Production of UHPC combat binder and concrete under war conditions

For more than two years, the demand for HPC and UHPC binders for military applications has been
increasing extremely for us. As reported earlier, we have produced and delivered several hundred tonnes of special HPC and UHPC for testing purposes. For these test purposes, special mixes were developed and produced according to customer requirements. The material pre-tests were carried out here in Germany. The military load tests are carried out in the respective customer country.

It is one thing to produce special UHPC combat concrete in peacetime under controlled conditions, it is another to produce such concrete under wartime conditions.
For this reason, we have also started a production and mixer system development in parallel to the binder development.
The technical requirements for such a system are very long and very complex.

Here is just a small excerpt from a list of requirements.

Requirement plant (40 feet container system)
- The system must be easily transportable
- The system must be robust

- The system must have an independent energy system.
- The system must be easy to operate
- The unit must be able to operate under extreme cold, heat and humidity conditions.
- The system should be divided into combinable modules.
- The plant should be able to produce binders and concrete
- The plant should have all the necessary processing machines
 

Requirement UHPC combat binder and combat binder concentrate
- The UHPC combat binder should be able to meet certain minimum technical values
- The UHPC combat binder should be produced as completely as possible with local raw materials.

- The concrete should be produced with local aggregates
- It should be possible to produce combat binder versions as mortar, castable, pumpable and sprayable.
- No additional additives should be necessary
- Extremely little mixing water should be used.
- The concrete should also be processable under extreme environmental conditions.
- The concrete should be workable under water
- It should be possible to use a wide variety of aggregates from destroyed buildings, sands, soils, plastics, metals, etc. The reprocessing should be as low as possible

The HPC and UHPC combat binder production and concrete mixing plant will soon be available to us as a basic prototype plant for testing purposes. Individual parts have already been in use for several decades. Several more special expansion stages will be available to our customers.

UHPC combat concrete for bunkers and security rooms

Over 20 years ago, we were very involved in the security industry and military. We tried a lot of things
successfully and carried out some interesting projects. Then it was very quiet for many years and we successfully focused on other projects and markets.
For the last two years we have been asked again from non-civilian areas. Now we are developing our UHPC combat concrete further in all areas, especially for safety or bunker construction, both above ground, under water and underground. In the development of UHPC materials, we have to take modern weapon systems into account. Several hundred tonnes of special UHPC combat binders are now being shipped by us for testing and the worst conditions.

There is also interest in UHPC material for civil shelters of different load types. Here we will have to meet new regulations and material tests.

WPE DK International

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

Special technical sales training sessions for HPC and UHPC markets and related products

In the last quarter of this year, we are almost fully booked with our technical sales training sessions (by no means to be confused with a presentation). 

 

These very specific training sessions focus entirely on the local market of our participants and the related HPC and UHPC materials. For this reason, only one country is admitted per training session. There are still training sessions booked this year by companies from Poland, Switzerland, Italy and South Korea. We do not charge our clients for the training. Therefore, only travel costs are incurred for our customers.

The joint preparation for the training usually takes about  4 weeks.
 

In the coming year, our new mobile training unit for practical processing training will start its service and can be booked by our customers worldwide. Here, all types of mixing and processing with all HPC and UHPC can be carried out practically.

WPE DK International

Phone: 0049 176 601 73146
E-mail: info@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

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 - 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

 

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

Past and future of concrete in security and military

In the past there have always been interesting

safety solutions with concrete.

Some were successful, some were not. A

success story were bunker structures

underground or above ground for the navy, air

force and army. Even today, concepts for

military and civil security rooms are carried

out with concrete structures.

The next generation in which concrete is

replaced by Ultra High Performance

concrete, or UHPC for short, has been used

very successfully worldwide for a few years.

These UHPC security concepts resist the

strongest attacks, penetration is almost

impossible with the current known weapons.

UHPC security concepts are also increasingly

used in the civil construction industry for

security constructions in safes and security

rooms, coastal protection, fire protection, storm

protection, disaster protection and terrorism

protection.

We are constantly developing UHPC for new

applications, such as floating, unsinkable

platforms that can be used anywhere in the

world, both civil and military.

 

 

WPE DK International

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

UHPC Security projects in south of Europe

Two new UHPC security projects are
scheduled for the coming year. Both
projects are to be carried out in Europe.



The first project is a concept for securing
private property. In a former mine in the
Alps, securing rooms of the highest security

class are to be installed in former tunnels
on different levels of this mine. In order to
maintain this safety class by insurance
companies, investors have specified the
extension of the tunnels and individual
rooms using UHPC concrete.
In the first stage, about 8000 tons are to
beinstalled.



The second project also applies to the
protection of private property. In this
concept, a former military nuclear bunker
is being rebuilt. Again, most of the new
structural alterations are planned with
UHPC.
For both projects, UHPC concrete is just
one part of the backup work. We have
developed a new UHPC material quality
for both projects, which can be optimally
processed in very large quantities in both
very different locations.

UHPC Helicoper landing pads concstructions

For more than 20 years, UHPC Ultra High Performance Concrete has been used as a
floor covering at airports worldwide.

UHPC as a concrete floor covering or in combination with asphalt (UHPC Phalt) are extremely resilient floor coverings for runways, hangars, aprons and warehouses. In terms of their technical properties, they exceed the existing standard coverings several times over, especially with regard to compressive strength, temperature resistance, corrosion resistance and wear resistance.

Helicopter landing pads for civil and military helicopter are rarely made from high performance UHPC unless the landing pads are to be created in exceptional locations or under exceptional environmental conditions, such as in extreme altitudes, extreme climatic conditions, offshore platforms, exceptionally low ground structures, civilian and military vessels.

Certain UHPC material combinations have ductile properties which have proven to be
particularly suitable for moving steel
constructions in many industrial sectors.

UHPC in combination with steel constructions can increase the load bearing capacity of the steel constructions while protecting them from all extreme environmental influences.

In addition, our UHPC concrete or UHPC Phalt  has an extremely fast strength development, so that the landing area can be used after a short time.can be laid very quickly and the  and can be used in a very short time.

UHPC Binder systems development for customer

Experience and Know how - Everything from one source
We develop new innovative UHPC binder systems for a wide range of requirements for our customers. These materials developments incorporate more than twenty years of worldwide experience in the development, production and application of UHPC materials.
We have developed, produced and applied UHPC products for architecture, design, facades, offshore, anti-corrosion, wear protection, flooring, power plants, steel mills, mining, shipping, military, engineering, airports, port facilities, etc.

You would like to have your own UHPC binder production?
We advise and assist you

• In the design of the production plant
• Raw material evaluation of local raw materials
• Research and selection of alternative raw materials
• Assistance with the procurement of production facilities
• Production preparation and production start
• Accompaniment of local production by our specialists
• Training of local staff through workshops
• Introduction of a material and quality inspection

We develop according to your requirement specification for you

• UHPC binder systems for use as mortar, casting compound, shotcrete products
• UHPC binder systems for continuous temperatures up to 1200°C
• UHPC binder systems with fast-curing properties
• UHPC binding systems as lightweight concrete
• UHPC binder systems, impermeable to water and underwater applications

We produce for you according to your recipe your UHPC quality as ready mix in standard paper bags, plastic containers, bigbags or silo trucks in any quantity you want.

We can be your development partner
You have innovative, extraordinary UHPC material, product or application ideas and are looking for a development partner. Please contact us at any time. With your ideas and our experience, interesting future-oriented products should be created for you.

UHPC use under extreme cold conditions in the offshore industry

UHPC Ultra High Performance Concrete in his

high quality material version is an interesting

alternative to steel in many applications in

water and ice.

Benefit of UHPC

 -  UHPC is extremely resistant to wear and can

        withstand even the hardest ice floes.

 -  UHPC does not require corrosion protection.

 -  UHPC is absolutely seawater resistant.

 -  UHPC has tremendous strength.

 -  UHPC can easily withstand temperatures from 

        -180°C / 356°F to + 500°C / 932°F without

        being damaged.

 -  UHPC can adapt to all geometries.

 -  UHPC can be processed locally by local

        installers without special machinery.

 -  UHPC can be processed as casting compound,

        mortar or as a shotcreating compound.

 -  From UHPC very small as well as extremely

        large prefabricated elements can be manufactured.

 -  UHPC can be used to statically carry parts.
 -  UHPC is very resistant to a variety of chemicals.

 -  High temperature resistant UHPC does not lose

        its strength even at high temperatures.

 -  UHPC has a lower weight than steel.
 -  UHPC is made more sustainable than steel.

 -  UHPC can also be processed in damp areas

        and underwater.

For some years, UHPC has been used in the offshore

industry to repair oil rig platforms. You could
imagine producing whole oil rig platforms made of
UHPC. The foundations for all offshore wind
turbines worldwide are manufactured using UHPC
materials. In the past, complete ships were made
from UHPC.

Port facilities, jetties, quay walls, weirs, dykes, etc.
were already made from UHPC. UHPC offers new,
long-lasting options for coastal protection and life
on and in the water.

www.hhbc-consulting.de
info@hhbc-consulting.de

UHPC Shotcrete system - more than 20 years in use

For large areas that are to be lined in a short time, 
UHPC Shotcrete is here a very good solution. 
UHPC Ultra High Performance Concrete qualities 
easily achieve minimum 120 MPa/1750 psi 
compressive strength.

UHPC Shotcrete material must be mixed before 
actually spraying. It is importance for the quality of 
UHPC Shotcrete that the amount of water is kept 
very precisely. Too much water reduces the material 
quality to a decisive extent. UHPC Shotcrete is using
a water/cement ratio of 0,2.
Our UHPC Shotcrete binders have a continuous 
temperature resistance up to 450°C/850°F. For 
temperatures over 450°C/850°F up to 
max. 1200°C/2200°F, we produce a UHPC HT High 
Temperature binder. The processing of the UHPC HT
version is carried out in the same way as with 
the normal temperature versions.

 

Characteristics of UHPC Shotcrete

 - No dust development, better working conditions
 - Due to the very high strength values, material
   layer thicknesses can be reduced
 - As with all other UHPC grades, a water
    impermeability is achieved from a layer
    thickness of 10 mm.
 - UHPC spray is very resistant to any corrosion
    attac
 - More constant concrete quality due to pre-
   defined water/cement content
 - Higher compressive strength with no
   fluctuations

 - Fast uniform strength development
 - Larger layer thickness due to more effective
   reaction of the additives
 - Low material rebound (below 2%)
 - Extrem good adhesion
 - Significantly larger spray performance
 - Minimal air consumption
 - Easy use of fibres
 - High security

UHPC Shotcrete in the new construction of tunnels or canals
Especially for tunnel construction, the use of UHPC
Shotcrete is an advantage. There is no need for high air
pressures like a standard shotcrete, UHPC Shotcrete is
self-compacting, the adhesive properties are extremely
good, so there is extremely little rebound and material loss.

A possible desired reworking of the surface is easily
possible without any effort. The material dust development during injection is extremely low.

UHPC shotcrete as repair material for existing tunnels or canals
Whether large or small tunnels and channel geometries whether concrete, steel or corrugated metal constructions can be repaired quickly, permanently and cost-efficiently.
Due to the fast development of strength, even larger repairs can be carried out quickly and efficiently with little machine outlay.
Due to the extremely good adhesion and corrosion resistance,
elaborate preparation is not necessary. With a simple high
pressure cleaning device, the loose particles should be
removed and then UHPC Shotcrete material can be installed.
Machines and material for minor repairs can be transported
without a problem with a normal pick-up vehicle.

 

WPE DK International

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

UHPC - The ultimate protective armor

The article was published under the title "smart material" in the journal economist several years ago

http://www.economist.com/node/21548918

We have more than 25 years of experience
in the development, production and application of UHPC Ultra High Performance concrete materials in hundreds of different applications, including in the military sector.

This article is already several years old. The development of UHPC Ultra High
Performance Concrete materials has been advanced since then.

Whereby in this case of application for
military bunker or shelter systems
the UHPC material is important, but also the

intelligent combination with other materials
and finally the installation of this material
combination.

With such different UHPC material
combinations, it is possible to dramatically
reduce the impact of a wide variety of
weapon systems.
With UHPC materials it is possible to
produce effective protection systems
in any climatic environments.

WPE DK International

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

 This is a article which I found in the magazine ECONOMIST about the use of "Smart Concrete" in the militaryrld.

UHPC for military use

Safeguards whether for civilian or military objects to protect against bombings, terrorist or military attacks are always current.

We distinguish in stationary safeguards such as airfields, messages, data centers, headquarters, supply centers, etc., and mobile systems for protecting people, military equipment we e.g. properties, observation posts, etc. in international use.

Due to their unique properties UHPC Ultra High Performance Concrete can hereby assume a large part of these tasks. UHPC concrete can be combined with virtually all materials. From these combinations, we can create unique technically properties.

A little story from the past

Many years ago it was asked if we could cover the floor of a barracks with UHPC, because we would have a "super concrete". The local situation was that due to the movement of the tank tracks, the standard concrete was nearly crushed in a short time and it can always be repaired, which were crushed even faster. So that the floor area holds at least a while, the steel chains of the tanks were exchanged for tank tracks with a hard rubber coating.
The damaged floor area was jointlessly grouted with a UHPC soil material of the hardest grade in a special process. After two days, the tanks could roll again.
After several months, I asked if the commander are now satisfied that they no longer need to change the tank tracks. Surprisingly, the commander was not satisfied. He found out that he has been driving very hard on the new lined area, that causes the tank tracks to wear very quickly because now the ground is harder than the tank tracks. Now he has to go back to the tanktracks with hard rubber.
We were just too good.


Advantages:

• Extreme high compressive strength 200 – 300 MPa (29000 - 43500 psi)
• In conjunction with intelligent reinforcement, the strength can be increased many times over.
• UHPC constructions are able to absorbs heavy blasts
• UHPC structures with the same wall thicknesses than standard concrete can give 4 times more security
• UHPC have extremely high early strengths compare to standard concrete
• UHPC is high temperature resistant, up to 1.200°C/2192°F
• Seawater resistant
• Precasted constructions with very high dimensional accuracy
• Significant improve resistant to penetration from high velocity fragments
• High wear and corrosion protection 
 

UHPC protection systems are used as

Firearms protection

 - Guns with differend calibers*

 - Pistols with differend calibers*

   *Ammunition: full metal jacket bullet, hollow piont bullet, expanding bullet, high velocity bullet

Splitter proof wall construction

 - Protection from car bombs in close range, handgranates, small and medium explosions

Floor systems

 - UHPC floor and pavement systems with extreme resistance to mechanical wear of 
   heavy chain vehicles in motion.

Military bunker and shelter system

 - Special UHPC in combination with special aggregates and reinforcement is extreme
   high impact resistant against any bomb attac.

Areas of use

AIRFORCE

• Jet shelter
  
• Ammunition bunker
• Runways
• Air field repair
• Blast shelter
• Bunker
• Air field building protection
• Special air field installation for vertical starter jets

NAVY 

• Harbor facilities protection 
• Ammunition bunker
• Submarine bunker
• Dry dock
• Blast shelter
• Air field repair
• Special air field installation for aircraft carriers
• Bunker

 

WPE DK International

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