A Study on the Pore and Strength Characteristics of an Eco-Friendly Sprayed Ultra High Performance Concrete with Manufactured Sand
Abstract
:1. Introduction
2. Experimental Materials and Methods
2.1. Materials
2.2. Preparation of the Sprayed UHPC and Cast UHPC Specimens
- (1)
- Dry mixing of the PC, SF, WRT, and MS took place for 1–2 min at a speed of 65 rpm; the subsequent addition of water and SP with continued mixing for 6–8 min to form a homogeneous slurry; and a final incorporation of PP fibers with additional mixing for 2–3 min to ensure uniform dispersion occurred. After mixing, a flow expansion test was carried out to evaluate the concrete’s flowability. The total mixing time was controlled within 15 min, and the fresh slurry was required to be sprayed within 40 min.
- (2)
- Before commencing the spraying operation, the air compressor should be activated to maintain a constant pressure of 0.6 MPa in the air receiver tank. Subsequently, the UHPC slurry was poured into the hopper of the wet-spray machine, with the slurry pumping speed maintained at 3–5 m3/h. To ensure operational safety, the procedure requires that the high-pressure air be turned on before the UHPC slurry is pumped. Referencing the Chinese standard GB 50086–2015 [26], with the assistance of high-speed air, the UHPC slurry was sprayed into the mold (450 mm × 450 mm × 120 mm). During the spraying process, the spray nozzle should be perpendicular to the mold and maintain a distance of 1.3–1.7 m.
- (3)
2.3. Experimental Methods
2.3.1. Mechanical Performance Tests
2.3.2. Porosity Test
2.3.3. SEM Analysis
3. Experimental Results and Discussion
3.1. Mechanical Properties
3.2. The Porosity and Microstructure
3.3. Engineering Application
4. Conclusions
- (1)
- The mechanical properties of the sprayed UHPC material were examined through a series of strength tests. Experimental results demonstrated that by incorporating manufactured sand into the UHPC matrix, the mechanical properties of sprayed UHPC are comparable to those of cast UHPC across various spraying orientations, confirming its structural reliability for practical applications. This study offers robust theoretical underpinnings and practical guidance for the development of sustainable green sprayed UHPC, effectively driving down UHPC costs and advancing its progress in environmental protection and resource recycling.
- (2)
- The pore characteristics of the sprayed UHPC material were revealed through advanced microstructural analysis using SEM. The pore structure was primarily characterized by isolated and non-interconnected micropores with diameters smaller than 100 nm. The high pressure air-driven spraying technique effectively prevented the formation of harmful macropores larger than 10 μm, thereby enhancing the mechanical properties of the material. This process simultaneously reduced early age porosity and improved pore connectivity in the UHPC, providing a critical reference for advancing research on enhancing UHPC durability through process optimization.
- (3)
- The early age strength development and low rebound rate of sprayed UHPC were validated through field tests. A compressive strength of 30 MPa was achieved within 24 h, reaching 60 MPa within 48 h, while the rebound rate remained consistently below 5%. The systematic refinement of indoor spraying process parameters, which integrates material fundamentals with engineering considerations, establishes a robust theoretical framework and actionable technical guidelines for implementing sprayed UHPC technologies. This study offers pivotal insights into the technological evolution of sprayed UHPC systems, thereby expanding their applicability in specialized domains such as tunneling and underground construction.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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WRT | Primary Technical Specifications |
---|---|
Chloride ion content | ≤0.6% |
Alkali content | ≤1.0% |
Compressive strength ratio | ≥100% |
Fineness (85 μm Residue) | ≤10% |
Setting Time Difference | −90~+120 min |
Materials | Sprayed UHPC | Cast UHPC |
---|---|---|
Portland Cement | 720 | 720 |
Silica Fume | 200 | 200 |
WRT | 100 | 100 |
Manufactured sand | 1070 | 1070 |
Superplasticizer | 20 | 21 |
Water-Binder | 0.18 | 0.18 |
Alkali-free accelerator | 16 | 0 |
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Wang, Z.; Tan, X.; Yuan, J.; Wang, C.; Liu, Y. A Study on the Pore and Strength Characteristics of an Eco-Friendly Sprayed Ultra High Performance Concrete with Manufactured Sand. Appl. Sci. 2025, 15, 3776. https://doi.org/10.3390/app15073776
Wang Z, Tan X, Yuan J, Wang C, Liu Y. A Study on the Pore and Strength Characteristics of an Eco-Friendly Sprayed Ultra High Performance Concrete with Manufactured Sand. Applied Sciences. 2025; 15(7):3776. https://doi.org/10.3390/app15073776
Chicago/Turabian StyleWang, Zhonghao, Xianjun Tan, Jingqiang Yuan, Chongge Wang, and Yubiao Liu. 2025. "A Study on the Pore and Strength Characteristics of an Eco-Friendly Sprayed Ultra High Performance Concrete with Manufactured Sand" Applied Sciences 15, no. 7: 3776. https://doi.org/10.3390/app15073776
APA StyleWang, Z., Tan, X., Yuan, J., Wang, C., & Liu, Y. (2025). A Study on the Pore and Strength Characteristics of an Eco-Friendly Sprayed Ultra High Performance Concrete with Manufactured Sand. Applied Sciences, 15(7), 3776. https://doi.org/10.3390/app15073776