UHPC flooring for the most extreme loads

UHPC Phalt and UHPC TopLayer are floor coverings for the toughest environmental, temperature, corrosion, load, wear and tear, extreme loads from special vehicles and their movements and the combination of all these loads.

UHPC Phalt is a semi-flexible overlay, a combination of UHPC mortar and asphalt.
The pavement is laid without joints, similar to an asphalt pavement, using the same machines.

 

 

 UHPC TopLayer systems are UHPC grout concrete floor coverings for extreme loads, wear and corrosion. As a special UHPC TopLayer system, we produce high-temperature resistant floor coverings for industry. Which can be subjected to continuous temperatures far above 800°C.

WPE DK International

Phone: 0049 176 601 73146
E-mail: info@wpe-dk.dk
Homepage: www.wpe-dk.com

What is hard concrete - and what is UHPC hard concrete flooring systems

Flooring systems

Hard concrete

Hard concrete is generally described by its manufacturers as a cementitious, highly durable and wear-resistant floor covering. It is laid in a bond to the substructure. An average layer thickness of 25 mm can be given.
The wear resistance has its limits where the floor is no longer grindable. In many countries, grinding of floor coverings is standard practice.

The characteristics of hard concrete are
- Highly resilient
- Scratch and wear resistant
- Liquid-tight
- Indestructible floor covering
- Design and showroom flooring

Areas of application
- Warehouses used by vehicles with rubber tyres
- Access ramps used by rubber-tyred vehicles
- Exhibition and show room flooring

 

 

UHPC hard concrete

UHPC high performance concrete or as we call it UHPC TopLayer is a mixture of special UHPC binder systems and ceramic aggregates. The average layer thickness can be specified as 15 - 50 mm. As UHPC TopLayer is designed to withstand the highest loads, it is almost impossible to grind the surface. UHPC TopLayer can be processed in the same way as hard concrete.

The characteristics of hard concrete are
- Extremely resilient
- Very high wear resistance
- Water and frost resistant
- Very high corrosion resistance
- Very high compressive and flexural strength
- Extremely temperature resistant

Areas of application
- Warehouses used by heavy vehicles and tracked vehicles
- Roads and storage yards for heavy load storage
- Flooring for ore mines, steelworks, foundries, cold stores, military areas and parking areas for heavy vehicles

 

 

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

 

Heat problems on airports

The climate is changing, the summers are getting much hotter. The summers are getting so hot that
infrastructure constructions such as concrete roads and asphalt roads are reaching their limits. Here is one of many examples, airfields. The taxiways, aprons and parking areas have to be cooled with water because the pavement may reach its load limit. Costly and time-consuming repairs are the result. The heat waves are getting longer every year.
Wouldn't it be an improvement to use semi-rigid floor coverings with a temperature resistance of up to +90°C and very high load-bearing capacity in highly stressed areas? An alternative would be UHPC TopLayers that do not lose their peak load-bearing capacity even at very high temperatures.

 

 

 WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

Comparison Sand for the construction industry - Alternatives to Sand for the construction industry

 The global construction boom is continuing and will not decrease significantly in the future. climate change is forcing new constructions. Old constructions have to be replaced. Most of the world's major sites are on the coasts, and constructive coastal protection will buy these sites some more time, but the major sites will also have to change in terms of construction technology. Concrete as a building material is needed for this transformation.
Sand as part of this needed concrete has become a big problem. The gigantic demand leads to a lucrative trade business worldwide, which permanently destroys the nature of the coasts and rivers.
Several years ago we pointed out that with the UHPC technology it is easily possible to replace a very large proportion with recycled sand. Only these recycling plants for construction waste are rarer to find worldwide than diamonds. And yet, the expansion would be an extremely lucrative business, also for investors.
The fastest way to drastically reduce the current demand for sand is to use desert sand. For several years now, it has been possible to easily produce concrete from desert sand that is much stronger and easier to handle than standard concrete. If one were to calculate the current worldwide sand consumption as a standard, the desert sand of the Sahara would last about 100,000 years.
Even if the entire global construction industry still finds it extremely difficult to use desert sand, which there is actually no reason to do, development will force them to do so. For investors who become active now, this will be a gigantic business in a few years.

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

CNN Article - It´s so hot, roads are buckling, they are putting foil on a bridge and roof....

 The climate has changed and even if all countries of the world would reach their climate goals, it would still take decades positively estimated until the climate change would move again in another direction. So we and the next generation of us have to live with the changes like heat. Now the architects are asked not to build beautiful glass palaces but buildings that resist heat. Take a look at the traditional building constructions in Africa and the Arabic countries and learn quickly. Our learning about building materials started years ago. We have a strong base in southern Africa. We learn and develop HPC and UHPC based on local raw materials and we combined our HPC and UHPC systems with local construction materials.
Many of our HPC and UHPC binder systems are high temperature resistant and may be easy to work with under higher ambient temperatures in the future.

 

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

UHPC Aggregate - Mining of Nature Corundum in Zimbabwe

After a hard day in the corundum mine, blasting, grinding and transporting, we earned a cold beer by the river. 

 

 

 

 

 

Of course, with a proper distance from the shore. Some river dwellers can really be very unpleasant. On
the way to the river we found some interesting minerals here and there.

 

 

 

 

 

 WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

                                                                                         

Comparison Nature Corundum - Industrial Corundum

 

Natural corundum is an important aggregate for many of our UHPC material qualities. It is a natural material that is mined without much effort. Quite the opposite of the industrial production of corundum. There, very large areas of land are destroyed for the production and an enormous amount of energy is required for the production.

 

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

 

UHPC Wear Protection installation for a Austrian mining company

For an Austrian mining company, we are to supply raw parts lined with UHPC wear protection and special ceramics. The pipe parts and their wear protection lining were not standard. The delivery was under extreme delivery pressure. Most of the conveyor system was already fully assembled and the customer was only waiting for our special parts to be able to put the conveyor system into operation. WPE DK fitters lined part of the system with UHPC wear protection on site in Austria. An assembly hall was built especially for this purpose. The other pipe parts were lined in the WPE DK workshop. The entire order was delivered on schedule. 

More than 40 tonnes of UHPC wear protection were installed.The average layer thickness was 25 mm.

 

 WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

Further development of HPC and UHPC binder systems for the African continent with African raw materials

Today we are starting a new UHPC development project that is unusual for us. With our friend and business partner Gordon Viol we are going to Africa, more precisely to Zimbabwe.
Gordon Viol has a mine where he mines natural corundum. Natural corundum is a very interesting material and important aggregate for some of our UHPC concrete systems. We want to have a look at the mining of natural corundum. 

But we also want to learn about local building materials and traditional building methods. How can we integrate these local materials in our HPC and UHPC concrete systems?

What are the requirements for building materials in Africa? What cement qualities are available here? How are these materials processed? It is exciting to learn about all this. Sustainable building materials, nature building materials and the processing of these building materials are at the top of our priority list for development projects. We already have many ideas. As always, we are ready to go unconventional ways. For example, we want to combine clay and earth with our UHPC binder systems. We already know very well from desert sand that it is possible to produce high-quality concrete with it. We are looking for new materials that can be combined with our existing binder systems or with binder systems yet to be developed. These binding systems should be processable under the local environmental conditions. 

For this project we want to take three weeks on site. Afterwards, we will evaluate all findings and materials in our development laboratory near Flensburg. We will report on this development project in loose order.

 

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

UHPC Special Binder System for a Flood Gate

For our customer FDN we have developed a special high performance UHPC binder. With this binder, FDN has developed the first flood gates made entirely of UHPC concrete. These flood gates will replace many old flood gates in the future. Floodgates made of UHPC are absolutely corrosion resistant and have an enormous strength. To prove this strength, the local authorities required a load test in addition to many material tests. In the attached video you can see the UHPC slab which has a similar wall thickness as the future gate constructions. 

 

 

Both load tests with a cast iron ball from different heights were passed without any damage.
We assume a life expectancy of at least 100 years for the UHPC concrete without the need for regular maintenance work.

 

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

UHPC OilWell Binder for local production

Offshore and onshore oil drilling projects and active oil production platforms number in the thousands worldwide. OilWell cement binder is required for all these objects and in large quantities. Until now, these extreme quantities were shipped worldwide to the places of need, transported by truck or by a combination of both, regardless of which transport route was chosen, it was time-consuming and expensive.
Today and in the future, these transport routes will become more complicated, unreliable and much more expensive.

We would like to offer an alternative to the standards used so far. We have been developing and producing UHPC binder systems for more than 25 years. Among other things, we also produce UHPC binders for the offshore industry.

Our alternative to the current transport routes is the production of UHPC OilWell binder on site with local raw materials. After testing the local raw materials, it is possible to quickly determine which OilWell qualities can be produced locally and replace standard OilWell binder from overseas.
For the production, a mobile production unit consisting of three to four containers is used, depending on the desired production quantity, which can load the produced binder into BigBags or silos.

WPE DK International

Phone: 0049 176 601 73146
E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com