A guide to CorTuf

Precast CorTuf™ ultra-high-performance concrete

Introduction Material Applications Engagement Page 2

Contents
Introduction
About us 3
UHPC 4

Material
CorTuf 5
Resources 6
Performance 8
Quality 12
Appearance and finishes 13

Applications
Industries 16
Advantages 19

Engagement
Our approach 20
Sustainability 21
Introduction Material Applications Engagement Page 3

Founded in 2020 as Solid Block Group, CORTUF International has grown from a small startup
to a renowned industry leader. Our journey began with a vision to revolutionise the way
businesses operate by leveraging cutting-edge technology and a deep understanding of our
clients' needs. Over the years, we have built a reputation for delivering top-notch solutions
tailored to the unique requirements of each client. CORTUF International is committed to
expediting the shift to long-lasting and environmentally friendly concrete solutions and
making cutting-edge building materials available to anyone anywhere, whilst understanding
the importance of working within a strong environmental, social, and corporate governance
framework.

Our CorTuf™ ultra-high-performance concrete (UHPC) products are designed to work with
local materials. With CORTUF International’s help, concrete producers and precast
manufacturers around the world are able to meet the needs of modern construction focused
on durable and sustainable solutions. CORTUF International further develops CorTuf™ UHPC
which was originally created by the United States Army Corps of Engineers, the main
component of which is a CTI Concentrate. It is manufactured under strict quality control with
responsibly-sourced raw materials and shipped to licensed CorTuf™ producers. Together
with local concrete constituents, this premixed addition turns concrete into CorTuf™ ultra-
high-performance concrete.

We understand that every client is unique, and their success is our top priority. That's why
we take a client-centric approach, working closely with our clients to gain a deep
understanding of their business objectives and challenges. By forging strong partnerships
and fostering open communication, we ensure that our solutions align perfectly with our
clients' needs, leading to successful outcomes.

Innovation is at the heart of what we do. We constantly explore emerging technologies and
industry trends to stay ahead of the curve and provide our clients with the most advanced
solutions available. Our commitment to quality is unwavering, as we adhere to strict
standards and best practices to deliver products and services that exceed expectations.

At CORTUF International, we believe in the power of collaboration. We have established

strategic partnerships with leading material and technology providers to leverage their
expertise and deliver best-in-class solutions to our clients. By working together, we can
address complex challenges, accelerate innovation, and drive mutual success.

We are proud to be an active member of the communities we serve. We believe in giving

back and making a conscious effort to contribute to social causes, support local initiatives,
and promote environmental sustainability. Through our corporate social responsibility
programs, we strive to make a positive impact and create a better future for all.
Introduction Material Applications Engagement Page 4

World’s first UHPC

The history of UHPC goes back to 1964, when Hans Henrik Bache theorised and, in 1978,
developed the first densified cement-based system later on called ultra-high-performance
concrete. Bache’s work showed that the ultimate compressive strength of concrete depends
not only on the quality, quantity and efficiency of the cementitious materials used but also
on the degree of compaction and ultimate porosity of the solid matrix formed after the
hardening process is completed.

However, these systems were brittle and displayed high autogenous shrinkage. In the period
between 1982 and 1986, various studies were conducted by numerous researchers to
challenge those issues, and in 1986, Bache developed the very first modern ultra-high-
performance fibre-reinforced concrete called Compact Reinforced Concrete. It was an
extremely strong and stiff composite material with an unseen-before-in-concrete high
ductility. Throughout the 1990s, UHPC started entering the market with proprietary
composition. Since the early 2000s, the number of projects with ultra-high-performance
concrete has grown exponentially. Its unique properties are indispensable in civil and military
infrastructure applications. Furthermore, architectural UHPC has become a go-to solution in
thin-section facade cladding over the past ten years.

The US Army Corps of Engineers (USACE) developed its first baseline UHPC in the late
1980s which became known as CorTuf™. Through extensive research, the US Army
Engineering Research and Development Centre (ERDC) has created a family of ultra-high-
performance concretes that was used in military and civil engineering applications by
USACE around the world. CorTuf™ is specifically designed to guarantee blast resistance to
protect military personnel, munition and equipment, also suitable for limiting the penetration
of ballistic fragments.
Introduction Material Applications Engagement Page 5

CorTuf
CorTuf™ is the nomenclature given to a family of ultra-high-performance concretes
developed at the US Army Engineer Research and Development Center. It is an advanced
fibre-reinforced cementitious material with greater strength, tensile ductility, and durability
properties when compared to conventional or even high-performance concrete. CorTuf™
exhibits elastic-plastic or strain-hardening characteristics under uniaxial tension and has a
very low permeability due to its dense and discontinuous pore structure.

CorTuf™ is a tailored UHPC and was designed to work with local raw materials. The CTI
premixed concentrate, the core ingredient of the UHPC, is only 25 percent of the final
product’s volume. And sourcing all other constituents locally eliminates the need to ship
large volumes around the world.

Together with Portland cement, the active components of a CTI Concentrate create a
reactive binder that, when combined with fine aggregates and high-range water reducers,
hydrates into a densely-packed matrix.

The main characteristic of CorTuf™ are achieved through homogeneity encasement by

eliminating coarse aggregates in the matrix, density encasement by optimising the packing
density, and ductility enhancement by the introduction of fibres. The result of combining
these concepts is an extremely compact material, in which pores are not communicated, so
the lifespan of a structure made of CorTuf™ is significantly extended. The corrosion
resistance even in the cracked state increases significantly even when exposed to an
aggressive environment due to the low permeability and discontinues fibre reinforcement.

No coarse High particle Water/binder Fibre

aggregates packing density ration of 0.14-0.25 reinforcement

Fibre reinforcement solves the problem of brittleness in CorTuf™ and drastically improves
tensile strength in impact resistance. Alongside the low water-binder ration optimised
particle packing, fibres are an essential part of ultra-high-performance concrete. There are
up to 60 million fibres in just 1 cubic metre of CorTuf™. And for special requirements, this
number can go even further. Other types of fibres such as synthetic, mineral or even
recycled steel can also be used to reinforce CorTuf™. They can be combined with
conventional reinforcement and prestressing when needed.

! CorTuf™ is mortar and does not contain coarse aggregates

Introduction Material Applications Engagement Page 6

Resources
CorTuf™ is a fibre-reinforced ultra-high-performance concrete, and, like traditional concrete,
made of Portland cement-based binder, aggregates, admixtures and water, with added
steel-fibres reinforcement.

All constituents of CorTuf™ are tested in licensed laboratories worldwide prior to the initial
trials to ensure the high quality of the ultra-high-performance concrete. Product integration
into the existing or new production lines is closely associated with raw materials testing.

CTI Concentrate
The key ingredient of the CorTuf™ family of UHPCs is a CTI Concentrate. It is a specially
designed addition that transforms a mixture of those locally-sources conventional
ingredients into ultra-high-performance concrete. A CTI Concentrate is a proprietary
concrete addition intended to work with different Portland cements around the world.
The manufacturing of CTI Concentrates can be licensed and set up at any location to drive
the cost of CTI Concentrates down even further.

Cement
CorTuf™ does not require special types of cement and works well with ordinary Portland
cement (OPC). This type of cement is the best choice thanks to its worldwide availability,
chemical composition and absence of other major additional constituents which can
interfere with CTI Concentrates. Still, the cement shall be tested prior to use with a CTI
Concentrate and chemical admixtures.

Fine aggregates
CorTuf™ is a mortar and does not contain coarse aggregates. Traditional UHPCs are made
with high-purity silica sand. However, CorTuf™ can also be made with normal concrete all-in
fine aggregates with a size of up to 4 mm, both crushed and natural. A lot of attention
should be given to the quality of aggregates as it may affect the properties of CorTuf™
significantly.

Aggregates such as calcined bauxite, steel slang, corundum, silicon carbide, etc., can be
used in special applications.
Introduction Material Applications Engagement Page 7

Admixtures
CorTuf™ UHPCs usually consist of two types of admixtures: superplasticisers and
accelerators. Depending on the application, there can be other admixtures used in the
composition. These constituents can be either sourced locally or shipped from the US.
Nevertheless, their computability with the cement shall be confirmed prior to the initial
testing stage.

Polycarboxylate either (PCE) superplasticisers are the main type of admixtures used in
CorTuf™.

Fibres
CorTuf™ is a fibre-reinforced UHPC. High-performance steel microfibres are the standard
type of fibre reinforcement in CorTuf™. They guarantee a minimum flexure strength of over
21 MPa for a baseline CorTuf™ material. This value grows depending on the dosage and the
type of fibres. The standard fibres for CorTuf™ have a width of 0.2 mm and a length of 13
mm and can be either coated or uncoated.

Fibres can be made of steel, both coated and undated, polyvinyl alcohol, basalt, alkali-
resistant glass, polypropylene, etc. They have different shapes and sizes. Nanofibres can
also be incorporated when needed.

Steel
micro
fibres

The composition of CorTuf™ differs depending on the application and availability of

constituents. Most of the materials can be sourced locally including the fibres. If not, they
can be provided by CORTUF International anywhere in the world.
Introduction Material Applications Engagement Page 8

Performance
CorTuf™ has significantly higher performance than conventional concrete. An appropriate
and competitive design with UHPC is up to 75 percent lighter than the same design made
with ordinary concrete. This implies not only an environmental advantage due to the
reduction of resources consumed but also a significant reduction of the dead load of the
structure and the transport and commissioning resources required. Finally, when the long
lifespan of a structure made of CorTuf™ arrives at its end, the amount of material to be
recycled is significantly smaller than the amount of a similar structure made with ordinary
concrete.

Just like traditional concrete, CorTuf™ is easy to produce and transport, being up to 4 times
lighter in weight than reinforced concrete and up to 3 times lighter than prestressed
structural precast elements.

CorTuf™ does not require traditional steel reinforcement on top of integrated fibres in many
applications. But when it is inevitable, the weight of the reinforcement can be reduced up to
4 times for even the most heavily reinforced structural elements thanks to CorTuf’s superior
strength.

Tuf!!! Pres tresse d Reinforceed

C o r
concrete concret

Steel

CorTuf™ ultra-high-performance fibre-reinforced concrete is designed for durability.

The high durability of CorTuf™ is based on the concept of particle packing and the absence
of capillary pores. These two parameters are responsible for the permeability of concrete.
No outside chemicals, moisture or gasses can easily penetrate elements made of CorTuf™
and cause corrosion of concrete or reinforcing steel.
 Introduction Material Applications Engagement Page 9

Properties of CorTuf
CorTuf™ UHPC is concrete that has a minimum specified compressive strength of 150 MPa
(cylindrical specimen) with specified durability, tensile ductility and toughness properties.

Property Result Normative reference

Compressive strength > 150 MPa ASTM C39/C39M

Modulus of elasticity > 45 GPa ASTM C469/C469M

Flexural strength > 21 MPa ASTM C1609/C1609M

Direct Tensile Strength > 11 MPa FHWA‐HRT‐17‐053

Shrinkage (Length Change) -0.033% ASTM C157/C157M

Penetration of Chloride Ions ≤ 100 (Negligible) ASTM C1202/C1202M

Resistance to Abrasion 0.56 g ASTM C944/944M

Even though high compressive strength is a fundamental parameter of any ultra-high-

performance concrete, durability and ductility play an essential role in characterising
CorTuf™. Conventional concrete is brittle and significantly lacks durability when exposed to
an aggressive environment. Thanks to fibre reinforcement and dense, discontinuous pore
structure, CorTuf™ exhibits ductile behaviour and becomes impervious to moisture,
aggressive chemicals and gasses.

As a fibre-reinforced concrete (FRC), CorTuf™ contains a large number of high-performance

microfibres which are randomly and uniformly distributed within a body of the UHPC. This
ensures CorTuf’s strain-hardening behaviour under tensions, which means strengthening by
plastic deformations. Other FRCs, where the fibre content is not as high and the fibre-to-
matrix bond is weaker, tend to react to tension with strain-softening and rapid localisation of
the strain.

FRC’s tensile behavio ur

Stress
Crack
localisation

Strai
n-so
ften
ing
ti c
Elasion
reg

Strain

Crack opening
continue
 Introduction Material Applications Engagement Page 10

Stress
CorTuf’s tensile behavio ur

Multi-cracking

!
(II stage)

Strain-hardening St r
ain
-so
fte
ti c n
Elasion ing
reg

Strain

Multi-cracking Crack opening

The post-cracking tensile behaviour of UHPC can either be strain-hardening

(that is, the resistance continues to increase after the cracking stress is
reached) or strain-softening (that is, the resistance decreases after the
cracking stress is reached). Once the highest tensile resistance is reached,
crack localisation occurs.

Stage I consists of linear-elastic behaviour to the first cracking strength σcc

! (Point A). The strain hardening stage (Stage II) only occurs in CorTuf™ and is
characterised by the formation of multiple fine cracks, and the overall
behaviour can be seen as a phenomenon that occurs in the entire specimen. In
contrast, the stress drops in conventional FRC after the first cracking strength.
Once the specimen reaches the post-cracking stress σpc (Point B), crack
localisation and softening occur for both the conventional FRC and CorTuf™
(Stage III).

The increases in tensile cracking strength and post-cracking tensile capacity, when
compared to conventional concrete, also affect CorTuf’s impact response, toughness, and
energy dissipation. CorTuf’s energy dissipation is up to 100 times greater than that of
conventional concrete. As expected, the blast response of CorTuf™ is better than
conventional concrete. Because of CorTuf’s impact response and energy dissipation, there is
also interest in CorTuf™ for seismic applications.

Properties of fresh CorTuf

In its original form, fresh CorTuf™ is a self-compacting concrete (SCC). However, any
consistence, as well as any other property of fresh CorTuf™, can be achieved to meet a
project specification with minor modifications to the composition. The rheology of CorTuf™
allows it to be pumped over long distances and sprayed up onto any type or shape of the
surface, including vertical and overhead areas.
Introduction Material Applications Engagement Page 11

CorTuf™ exhibits superior durability in aggressive environments when compared to high-

performance and conventional concretes. It delivers up to 100 times more resistance to
corrosion than traditional concrete, being virtually impervious to aggressive chemicals
thanks to its discontinuous pour structure and dense particle packing.

Relative durability of CorTuf™ to normal and high-performance

concretes

Salt Scaling Mass Lost (28 cycles)

Chloride Ion Diffusion Coefficient

Chloride Ion Penetration Depth

Chloride ion permeability,

total charge passed

Oxygen permeability

Nitrogen permeability

Water absorption

Carbonation depth (3 years)

Reinforcement corrosion rate

Abrasion resistance relative

vol. loss index

0 0.25 0.5 0.75 1

CorTuf™ HPC Normal Concrete

• CorTuf™ is more durable than conventional concrete (CC) and high-

performance concrete (HPC)

• CorTuf™ is resistant to freezing and thawing, alkali-silica reaction, and

! •
chloride ion penetration

CorTuf™ can be used in a variety of harsh environments, such as marine

environments and wastewater treatment plants

• The durability of CorTuf™ is due to its dense microstructure, which is

achieved by using a low W/B ratio and high-quality materials
Introduction Material Applications Engagement Page 12

Quality
All the constituents of CorTuf™ and, especially, a CTI Concentrate come from reliable
sources and are produced responsibly under strict quality control following the CORTUF
Supplier Code of Conduct and the CORTUF International Environmental Policy. All approved
suppliers of materials and manufacturing equipment make it into the CORTUF Supplier List
which is revised annually to ensure the high quality of what will go into CorTuf™ UHPC.

CORTUF International is committed to continuous improvement and has established a

Quality Management System which provides a framework for measuring and improving
performance.

Up until today, there have been only a few countries that developed a specific norm or a
recommendation for UHPC: France, Switzerland, Germany, USA, Canada, Japan, South
Korea and Australia. In many other countries, as in Spain, it is allowed to support the
structural designs done with this material using foreign norms or with a well-argued
technical justification. The French set of standards is the most advanced and widely
accepted normative reverences in Europe:

• NP F 18-460:2016 Concrete – Ultra-high performance fibre-reinforced concrete –

Specifications, performance, production and conformity;
• NP F 18-710:2016 National addition to Eurocode 2 – Design of concrete structures:
specific rules for ultra-high performance fibre-reinforced concrete (UHPFRC);
• NP F 18-451:2018 Concrete – Execution of concrete structures – Specific rules for
UHPRFC.

Since CorTuf™ was developed in the United States, it was extensively tested according to
the American standard ASTM C1856/C1856M Standard Practice for Fabricating and Testing
Specimens of Ultra-High Performance Concrete. Based on works of the United States Army
Engineering Research and Development Centre and a number of companies which
pioneered the development of UHPC in North America, many national industry
recommendations are now available such as:

• Numerous recommendations on UHPC by the Federal Highway Administration;

• ACI 239R Ultra-High-Performance Concrete: An Emerging Technology Report;
• ACI 239C The Structural Design of Ultra-High Performance Concrete;
• PCI TR-9-22 Guidelines for the Use of Ultra-High-Performance Concrete (UHPC) in
Precast and Prestressed Concrete.

The Federal Highways Administration has been at the forefront of the development of
standard practices for using ultra-high-performance concrete in bridge construction,
preservation and rehabilitation.
Introduction Material Applications Engagement Page 13

Appearance and finishes

CorTuf™ is a self-compacting UHPC when in the fresh state. This provides superb surface
quality and the ability to replicate even the most intricate shapes. For this reason, UHPC is a
popular material in architectural applications such as lightweight facades, and visible interior
and exterior structural elements.

Fresh CorTuf
Even during the mixing process, CorTuf™ looks and feels different from conventional
concrete. Unlike traditional concrete, fresh CorTuf™ exhibits the shear-thickening properties
of a non-Newtonian fluid: the more force applied, the more the mixture resists it. The
viscosity in this case increases, and the mixture becomes hard to work with. However, when
the force is not applied, a fresh CorTuf™ becomes self-compacting and immediately “thins”
down. The viscosity level of fresh UHPC is still higher than that of conventional concrete,
giving the mixture a honey-like appearance.

Hardened CorTuf
The absence of coarse aggregate and the self-compacting property allow CorTuf™ to
replicate any detail and texture of the formwork. It is used in architectural applications due
to its high surface quality. This also helps elements made of CorTuf™ to be impervious to
moisture, aggressive chemicals and gases, prolonging their longevity in virtually any
environment.
Introduction Material Applications Engagement Page 14

Applications
The first civil engineering structure built with UHPC was the Sherbrooke footbridge (1997,
Canada), followed by an increasing number of applications in the field of energy, industry,
architecture and civil and military engineering. The most active countries using it structurally
are the United States, France, Switzerland, Denmark, Spain, Japan, South Korea and
Malaysia. Many developing countries have started exploring and using UHPC in recent years.

In Switzerland, over 350 projects have been completed in the past 20 years with over
15,000 m3 of UHPC.

Road Building Rail Footbridge Other

In this country, some UHPC footbridges have been installed, but it stands out for executing
more than 250 projects of thin overlays to guarantee the high durability of the structures.
Introduction Material Applications Engagement Page 15

In 2016, the Swiss Society of Engineers and Architects released the Technical Report SIA
2052 which provides information regarding designs, concepts and research results obtained
from using UHPC in the country.

Since 2000, when UHPC became commercially available in the United States, a series of
research projects have demonstrated the capabilities of the material. A handful of State
departments of transportation have deployed UHPC components within their infrastructure,
and many more are actively considering the use of UHPC. Since then, UHPC, including
CorTuf™, has been used in the construction and rehabilitation of over 350 bridges.
Nowadays, the Federal Highways Administration recognises the benefit of UHPC in
applications designed for durability.

2021 2020 2019 2018 2017 1997-2016

80 77
70
64
60

40 37
34
29
22
20
14
11 10
6
2 2
0
1 0 0 !
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Introduction Material Applications Engagement Page 16

Industries
Transportation
The industry that benefited the most to date with ultra-high-performance concrete is bridge
construction and rehabilitation. The Federal Highways Administration of the United States
Department of Transportation has been in use of this material for a while and stays a big
promoter of UHPC.

Bridge construction and rehabilitation stay on top of the UHPC applications worldwide. A
popular method of bridge construction is Accelerated Bridge Construction (ABC). ABC is a
process that involves constructing large portions of bridges offsite and then installing them
quickly. Doing so can reduce road closures, traffic delays and overall project costs. ABC is a
paradigm shift in the project planning and procurement approach where the need to
minimise mobility impacts which occur due to onsite construction activities are elevated to a
higher priority. Approximately one-fourth of the US' 600,000 bridges require rehabilitation,
repair, or total replacement. However, the work that occurs from on-site construction
activities can have significant social impacts on mobility and safety. In many cases, the
direct and indirect costs of traffic detours that result from the loss of a bridge during
construction can exceed the actual cost of the structure itself. For example, full-lane
closures in large urban centres, or on highways with heavy traffic volumes, can have a
significant economic impact on commercial and industrial activities in the region. Partial lane
closures and other bridge activities that occur alongside adjacent traffic can also lead to
safety issues. Because of the potential economic and safety impacts, minimising traffic
disruptions is a goal that should be elevated to a higher priority when planning bridge-
related construction projects.

Alongside the ABC methods, ultra-high-performance concrete is used in traditional bridge

construction. All around the world, UHPC has been used in prestressed concrete girder
simple-span bridges, precast deck panels and beams, and field-cast connections between
prefabricated bridge components, thin overlays, and columns. In the US, CorTuf™ has been
used extensively in ABC and bridge rehabilitation. UHPC has also been a popular solution in
precast footbridges.

Tunnelling is another area of interest due to its very high strength, ductility, durability and
impermeability. UHPC has been used in thin precast tunnel lining segments. Since UHPC is
an excellent and easy-to-use material for shotcrete, it is potentially beneficial in tunnel
construction.

The high flexural strength and ductility of UHPC have been beneficial in the railway industry.
Many types of structural elements in the railway infrastructure experience high loads and,
often, exposure to aggressive environments. Precast railway slippers and track slabs made
of UHPC have proven to be superior to traditional materials in terms of performance,
especially in high-speed rail applications.

The largest project with UHPC up to date is the Tokyo International Airport (Haneda Airport)
extension completed in 2010. Ultra-high-performance fibre-reinforced concrete was used in
250-mm prestressed slabs on the new runway and connecting taxiways spanning between
longitudinal steel girders above the Tamar River. The panels consist of ribs supporting a slab
with a minimum thickness of 75 mm. This reduced the dead load of the slab by about 56
Introduction Material Applications Engagement Page 17

percent compared with conventional concrete. Approximately 6,900 panels were produced
for this application.

Building and infrastructure

UHPC is also useful in buildings. Lightweight and thin structural elements made of this
material can reduce the dead load significantly, and provide more freedom in design to
architects thanks to its exceptional strength.

Precast balconies and stairs of UHPC have been one of the most popular applications in
this area.

One application that stands out is precast concrete cladding where UHPC has virtually
become the dominant martial. UHPC facade panels are lightweight and durable and do not
require a hydrophobic coating, unlike conventional concrete. It can replace already
traditional glassfibre reinforced concrete that often contains expensive polymers in its
composition. Fibres made of alkali-resistant glass or polyvinyl alcohol are usually used in
this case due to their lower specific gravity and high corrosion resistance. The rheology of
CorTuf™ can be modified to fit the both spray-up and casting (premix) methods.

Over the past several years, ultra-high-performance concrete has shown interest in the
manufacturing of precast piles. Soil composition can be aggressive to such structural
elements when made of conventional concrete. CorTuf™ has been used in the production of
piles up to 40 metres long.

Columns and slabs made of ultra-high-performance concrete can drastically reduce dead
loads in high-rise buildings and be smaller in size. Moreover, UHPC structures are
earthquake-resistant.

High abrasion resistance is mandatory for industrial flooring. UHPC flooring can be
irreplaceable in high-temperature settings and manufacturing, especially where cast iron
wheels are in use. Many structures in different industries are exposed to different aggressive
environments and require a protective coating. UHPC has low permeability and durability
and can be used without additional protection. There are examples of UHPC being used in
sewage pipelines. UHPC itself can act as a protective cover to prestressed anchorage
points as an example. It has also been used for more than 25 years as wear protection in
hydraulic and pneumatic transport and storage systems of abrasive materials.

The marine environment is hostile to conventional concrete structures. UHPC elements are
way less affected by it. Numerous floating farms for mussel cultivation, known as rafts, have
been built since 2016, and until today, no signs of corrosion or damage to the structures
have been observed.

Energy
Ultra-high-performance concrete has been used in onshore and offshore wind turbines,
particularly as grout in the connection between a foundation and a turbine tower or bedrock.
It’s proven exceptionally useful in oil and gas well cementing, corrosion protection and
strengthening of offshore structures.
Introduction Material Applications Engagement Page 18

The nuclear energy sector is known to be a sensitive area for safety reasons. The feasibility
of using UHPC in high-risk structures has been studied for many years. It can be utilised in
an external storage facility of spent fuel in the form of a vertical concrete cask, or in a
containment building.

Some hydropower structures experience a risk of erosion, where UHPC has proven to be
beneficial due to its corrosion and abrasion resistance in the inlet and outlet areas, as well
as spillways and toes or any other structure exposed to hydraulic erosion or high pressure.

Numerous coastal floating solar power plants in Europe have used UHPC in their structures.
This is one of the newest applications in the marine environment but has gained popularity in
recent years.

Defence and security

CorTuf™ was developed with the idea of protection against projectiles, ballistic fragments or
an explosion. A hardened aircraft shelter is one of the structures in which CorTuf™ has been
used. UHPC provides excellent resistance to impact and blast that is important for
structures such as bunkers, munition and equipment storage.

For more than 20 years, high-strength, lightweight security barriers have been used in the
manufacturing of classified safes, vaults and ATMs. UHPC barriers are continuously tested
and approved by the leading test institutes around the world. Small barriers like ATMs and
safes have double steel walls, often in combination with specially designed and patented
reinforcement and/or profiles, which are filled with UHPC of different compositions
depending on a required level of resistance. Large vaults and strongrooms are built from
prefabricated UHPC in combination with special connection systems.

Coastal defences and flood barriers made of UHPC outperform conventional concrete in
strength characteristics, wear resistance and durability.

Rehabilitation and retrofitting

In many applications for the sections above, the use of UHPC has been feasible not only in
the new built but in rehabilitation through strengthening or partial replacement as well. Old
concrete or even steel structures can be repaired and strengthened in contrast with costly
replacement. Partial replacement can be achieved by keeping undamaged parts of the
structure and covering it with UHPC. Replacement of concrete overlays is one of the main
applications of UHPC nowadays.

The strengthening of steel structures by jacketing has been done in several bridges and
tunnels across the US. Ultra-high-performance concrete cover protects the steel from
corrosion and does not require frequent replacements, unlike coatings.

UHPC has also been used to repair eroded and corroded structural elements, especially in
the marine environment with cyclic saturation and drying. Conventional reinforced concrete
does not perform well in these conditions and its lifespan is drastically reduced.
Introduction Material Applications Engagement Page 19

Advantages
Ultra-high-performance concrete is a type of concrete that has exceptional strength,
durability, and resistance to environmental factors. UHPC offers numerous advantages over
traditional concrete, making it a valuable material for a variety of applications. Its high
strength, durability, and aesthetic properties, along with its sustainability and life-cycle cost-
effectiveness, make UHPC a compelling choice for construction projects that require
exceptional performance.

! kg UHPC has an impressive compressive strength of over 150 MPa. This high
strength makes UHPC ideal for applications that require extreme load-bearing

! capacity, such as bridges, high-rise buildings, and tunnels.

UHPC has excellent resistance to corrosion, abrasion, and chemical attacks.

! These properties make UHPC an ideal choice for structures that need to
withstand harsh environmental conditions, such as marine structures and
offshore platforms.

UHPC can be easily moulded into different shapes and sizes, which makes it

!
ideal for architectural applications. It can be used to create thin, lightweight
panels, complex geometric shapes, and intricate designs that are difficult to
achieve with traditional concrete. UHPC also has a smooth, polished finish that
gives it a modern, sleek look.

UHPC is a sustainable material that can help reduce carbon emissions and

!
environmental impact. Its high strength and durability mean that structures
made with UHPC have a longer lifespan, reducing the need for frequent repairs
and replacements. Additionally, the use of local materials in the production of
UHPC can help reduce transportation costs and carbon emissions.

While UHPC may be more expensive than traditional concrete, it can offer cost

!
savings in the long run due to its durability, low maintenance requirements and
accelerated construction. Its high strength also means that less material is
needed to achieve the same load-bearing capacity as traditional concrete,
which can help reduce construction costs.
Introduction Material Applications Engagement Page 20

Our approach
CORTUF International only ship what’s necessary. Now, you our clients can utilise local raw
materials to produce CorTuf™ wherever and whenever you need it. The only shipped
component is a CTI Concentrate, a powder blend of supplementary cementitious materials
that turns concrete into UHPC. And it can be stored indefinitely: it does not react with
moisture or to changes in ambient temperature and is not affected by microorganisms.

To reduce the production and transportation costs even further, CTI Concentrates can be
manufactured under the licence in the country where the producer of CorTuf™ UHPC is.
CORTUF International provides technical support to concrete producers anywhere around
the world. Make CorTuf™ UHPC with our help. No special equipment is needed.

CORTUF International provides technical support and quality assurance anywhere around
the world.

We join your effort in providing industry-leading precast UHPC solutions and supporting
services.

CTI Concentrate

Local raw materials

Introduction Material Applications Engagement Page 21

Sustainability
Construction has always been on the frontline of human progress, and concrete is its major
tool. Since the 20th century, concrete has become the most used man-made material on
Earth. For this reason, it is responsible for over 8 percent of the world’s CO2 emissions.
Concrete needs to lose its colossal carbon footprint before it’s too late.

Lowering the amount of concrete needed for structures ultimately reduces a growing
demand for metals, minerals and hydrocarbons, mining and extraction of which frequently
comes at a high environmental and social cost. The same structural capacity with a lot less
concrete and steel is achieved by combining innovative design with the CorTuf™ UHPC
technology.

Elements made of CorTuf™ have up to 6 times higher compressive strength and up to 8

times higher flexural strength than the top grades of conventional concrete available on the
market. And most importantly, excellent durability allows CorTuf™ ultra-high-performance
concrete to last over 150 years in aggressive environments without the need for major
repairs or replacement. We believe in building once. Environmental impact can double or
even triple when structures have to be repaired and even constructed all over again. Despite
the high amount of cement and chemical admixtures required to manufacture CorTuf™, the
lower volume of the material and long-lasting durability level out its negative environmental
impact.

Our environmental goals extend well beyond the use of local constituents. Whilst we ship
only 25 percent of the final product, we also explore secondary and recycled materials and
increase their share in CorTuf™. By 2025, that same product will use more recycled materials
than ever, like the 99 percent recycled content in steel fibres for the majority of applications,
and the 50 percent by-products we already use in our UHPC concentrate.

To know more, see the CorTuf Sustainability Report.

Up to Up to Up to

75% 35% 50%

locally-sourced reduction in kg CO2 is by-product
constituents eq emission at from other sectors
construction stage

Up to 500% reduction in kg CO2 eq

emission over a life cycle
 Page 22

For more information about the CorTuf™ UHPC program, visit http://www.cortuf.international

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