UHPC concrete for new precast bridge construction or bridge repair

For more than 25 years, UHPC Ultra High Performance concrete has been used for the construction and repair of concrete bridges worldwide. The mechanical and durability
properties are absolutely ideal for modern bridge construction.

WPE DK UHPC concrete is used in the production of precast concrete parts and for on-site assembly. With UHPC concrete, very slim and high load-bearing elements can be manufactured quickly, cost effectively and very precisely. All of our UHPC material qualities can be processed with most types of concrete mixer.

Our UHPC bridge material qualities are usually mixed with a water / cement ratio of less than 0.25 and a proportion of steel fibers. Compressive strengths of 150 MPa / 21800 psi to over 230 MPa / 33400 psi are achieved in our standard quality.

Our UHPC material properties meet all required technical data, including in the USA from the responsible DOTs. All of our UHPC material qualities are subject to a permanent quality check of the raw materials used, finished products and processing on site on the construction site.

We use our UHPC castable materials for joint fill solutions or connection of precast bridge elements. With UHPC castable you can minimizse the connection joints.

We manufacture UHPC mortar, UHPC Castable, UHPC Shotcrete and UHPC Rapid material qualities for bridge construction. At the customer's request, we also develop and manufacture special qualities.

UHPC mortar, UHPC Shotcrete and UHPC Rapid are mainly used for repairs. No extensive preparatory work is necessary for repairs with our UHPC materials. After less than 48 hours, our standard materials reach more than 70% of their maximum strength. UHPC is waterproof from a layer thickness of 5 mm.

We use our UHPC TopLayer or UHPC Phalt material qualities for bridge decks. In Europe we use UHPC TopLayer for new wood bridge construction. All UHPC can be mixed on site and processed quickly and inexpensively with standard processing machines.

The mixing is very simple. You mix 1 part UHPC Binder with 1 part aggregates and clear water, that is all. Everybody can mix it. No additional addives are necessary.

 

 

WPE DK International

Phone: 0049 1514 6318334
E-mail: info@wpe-dk.dk
Homepage: www.wpe-dk.com

UHPC Concrete tower construction up to 300 meter

Industrial chimneys and lighthouses have always

been bricked up, and so well that they are still

fully functional to this day and would be a while

if they weren't torn down. Today you would not

be able to pay for such a construction method

and you would no longer have the time to assemble

it.

Large or tall towers such as TV towers, radio masts,

offshore / onshore wind turbines and similar

structures are made of steel or reinforcing concrete.

High-quality UHPC materials can take on

compressive strengths of more than 240 MPa /

34.800 psi and thus corresponding bending tensile

strengths without reinforcement.

With appropriate reinforcement, these values ​​can

be multiplied several times. Today, slim, high-

strength tower constructions are possible that

cannot be achieved with standard concrete. The

main tube construction of radio masts can also

be made entirely of UHPC today.

Towers for onshore and offshore wind turbines

are already made from UHPC prefabricated parts

or cast on site.

UHPC has many technical advantages over steel

or reinforced concrete structures. UHPC towers

are absolutely corrosion-resistant, quickly

installed and maintenance-free.

 

 

Comparison HPC/UHPC - Standard concrete according DIN EN 206-1

This is a small excerpt from our HPC - UHPC manual book 2020. it shows a small technical section of our possibilities.
Our HPC - UHPC manual book 2020 is currently being revised and will then be available to our customers.

 

 

 WPE DK International

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

 

 

 

 

An old article about the military use of special UHPC concrete systems. The article is still relevant today.

 

 

 

 

WPE DK International

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

New Generation low price HPC and UHPC Binder systems

 

For more than 25 years, we have been involved in the development, production and processing of HPC
and UHPC binder systems. Since then, we have always worked with the same reliable raw material suppliers. This long-standing cooperation guarantees quality, reliability and available.

This has enabled us to keep our HPC and UHPC binder prices unchanged since 2020. Our new UHPC concrete laboratory, which has been active since the beginning of this year, has revised some HPC and UHPC binder systems and these new versions particularly concern the qualities C80 to C140 as fibre-reinforced mortar, castable and shotcrete. We will be able to offer these qualities at a reduced price from June this year.

Would you like to know more about our HPC or UHPC binder systems or just a price for your current project? 

 

 

 

 

WPE DK International

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

Intercor our partner in Switzerland, Poland and Austria

The company Intercor with its owner Gordon Viol is a partner for Switzerland, Germany and Austria we have been working with for a very long time. Intercor AG is a specialist in HPC and UHPC security (safe construction and military), UHPC Phalt and UHPC TopLayer materials.

Gordon is also supplier of us for some of our raw materials. He is owner of mineral mines in the southern part of Africa.
 

Contact:
Intercor AG
Untermüli 11
6302 Zug
Switzerland

Tel: +41 76 428 79 77
www.intercor.ch

Living and working on water and under water with UHPC as construction material

Since than 30 years, UHPC Ultra High
Performance Concrete has been used
worldwide in the offshore sector as
a foundation, repair and construction material.
In offshore wind power technology, UHPC
is used as a floating foundation construction.

Deep sea constructions with UHPC have
also been successfully tested down to a
depth of 3500 m / 11480ft. Together with a  
German university, we tested dome 
constructions with different concrete 
qualities and UHPC. Only UHPC was able 
to withstand the enormous water pressure.

Likewise, energy storage systems for

offshore wind turbines are currently being
developed, which consist of hollow concrete
balls measuring over 30 m in diameter,
which are sunk to a depth of 300 m. These
energy storage systems would also be ideal
for supplying energy to floating cities.

Living and working on water and under water
can be realized sustainably and without an
problems with UHPC Ultra High Performance
Concrete materials.

The first serious projects are already planned
and are about to be realized. International
architect groups are already working on
self-sufficient cities above and under water.
UHPC is an important building construction
material for the designs, which are designed for
extreme longevity with very little to no
maintenance.

The advantages are

• Absolute seawater resistance
• Extreme corrosion resistance
• Extreme compressive strength
• Extreme tensile strengths
• Almost any design geometry can be made
• Material combinations of all kinds are easily possible
• Installation methode same as standard concrete

UHPC for maximum safety and performance

Today, UHPC concrete is used as a construction
material all over the world for maximum safety
and performance. One example of this are the
transport tubes for the Hyperloop system.
Tubular elements made of UHPC concrete have
already been manufactured here for test purposes. 

UHPC concrete is constantly evolving in terms
of its technical material properties and application.
We expect further big changes in our UHPC
material development in the next few years,
which go far beyond what we have so far. Many
materials such as standard concrete or standard
steel will no longer be able to follow this.

WPE DK International

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

UHPC - Concrete - Steel Dimensional comparison

Measurements on the standard concrete structure are in
centimeters, meters, inches, feet and yards. 

Measurements in steel construction are made in
millimeters, inches, feet and yards.

Measurements in mechanical engineering are
made in millimeters, tenths and hundredths of
a millimeter.

Today UHPC construction and mechanical elements can be manufacture and polished so precisely that they can be measured with a tolerance of tenths or sometimes hundreds of a millimeter.

In the near future we will leave standard concrete behind and
make steel competition in a many industrial application
areas for machinery and construction parts. 

As a construction material, UHPC has an enormous number of advantages when compared to standard steel grades and their often complex processing. UHPC as we understand and produce it can be used as a construction material, sealing material and adhesive of high quality.

.

Final storage of radioactive substances in special UHPC concrete container or strong rooms

One way to encapsulate such substances more

safely and cost-effectively than is currently

practiced is to pour into UHPC Ultra High

Performance Concrete blocks. UHPC has a

large number of advantages over the previous

storage in barrels of different material quality

and pouring into glass.

The advantages of new designs are:

 - UHPC is very easy to process as a casting

    and spraying compound.

 - UHPC has an extremely high pressure

    resistance compared to all standard concretes

 - UHPC is completely waterproof

 - What is poured into UHPC can not corrode

    anymore

 - UHPC is saltwater resistant
 - UHPC also hardens under water

 - UHPC in its high temperature version can

   be used at continuous temperatures up to

   1200°C/ 2192°F. This means that the

   UHPC HT (High Temperature) block is

   stable with internal temperature increase

   as well as with external fire.

   A secure above-ground storage against

   theft is possible because the blocks are heavy,

   large and therefore unwieldy for a quick

   removal. Getting the radioactive material out

   of the block is only possible with extreme

   effort and tools and time.

 - UHPC is based on nanotechnology, the material 

   particles are extremely fine. Almost allother

   particles are surrounded by this glue from

   extremely fine particles. Even with a break of a 

   UHPC block, the foreign matter is firmly trapped

   in the debris.

- It is easy to mix radiation-reducing materials into

   the block

-  UHPC concretes can be very good heat-insulating 

   or very good heat-conducting. It's just a question 

   of the UHPC concrete mixture

The advantages of sealing existing deposits are

• UHPC casting compounds can have a very high                       flowability and easily penetrate into cracks and                          joints and seal them.
• UHPC casting compounds are self-compacting.
• All casting compounds are pumpable and sprayable
• All casting compounds reach more than 70%                            after 48 hours

 

 

WPE DK International

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

 

UHPC Residential house construction and wooden residential house construction in case of a fire

I see the forest fires on the news and mourn the
destruction of nature and houses. We are
repeatedly asked whether it is not possible to
build fireproof houses with our UHPC.

Concrete and UHPC are non-flammable, so
basically you can say yes we can build fire-proof
houses.
Fireproof houses are not the whole solution to
this problem.

But let's start with the houses.

Most houses are made of wood, making them
a feast for any fire. The houses are set up at a
distance from the ground. In the event of a fire,
the fire is happy to attack from anywhere.
The roofs also often have rear ventilation,
which is like a Christmas present for the fire
and life-threatening for the fire brigade. The
roof still looks good, but underneath it is
burning, whoever goes on such a roof is, in
my opinion, tired of life. Of course you have
large glass surfaces or glass doors to the terrace in the living room, which is of course also made of wood, after all you want to enjoy the wonderful panorama. The fire loves such glass fronts, they are like open barn doors to the fire. The same applies of course to the large entrance area with a wonderful large wooden door.

So there is nothing in this type of house construction that can stop a fire. The photos taken after a fire confirm that there is nothing left.
It is possible to construct a house with UHPC, which keeps fire out for an extremely long time.

Houses can be constructed from precast concrete,
which increases quality, reduces assembly time
and reduces the total cost of a house. Compared
to standard concrete, the prefabricated parts can
be made much thinner. UHPC finished parts can
be removed from the mold very quickly. Due to
the thin UHPC panel construction, the elements
are lighter than those made of standard concrete
and can also be transported and installed more
quickly and easily.

It is also possible to mix thermal insulation into the UHPC material, which significantly reduces
the weight of the material construction. UHPC concrete is permanently heat-resistant up to 842°F.
We also produce high temperature resistant UHPC materials that are permanently temperature resistant up to 2192°F.

UHPC materials are naturally resistant to all types of insects and fungi.

Problem spot: Doors
UHPC can be used to produce doors that are similar in weight to wooden doors but are fire-proof and highly burglar-proof. With UHPC, door manufacturers can meet every design requirement in terms of surface structure, color and construction.

Problem spot: Windows, Glass Fassade
We can only help indirectly here. We are currently working with a window manufacturer to produce window frames from UHPC. Because window frames made of plastic or wood are flammable.
We are also currently developing window protection made of UHPC that closes the window in the event of a fire.

Problem spot: Roof

We can easily make a pitched roof or flat roof
from UHPC. A pitched roof can have any
desired surface design and color.

A wonderful fire protection is a flat roof with
greenery. Because of the soil that is required
for planting and which should always be kept
moist as possible, fire does not have the
slightest chance. The same can be done with facade surfaces. Today designers call it horizontal and vertical gardens. In many large cities, high-rise buildings with a green facade are now being built.

So we can easily provide fire-resistant house structures in the shortest possible time in cooperation with a locally available precast concrete plant and a locally available assembly company. Architects and designers have to take care of the development of the construction and the design.

Should the fire brigade use water, this is no
problem for a UHPC construction. Since water
does not penetrate the UHPC construction, the
interior can be cleaned and re-used quickly and
easily. A complete interior renovation as with
wood and plaster constructions is not necessary.

Annotation:
The best fire protection doesn't help if you build
houses right next to trees. When houses are far
from something flammable like trees, the fire has enormous problems jumping over these areas without fire fodder. That is also the reason why firebreaks are laid in forests when there is a fire. Landscape architects can offer many ideas for this.

 

 

WPE DK International

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

Combination of UHPC and Nanotubes

We are being asked more and more often by
customers in Asia about the use of Nanotubes
in our UHPC products.
It is always the same question, can nanotubes
improve the technical properties of our UHPC
products? 

Our answer to that is:

Yes, Nanotubes with a certain geometry and size
can do that.  

BUT that's like trying to install an additional
carburetor / turbo system in a Bugatti Viron to
get 10% more engine power, with a standard
engine power of over 1000 hp. The Bugatti Viron
is a perfect car system, making it better with a
possible slight increase in performance only rarely
makes sense.

In other words:
A really good UHPC is a perfect, extremely
powerful system, which in today's industry
hardly ever reaches its performance limit.
The UHPC we make is made by creating a
perfect physical packing of specific particles
in order to achieve perfect chemical reactions.

We have been developing and testing the use
of Nanotubes in our UHPC products for more
than two years.
So far, these UHPC special products have only
been used in very special areas of application
that required very special technical solutions
in the areas of mechanics, electrical engineering
and thermal conductivity.
We have been developing and producing UHPC
systems for more than 25 years. We develop
UHPC products for the future. The processing
of Nanotubes and desert sand with our UHPC
products is part of our ideas for the future.

Sustainability and the use of natural materials
such as bamboo or natural fibers is another
development we are taking. The use of sustainable

raw materials in combination with our UHPC
materials, some of which will also be made from
sustainable raw materials in the future, is one of
our goals.

WPE DK International

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

UHPC Phalt a semi rigid top layer for all areas of an airport

Our nanotechnology for UHPC binder is now

over 30 years old and has been used in a wide

variety of areas worldwide.

From the beginning, the idea was to create a

material combination that combines the best

material properties of both products in an ideal

and flexible manner.

We call this combination material UHPC-Phalt.

The technique is simply, lay a coarse-grained,

porous, locally produced standard asphalt and fill

the pores with an extremely liquid UHPC concrete.

The result is that a flexible, temperature-resistant, 

high-pressure-resistant and extremely resilient, 

frost and de-icing salt-resistant, long-lasting

runway surface is created.

Benefit:

High axle loads, extreme ambient temperatures,

limited construction time and

constrained budgeting.

Standard laying machines and mixing machines

can be used for processing. Asphalt assembly

companies can easily lay this combination of

such materials

Local asphalt qualities can easily be used for

processing.

Fine sand or desert sand can be used for the

UHPC concrete.

Our UHPC binder can be flexibly adapted to

customer requirements. Curing speeds can be

adapted to customer requirements so that the

laying speeds of the laying machines can be

used to the maximum.

WPE DK International

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

We increase the sustainability of UHPC

With our high-performance UHPC products, we started

using sustainable products years ago. We are also

increasingly focusing on sustainability when it comes

to units for our UHPC binders.

One example is corundum, which we use as an aggregate,

among other things. Corundum can be produced as

synthetic corundum with very high energy consumption

or can be mined as natural corundum in open-cast mining.

We have chosen natural corundum for more than 15 years.

Together with our partner in Africa, we pay attention to a

nature-friendly mining and an equally nature-friendly

restoration of the surface areas. The natural corundum

mined by our partner has proven to be an almost perfect

unit for our UHPC over many hundreds of applications

in the offshore industry, architecture, wear protection

and security industry.

Another problematic aggregate of quartz sand, we can

completely replace today with desert sand, including

from Africa. The technical values ​​of desert sand

concrete are far above the best standard concrete.

In our opinion, it is not necessary to destroy beaches

and rivers by sand mining. The cost of desert sand

mining is many times less than the predatory mining

of river sand or beach sand.

As far as the reinforcement systems or fiber systems

are concerned, nature offers us very sustainable

products that can be used in combination with

high-quality UHPC binder systems to create a perfect

sustainable product.

Our goal is always to produce UHPC binder systems

so flexibly that we can always use a high proportion

of local raw materials.

WPE DK International

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

 

Repair of dams and hydroelectric power plant constructions with UHPC concrete

Hydroelectric power plant

UHPC Concrete has been used as a construction or

repair material in offshore, port construction and

coastal protection worldwide for more than 25

years. UHPC concretes are far superior to standard

concretes in their application and service life

expectations.

Typical areas for UHPC concrete repairs

 - Core walls
 - Deflection tunnel
 - Spillways
 - Stilling basins
 - Slope protection

Advantages of UHPC compared to standard concrete

 - Extremely high compressive strength
 - Very good adhesion
 - Waterproof from a layer thickness of 15 mm
 - Very high wear resistance
 - Very high corrosion resistance
 - Very high resistance to frost and ice
 - Very good impact resistance
 - Quick and easy installation, even of large areas
 - Thanks to the extremely fine UHPC binder, even the

   smallest joints and cracks can be closed well and permanently
 - UHPC can be processed as shotcrete, castable or as mortar.
 - UHPC reaches more than 70% of its maximum nominal

   strength after 48 hours.

Dams
Especially the slides of a dam are subjected to high amount

of wear as a very high volume of water is running over

these. UHPC can easily withstand this water. UHPC is the

ideal material for dam reinforcement and repair/maintenance.

UHPC materials can be quickly and extensively processed

as mortar, cast or shotcrete.

The rapid and high strength development favors a quick

restart of the system.
In the lake in front of the dam, the dam will be subjected

to impact by debris, which can deteriorate concrete. Placing

a layer of UHPC will end the deterioration.

New build and repair of sewage treatment plants and sewers with UHPC concrete

Sewage treatment plants and sewers are exposed
to a permanent chemical and mechanical attack
by sewage from households and industry. Due
to the changing climate conditions and the resulting
extreme rain or flood masses, the systems and
channels are extremely stressed and damage that
their function is no longer guaranteed.

A material with high resistance to chemical and
mechanical attacks is necessary for the maintenance
of these systems.
This material should also be able to be processed

flexibly on site and should not require any complex
machinery.

Damage causes in a sewage treatment plant
- due to mechanical wear
- through frost and de-icing salt
- due to chemical attacks or solvents
- due to concrete corrosion in closed systems

UHPC Ultra High Performance Concrete
UHPC are special concrete products with a minimum
compressive strength of 130 MPa and a water/cement
ratio of less than 0.2.UHPC products can be used very
well for the rehabilitation of concrete - and steel structures.
UHPC products can increase to be rehabilitated
construction next to the corrosion protection even
with admixture of ceramic aggregates the static
bearing capacity.

Benefits of UHPC
- Easy installation as spray, mortar, cast
- Very high corrosion resistance
- Extremely wear-resistant
- Extreme low to no carbonation
- Usable at very high humidity
- Very high impact strength
- Extreme low chloride permeabilit
- Very high resistance to mechanical loads
- No pore formation
- Maritime and port water resistant    
- Installation in the water possible
- Duration resistant
- The standard drying time is under 48 hours
- Penetrates into the smallest joints and cracks,
   and closes them permanently
- Joint less installation
- Very good thermal shock resistance
- Absolutely frost and de-icing salt resistant

An unusual adhesion and tensile test with UHPC Cast

 An unusual adhesion and tensile test with UHPC Cast

A customer asked us to demonstrate the exceptional adhesion and tensile strength of our UHPC Cast binder. Our test idea was also unusual. For this test in our workshop we needed a Monster can, two simple rusty flat irons, some UHPC Cast binder, a few steel fibres and bigbags with different fillings.
The Monster can was cut at the top and bottom and the flat irons were put in without touching each other in the can, then the UHPC cast binder material was filled in. We left the material to harden for 24 hours.

After 24 hours a flat iron should be attached to a crane hook and at the other flat iron weights of 1to, 2to and 3 to were attached. The respective weight should hang in the crane hook for at least 2 days without releasing one of the flat iron from the UHPC.

All three weights hung a week in the crane hook without any problems.

We also did a similar experiment with polished metals. The loads were increased in these experiments to 10 to without causing damage.