PRODUCTION OF ULTRA HIGH PERFORMANCE CONCRETE

How we create strength, durability, and design freedom

An office worker looking at concrete elements

AN INNOVATIVE MATERIAL

Ultra High Performance Concrete (UHPC) is an innovative material that combines exceptional strength, durability, and architectural freedom. This advanced concrete type enables the creation of structures that are both slimmer and more durable than those made with conventional concrete.

Here, you can learn more about the production process of UHPC, particularly Hi-Con’s proprietary variant, Compact Reinforced Composite (CRC), and the unique properties that make this material a preferred choice in modern construction.

See all our UHPC solutions here

WHAT IS ULTRA HIGH PERFORMANCE CONCRETE?

Ultra High Performance Concrete (UHPC) is an innovative type of concrete which is characterized by compressive strengths between 130 and 200 MPa, significantly higher than conventional or fiber-reinforced concrete, which typically ranges between 50–90 MPa.

At Hi-Con, we use our own UHPC mix, known as CRC, which was developed and patented in 1986 by Hans Henrik Bache at Aalborg Portland.

CRC is designed to achieve an average compressive strength of around 165 MPa in production, although the characteristic strength may vary depending on project specifications. Its exceptional strength and durability stem from a dense matrix with low porosity, ensuring a service life of over 100 years, even in harsh environments such as coastal areas or regions with heavy frost.

CRC also contains a significant amount of steel fibers, which improve ductility and make it possible to use dense reinforcement without the risk of cracking.

PRODUCING ULTRA HIGH PERFORMANCE CONCRETE

The production of UHPC, and CRC in particular, follows a strictly controlled process to ensure the material’s superior properties.

The unique CRC mix includes a high content of binders, fine aggregates (sand), and steel fibers. The water-to-binder ratio is kept very low, contributing to the dense matrix and high strength. Adding steel fibers enhances tensile strength and toughness.

One of the most defining characteristics of UHPC is its microstructure, which is significantly different from traditional concrete. UHPC has an extremely dense matrix, meaning fewer pores and therefore less chance of water or chemicals penetrating and causing degradation.
Due to the low water content, UHPC requires longer mixing times to achieve a homogeneous mass. Standard concrete mixers can be used, but it’s essential that the equipment can handle the material’s high viscosity and fiber content. The extended mixing time ensures even fiber distribution and optimal concrete consistency.

A key component of the mixing process is the use of superplasticizers, which allow for a reduction in water content without compromising workability. This not only improves strength but also allows the material to flow more easily into complex molds, giving designers greater creative freedom.
Because of its high fiber content and viscosity, vibration is applied during casting to ensure full compaction and the removal of air pockets. Molds are designed with precision to achieve the desired geometry, and UHPC’s flowability allows for the production of complex and detailed elements.
After casting, CRC undergoes a carefully controlled curing process. While some UHPC variants require heat treatment to enhance mechanical performance, CRC cures at ambient temperatures. Its dense matrix and low water content reduce shrinkage and ensure dimensional stability.
After curing, all elements go through a finishing phase, where minor imperfections, air pockets, or irregularities are corrected—ensuring a clean, consistent appearance from every angle.

KEY PROPERTIES AND ADVANTAGES OF ULTRA HIGH PERFORMANCE CONCRETE

1. High Strength and Durability

Its high compressive and tensile strength enables the design of slimmer, lighter structures without compromising load-bearing capacity. The dense matrix also ensures excellent durability, even in aggressive environments — meaning no structural maintenance is needed during the element’s lifetime.

2. Design Freedom

Thanks to its fluid consistency and strength, UHPC enables the creation of complex, elegant forms that are difficult, or even impossible, to achieve with conventional concrete. This opens the door to innovative architectural solutions.

3. Reduced Weight and Material Use

Because of UHPC’s high strength, thinner and lighter components can be used without sacrificing performance. This can lead to significant weight savings on projects, lowering transport costs and simplifying installation on site.

ENVIRONMENTAL ASPECTS

Ultra High Performance Concrete has a very long service life. Its 100+ year lifespan means that structures made with UHPC require minimal maintenance and fewer repairs over time.

Compared to conventional concrete, UHPC is also more resistant to environmental factors. Its strength and durability even allow for the reuse of structural elements. Read more about sustainability and environmental aspects here.

DO YOU HAVE QUESTIONS ABOUT UHPC PRODUCTION?

At Hi-Con, we have many years of experience developing and producing elements in Ultra High Performance Concrete. We know that precise processes and the right material mix are crucial to unlocking UHPC’s unique potential. That’s why our experts are always ready to answer your questions.

Want to learn more about our UHPC solutions or receive guidance for your project? Feel free to reach out—we’re happy to help. You’ll find our general contact information on our website, or you can contact one of our specialists directly. We look forward to helping you and sharing our knowledge of UHPC production.