1. Water-reducing admixture : ASTM C494/C494M, Type A.

2. Retarding admixture: ASTM C494/C494M, Type B.

3. Water-reducing and retarding admixture: ASTM C494/C494M, Type D.

4. Water-reducing and accelerating admixture: ASTM C494/C494M, Type E.

5. High-range, water-reducing admixture: ASTM C494/C494M, Type F.

6. High-range, water-reducing, and retarding admixture: ASTM C494/C494M, Type G.

7. Viscosity- or rheology-modifying admixture: ASTM C494/C494M, Type S.

8. Shrinkage-reducing admixture: ASTM C494/C494M, Type S.

G. Steel fibers: ASTM A820/A820M, with a minimum tensile strength of 290 ksi (2000 MPa) and a
minimum nominal aspect ratio of 60, unless otherwise approved by the Engineer of Record based
on demonstrated adequate performance of the fibers when used in UHPC.

Retain the paragraph below if nonmetallic fibers are permitted. Revise list to suit Project.
Polypropylene (PP) or polyvinyl alcohol (PVA) fibers may be used if fire resistance is
required. The dosage of nonmetallic fibers used must be sufficient to provide fire resistance
complying with applicable requirements but should not negatively impact mechanical
performance. (Note: The definition of PCI-UHPC for precast, prestressed structural members
does not include use of nonmetallic fibers.)
H. Nonmetallic fibers:

1. Polypropylene fibers: ASTM D7508/D7508M

2. Polyvinyl alcohol fibers: Comply with fiber requirements in ASTM C1116/C1116M Section

4.1.3: Type III Synthetic Fiber-Reinforced Concrete.

Retain the paragraph below if preblended UHPC materials are permitted.

I. Preblended UHPC materials for which a Material Identity Card has been approved by the Engineer
of Record.

1. Follow all Manufacturer’s recommendations for handling, mixing, and placing.

2. Retain a sample of the preblended material from each lot received, in sufficient quantity
that the quality control testing of the fresh and hardened properties of the material may be
evaluated for compliance.
4.2 UHPC Mixtures

4.2.1 Mixture Proportions

A. Proportion mixtures with materials to be used on Project to provide UHPC with the following
characteristics:

A water-binder ratio of 0.20 or less is typical for UHPC production. This limit may be
exceeded if mixture performance criteria are satisfied. Consult local fabricators.
1. Maximum water-binder ratio w/b: 0.20

A steel fiber content of 2% was used in the definition of PCI-UHPC. Variation of the steel fiber
content has been used in UHPC production. However, guidelines for the applicability of PCI-
UHPC is based on the steel fiber content of 2%.
2. Minimum steel fiber content: 2% steel fibers, by volume of concrete (263 lb/yd3 [156 kg/m3]).

Retain the first paragraph below if fire resistance is required.

3. Minimum nonmetallic fiber content: As needed to achieve specified fire resistance.

4. Maximum water-soluble chloride ions: ASTM C1218/C1218M, 0.06% by weight of cement.

5. Minimum fresh properties: As defined in Section 4.2.2.

6. Working time: As needed for element fabrication.

7. Minimum hardened properties: As defined in Section 4.2.3.

Retain the paragraph below if durability requirements are specified.

8. Minimum durability properties: As defined in Subsection 4.2.3.B.

4.2.2 Requirements for Fresh UHPC

A. The fresh UHPC shall have the following properties:

Consult local fabricators for UHPC mixture performance at elevated placement

temperatures. Revise the paragraph below if higher temperatures are acceptable. Maximum
specified placement temperatures should not exceed 95°F (35°C) under any circumstances.
1. Temperature: ASTM C1064; between 50°F (10°C) and 80°F (27°C) at the time of placement,
unless otherwise approved by the Engineer of Record.

Retain the paragraph below if alternative flow spread limits are required. A flow spread of
greater than 10 in. (250 mm) may be associated with segregation or settlement of steel
fibers. Potential for fiber settlement should be evaluated in accordance with Subsection
5.3.1.D.
2. Flow spread: ASTM C1437 as modified by ASTM C1856; 8 to 10 in. (200 to 250 mm),
measured not earlier than 15 minutes before anticipated placement time.
Alternate design procedures may require higher or lower values or different standardized
test methods than the following section.
4.2.3 Requirements for Hardened UHPC
A. The hardened UHPC shall have the following mechanical properties:

Age at service is typically defined at 28 days. Consider permitting testing at or after 56

days. A minimum compressive strength at release of 10.00 ksi (68.95 MPa) is
recommended, but this limit may be modified as required for the Project.
1. Compressive strength: ASTM C39 as modified by ASTM C1856, with the exception that
either 3- or 4-in. (75- to 100-mm) -diameter specimens may be used.

a. At release: 10.00 ksi (68.95 MPa), minimum.

b. At service (28 days): 17.40 ksi (120.0 MPa), minimum.

2. Flexural performance: ASTM C1609 as modified by ASTM C1856, at service (28 days).

a. First-peak (first-crack) flexural strength: 1500 psi (10.34 MPa), minimum.

b. Peak flexural strength: 2000 psi (13.79 MPa), minimum.

c. Peak flexural strength shall be at least 1.25 times first-peak (first-crack) flexural strength.

d. Residual flexural strength at midspan deflection of L/150: 75% of first-peak flexural

strength, minimum.

Retain the applicable subsections below if durability criteria are specified.

B. The hardened UHPC shall exhibit the following durability characteristics:

Retain the next paragraph if the UHPC is to be tested for indication of resistance to chloride
ion penetration. Consider permitting testing at or after 56 days.
1. Indication of resistance to chloride ion penetration: ASTM C1202 as modified by
ASTM C1856, at 28 days; 250 coulombs maximum.

a. When UHPC mixture contains metallic fibers, testing shall be performed on specimens
produced from UHPC having the same relative proportions as the other constituent
materials but produced without metallic fibers.

Revise the list, criteria, or both, to suit Project. This testing is informational and not required
for structural design. If needed, it may be specified in addition to the indication of resistance
to chloride ion penetration test. Consider permitting testing at or after 56 days.
2. Chloride diffusion coefficient: ASTM C1556, at 28 days; 0.025 in.2/year (16 mm2/year).

a. When UHPC mixtures contain metallic fibers, testing shall be performed on specimens
produced from UHPC having the same relative proportions of the other constituent
materials but produced without metallic fibers.

b. Expose specimens to test solution for 90 days.

 3. Sulfate resistance: ASTM C1012, at 28 days.

a. If the UHPC mixture contains metallic or nonmetallic fibers, testing shall be performed
on specimens produced from UHPC having the same relative proportions as the other
constituent materials but produced without fibers.

Revise the subparagraph below to suit Project.

b. Comply with the expansion limits defined in ACI 318 for the specified exposure condition.

Historically, all UHPC mixtures satisfy the resistance to freezing and thawing stated in the
paragraph below. If this test is required for qualification, it is only required for the first
Material Identity Card for a given set of materials. Subsequent testing for the same
materials from the same sources is unnecessary.
4. Resistance to freezing and thawing: ASTM C666 as modified by ASTM C1856; minimum
relative dynamic modulus of 95 after 300 cycles.

5. Absorption: ASTM C642, at 28 days; 3.0% maximum.

4.2.4 Mixture Qualification

A. Material testing of each UHPC mixture shall be performed to support preparation of a Material
Identity Card and strength test records, as defined in Subsections 3.2.1 and 3.2.2, respectively, for
the purpose of mixture qualification.

B. Testing for mixture qualification shall include, at minimum, the properties listed as “Qualification”
and “Informational (mandatory)” in Table 4.2.4-1.

1. All test specimens shall be fabricated from UHPC mixtures produced with the same
materials, mixture proportions, batching equipment, and mixing sequence intended for the
Project.

2. Document the temperature, flow spread, and unit weight for each batch produced for mixture
qualification. The temperature and flow spread of the UHPC shall be within the specified
range at the time of specimen fabrication.

3. Where knowledge of working time is desired, working time may be determined as follows:

a. Measure flow spread according to ASTM C1437 as modified by ASTM C1856 at

15-minute intervals following initial measurement until two consecutive measurements

of less than 8 in. (200 mm) are recorded.

b. Working time is established when the flow spread equals 8 in. (200 mm) as determined
by linear interpolation.

4. Cure test specimens to match the required curing for the structural product.

a. If a thermal treatment will be applied to the product, apply the same thermal treatment
to all test specimens, in accordance with ASTM C1856, Section 7.4.
Revise “Purpose of Test” in Table 4.2.4-1 to suit Project requirements. Qualification tests are
required for mixture approval. Informational (mandatory) tests are required for submittal
but are not required for mixture approval.
Informational (optional) tests may be performed for informational purposes at the discretion
of the producer but are not required for submittal or approval.

Table 4.2.4-1 Qualification and informational test requirements

Propert Test method Purpose of test*
y
ASTM C1437 as modified by
Flow spread Qualification
ASTM C1856
Temperature ASTM C1064 Qualification
ASTM C138 as modified in
Unit weight Informational (mandatory)
Subsection 4.2.4.D
ASTM C1437 as adapted in
Working time Informational (optional)
Subsection 4.2.4.B.3
ASTM C191 as modified by
Time of set Informational (optional)
ASTM C1856
ASTM C39 as modified by
Compressive strength Qualification
ASTM C1856
ASTM C1609 as modified by
Flexural strength Qualification
ASTM C1856
ASTM C469 as modified by
Static modulus of elasticity Informational (mandatory)
ASTM C1856
ASTM C469 as modified by
Poisson’s ratio Informational (optional)
ASTM C1856
ASTM C512 as modified by
Creep in compression Informational (optional)
ASTM C1856
ASTM C157 as modified by
Length change ASTM C1856 and Informational (optional)
Subsection 4.2.4.D
ASTM C1202 as
modified by ASTM
Indication of resistance to C1856, with tests
Qualification
chloride ion penetration performed on
specimens without
metallic fibers
ASTM C1556, with tests
Chloride diffusion coefficient performed on specimens Informational (optional)
without metallic fibers
ASTM C1012, with tests
Sulfate resistance performed on specimens Informational (optional)
without metallic fibers
Resistance to freezing and ASTM C666 as modified by
Informational (optional)
thawing ASTM C1856
Absorption ASTM C642 Informational (optional)
*Qualification tests are required for mixture approval. Informational (mandatory) tests are required for submittal
but are not required for mixture approval. Informational (optional) tests may be performed and reported at the
discretion of the producer but are not required for submittal or approval.
 5. Number of tests:

a. A test shall be as defined as in Subsection 5.3.1.

b. Unless otherwise specified, a minimum of nine compressive strength tests and nine
flexural strength tests shall be performed to establish the Material Identity Card. The
tests shall represent a minimum of three consecutive batches, with no more than three
tests performed for each batch.

c. Unless otherwise specified, a minimum of one test shall be performed for all other
properties and performance characteristics to be reported.

C. Required average strength:

1. Determine the required average strength for the following properties, as defined below, based
on the specified strengths defined in Subsection 4.2.3 and the sample standard deviations of
the test results:
'
a. Compressive strength f cr

'
b. First-peak (first-crack) flexural strength f 1 r

'
c. Peak flexural strength f pr

2. Calculate the sample standard deviation ss of the test records.

3. Calculate the required average strengths based on the test records as follows. Use the larger
of the two values calculated.

[ ]
'
f X +1.34 k s s
f 'Xr=max '
0.9 f Xr +2.33 k s s
where
'
f Xr = required average strength for the property X
X = c for compressive strength, X = 1 for first-peak flexural strength, and X = p for peak
flexural strength
'
f X = specified strength for the property X in accordance with Subsection 4.2.3
k = a modification factor listed in Table 4.2.4-2 to adjust for the number of tests considered
in calculating the sample standard deviation

ss = sample standard deviation

4. The sample standard deviation used to determine the required average compressive strength,
first-peak flexural strength, or peak flexural strength shall be determined from a minimum of
nine consecutive tests, with no more than three tests performed from a single batch.
Table 4.2.4-2 k-factor for increasing sample standard deviation based on number of tests
Total number of tests considered k-factor for increasing sample standard deviation
9 1.25
15 1.16
 20 1.08
25 1.03
30 or more 1.00
Note: Linear interpolation for intermediate number of tests is acceptable.

D. Modifications to standard methods for UHPC:

1. Fabricate and cure test specimens for qualification and laboratory trial mixtures in accor-
dance with ASTM C192 as modified by ASTM C1856 and this specification.

2. Unit weight: ASTM C138, except the measure shall be filled in a single, continuous pour,
and consolidated by tapping 30 times with a rubber mallet.

3. Length change: ASTM C157 as modified by ASTM C1856, except that the initial reading
shall be taken at the time of final set or at 24 hours, whichever occurs later. Begin drying
immediately after initial reading.

5. Production
5.1 Forms

Include this section in the UHPC material specification or another specification section on
forms for the Project. The fluid nature of UHPC may result in a greater risk of UHPC leakage
if forms are not watertight. To avoid obstructing fiber flow, a minimum clear spacing
between the formwork surface and any internal reinforcing or adjacent formwork is required.
A. Form: Accurately construct forms, mortar tight, of sufficient strength to withstand pressures due to
concrete placement and vibration operations and temperature changes, and for prestressing and
detensioning operations.

1. Design formwork to withstand the full hydrostatic pressure of fresh UHPC.

2. The minimum clear spacing between the formwork surface and any internal reinforcing or
adjacent formwork shall be greater than both 1.5 times the fiber length and 1.5 times the
maximum aggregate size.

5.2 Concrete
A. Do not produce UHPC for construction production until the Material Identity Card has been
reviewed and approved by the Engineer of Record.

5.2.1 Storage and Handling of Concrete Materials

A. Comply with PCI MNL-116 requirements, with the following modifications:

1. Store and handle all supplementary cementitious materials and mineral fillers in a similar
manner to cement.

2. Store and handle aggregates in a wet or dry manner that limits segregation.

3. Store fibers in a dry, covered location to prevent oxidation (steel fibers) or ultraviolet (UV)
degradation (nonmetallic fibers). Some surface oxidation (rust) of steel fibers is permissible,
provided that the fibers remain as individual wires (that is, do not clump) and the severity of the
oxidation is documented. Discoloration of nonmetallic fibers may indicate UV degrada- tion;
therefore, discolored nonmetallic fibers shall not be used. Elevate fibers stored in bags or sacks
 on pallets or racks to limit exposure to moisture.

4. Store preblended materials in a similar manner to cement. If preblending materials on site, oven-
dry aggregates before blending to limit prehydration of the cementitious materials.

5.2.2 Mixing
A. Equipment: Comply with PCI MNL-116 requirements and tolerances for all batching equipment,
including scales, water meters, dispensing equipment, and concrete mixers.

B. Mixing: Comply with PCI MNL-116 requirements for batching and mixing, with the following
modifications:

1. Mixing time requirements specified in PCI MNL-116 do not apply to UHPC. The time from
the start of UHPC mixing to placement may exceed 1 hour, as long as the flow requirements
are met and the water-binder ratio of the approved mixture proportions is not exceeded.

2. Clean the mixer between consecutive batches of UHPC if the mixer is not loaded within the
working time of the previous batch.

3. If aggregates are used in a moist (that is, not oven-dry) condition, measure the aggregate
moisture content for each batch. Determine moisture content by calibrated moisture
probe, rapid measurement technique (ASTM D4944 or AASHTO T 217), oven-drying

(ASTM C566 or AASHTO T 255), or other approved method. Calibrate moisture probes and
rapid measurement techniques for each aggregate source.

4. Total water content shall include all sources of water in UHPC, including batch water, ice,
moisture content in aggregates, and water fraction of admixtures.

5. Total binder shall include the combined weight of hydraulic cement, supplementary cementi
tious materials, and mineral fillers.

6. The batching sequence and mixing procedures shall produce uniform dispersion of the
constituent materials and fibers, and achieve the fresh properties required for transporting and
placing the UHPC. The batching sequence and mixing procedures do not need to comply with
the requirements of PCI MNL-116.

a. Uniformity of dispersion shall be evaluated, at a minimum, by visual inspection of the

fresh UHPC at the time of discharge from the mixer. A well-dispersed UHPC mixture
will have no fiber clumps and no agglomerates of the powder constituents.

7. Batch materials within tolerances listed in Table 5.2.2-1.

 Table 5.2.2-1 Batching tolerances

Materia Maximum batching error Maximum batching error

l with plant-batched dry with preblended dry
materials materials

Water ±1% ±1%

Cement ±1%*

Silica fume ±1%*

Other supplementary ±2%

±1%* or ±5 lb, whichever is
cementi-tious materials or
greater
mineral fillers

Aggregates ±2%*

Chemical admixtures ±2% ±2%

Fiber –2%, +4% –2%, +4%

Note: 1 lb = 0.454 kg.

*Total weight of dry materials shall not exceed ±2% of target.

C. Mixture adjustments:

1. Adjustments to water or admixture dosages may be performed to achieve target flow proper-
ties. The maximum water-binder ratio in the submitted and approved mixture design shall not
be exceeded.

2. No adjustments to the mixture shall be made after the concrete is discharged from the mixer.

3. Changes to the constituent materials, mixture proportions, batching equipment, or curing

methods will require resubmittal of the Material Identity Card to verify compliance with
Project requirements. To limit production delays, provisional approval may be granted at the
discretion of the Engineer of Record before strength results at service have been obtained.

5.2.3 Transporting, Placing, and Consolidating Concrete

A. Comply with PCI MNL-116 requirements for transporting and placing concrete, with the following
modifications:

1. The temperature of the UHPC at the time of placement shall be between 50°F (10°C) and
80°F (27°C), unless otherwise approved by the Engineer of Record based on local experience.

2. Place the UHPC in a continuous operation that prevents cold joints or planes of weakness
from forming, limits fiber segregation, and reduces the entrapment of air.

3. Use placement methods that limit unfavorable alignment of fibers where possible. Because
fibers tend to align in the direction of the UHPC flow, avoid placement methods that cause
the UHPC to flow in a direction that is perpendicular to the direction of tensile stress if so
directed by the Engineer of Record.

4. Place the UHPC in a manner that integrates the new material into the previously placed UHPC.
 5. Limit free-fall placement to a maximum of 3 ft (1 m) above the top of the form.

B. Comply with all PCI MNL-116 requirements for hot- and cold-weather concrete placements.

C. Thoroughly consolidate the UHPC without dislocating or damaging the reinforcement (including
fibers) and built-in items. Minimize pour lines, honeycombing, and entrapped air voids on the
surface. Use consolidation equipment and procedures complying with PCI MNL-116 requirements,
with the following modifications:

1. Do not use internal vibration.

2. Use external vibration when concrete workability is not sufficient to complete placement
or if complex forming may inhibit flow. If external vibration is used, evaluate whether a
detrimental effect on fiber distribution is expected.

5.2.4 Finishing
A. Strike off or screed the surfaces of the UHPC product to the required level immediately after
placement. Finish as required by the project contract documents.

5.2.5 Curing
A. After finishing, immediately cover all surfaces with plastic, wet burlap, or curing compound to
prevent dehydration. Cure the concrete according to PCI MNL-116 requirements, either by moisture
retention without heat or by accelerated heat curing using live steam or radiant heat and moisture.
Maintain a minimum relative humidity of 95% if curing with live steam or radiant heat and moisture.

1. Accelerated heat curing, if used, shall be started after the concrete has attained initial set,
determined in accordance with ASTM C1856.

2. Cure members until compressive strength is high enough to ensure that stripping does not
influence the performance or appearance of the final product.

B. The compressive strength at stripping shall be determined according to Section 4.2.3.

Retain the subsection below if thermal treatment is allowed or required by the Project.
5.2.6 Thermal Treatment
A. Apply thermal treatment to members after curing, if used.

Retain the following paragraph. Thermal treatment performed in the forms may cause
cracking.
B. Do not apply thermal treatment until strands have been detensioned and the UHPC member has
been stripped from the forms.

C. Apply thermal treatment according to the method employed during qualification testing during
preparation of the Material Identity Card:

Reduce temperature and increase treatment duration in the following paragraph to 140°F
(40°C) and 72 hours if polymer fibers are used.
1. Heat member at 194°F (90°C) and at least 95% relative humidity for 48 hours.

2. Thermal treatment may be applied at any time until the member has reached 14 days of age.
 3. The rate of heating shall not exceed 20°F (10°C) per hour.

4. The rate of cooling after sustained heating shall not exceed 20°F (10°C) per hour.

5.3 Tests and Inspection

5.3.1 Quality Control Testing

The paragraph below establishes the minimum standard of plant testing and inspecting. PCI
MNL-116 mandates source testing requirements and a plant Quality Systems Manual. PCI
certification also ensures periodic auditing of plants for compliance with requirements in PCI
MNL-116.
A. Modifications to standard methods for UHPC:

1. Fabricate and cure test specimens in accordance with ASTM C31 or ASTM C192, as
modified by ASTM C1856 and this specification. Curing shall match the specified curing for
the structural product.

2. Unit weight: ASTM A138, except the measure shall be filled in a single, continuous pour,
and consolidated by tapping 30 times with a rubber mallet.

B. Test and inspect UHPC according to PCI MNL-116 requirements when used to fabricate precast
elements, with the following modifications:

1. A test for strength and other hardened properties of the UHPC shall be defined as the average
results from at least three specimens made from the same concrete sample and tested at the
same age.

Delete the last sentence of the following paragraph if air content measurement is required.
2. Perform temperature, flow spread, unit weight, compressive strength, and flexural strength
testing as defined in Table 5.3.1-1. Measurement of air content is not required.

3. If test specimens are match cured, follow procedures of AASHTO R 72, except that the
specimen sizes, specimen molding, and other testing are as defined herein.

4. Minimum testing frequencies are listed in Table 5.3.1-1. Perform additional testing and cast
additional samples if a change in quality is suspected.

5. Acceptance of concrete testing shall be as per PCI MNL-116 except the strength of the concrete
shall be considered satisfactory provided that both of the following requirements are met:

a. Every average of three consecutive strength tests equals or exceeds the specified
strength fX for the property.

b. No single strength test result falls below fX by more than 0.10 fX .

Table 5.3.1-1 Minimum testing frequencies

Propert Test method Minimum frequency

y

ASTM C1437 as modified by

Flow spread Each batch.
ASTM C1856

Temperature ASTM C1064 Each batch.

First batch per day,

whenever test specimens
ASTM C138 as modified in
Unit weight are cast, and whenever a
Subsection 5.3.1.A.2
change in quality is
suspected.

6 test specimens from 1

batch per day per element,
or every 25 yd3, whichever is
ASTM C39 as modified by more frequent. Test 3
Compressive strength
ASTM C1856 cylinders at release and

3 cylinders at an age defined

by the Engineer of Record.

3 beams from 1 batch per

day per mixture design. If
volume exceeds 25 yd3, an
ASTM C1609 as modified by additional
Flexural strength
ASTM C1856
3 beams are required. Test at
an age defined by the
Engineer of Record.

Note: 1 in. = 25.4 mm; 1 yd3 = 0.765 m3.

C. Concrete records: Maintain records of concrete operations consistent with PCI MNL-116
requirements, with the following additions:

1. Maintain reports of each batch of UHPC produced, including quantities of materials

weighed, the batching sequence used, the time that concrete was discharged from the mixer,
and the time that concrete was placed into the forms.

2. Record all testing performed as specified in Table 5.3.1-1.

3. Maintain records of any additional testing performed, including any strength testing per-
formed at ages other than at release and at an age defined by the Engineer of Record.

D. Evaluate the potential for fiber segregation and settlement during production or as part of a trial
placement.

A suggested method for fiber segregation evaluation is provided below. Alternative methods
may be specified.
 1. Fabricate a specimen mold with a height greater than or equal to the height of the element to
be produced, a width equal to that to be used for element, and a length of 1 ft (0.305 m).

2. Place concrete into the specimen mold and consolidate using the same transport, placement,
and consolidation methods used for production.

3. After the specimen has hardened, saw cut the specimen along the centerline over the full
height of the specimen. Inspect the cut surface for nonuniform dispersion, including fiber
settlement.

4. If nonuniform settlement is identified, establish a lower allowable limit on flow spread for
production of elements of the test height or greater.

Retain the section below if a production mock-up is required for the Project. Revise or add
details as needed.
5.3.2 Production Mock-Up
A. To verify that placement and consolidation methods do not adversely affect UHPC uniformity, including
fiber distribution and alignment, produce a mock-up element using the placement and consolidation
methods intended for the Project.

B. Evaluate uniformity of UHPC fiber at locations specified by the Engineer of Record using one of the
following methods.

1. Cut a minimum of three beams at locations specified by the Engineer of Record, with dimensions
as required by ASTM C1856, Table 3. Perform flexural strength testing at the designated age

in accordance with ASTM C1856. The tested beams should meet the requirements for flexural
strength as defined in Subsection 4.2.3.

2. Cut or core specimens from the concrete at locations specified by the Engineer of Record.
Characterize the fiber density and alignment using techniques approved by the Engineer of Record.