Recycling und Wiederverwendung von alten Baumaterial mit Hilfe von UHPC Bindersysteme

 Alte Häuser, teilweise historische Häuser,
werden in unserer schnelllebigen Zeit
brutal abgerissen, um Platz für neue,
modernere, größere, höhere und oft nicht
schönere aber effektivere neue
Gebäudekontruktionen zu schaffen. Dabei
bleibt sehr oft keine Zeit und oft ist auch
der Wille nicht da, das noch wertvolle
und wiederverwendbare alte Baumaterial
zu sichern.

Das Ende von einem alten Gebäude ist ein

Haufen Schutt, der sich noch maximal als
Schottermaterial eignet für den Straßenbau.

Dabei könnten sich gerade Architekten
für die Wiederverwendung solcher
Materialien einsetzen. Es wäre durchaus
möglich diese alten Werkstoffe in moderen
Designkonzeptionen wieder einzusetzen
und einiges an wertvollen Rohstoffen
einzusparen.

In nächsten Jahr werden wir einige Versuche
starten, UHPC mit einer Vielzahl alter,

gebrauchter Werkstoffe zu kombinieren.
Wir sind sehr sicher, das dass problemlos
möglich ist, sowohl in statischer und als
auch konstruktiver Hinsicht. Wir können
natürlich mit UHPC alte Werkstoffe in
Aussehen und Design extrem genau
kopieren, in manchen Fällen ist das
sicherlich sinnvoll und notwendig.
Wir wollen aber alte Werkstoffe wieder-
verwenden und einer neuen gestalterischen
Funktion übergeben. Selbst Bauschutt
könnte in Kombination mit UHPC zu
einem sehr interessanten Betonwerkstoff

werden.
Auch wollen wir den Architekten und
Designer neue gestalterische Kombinations-
möglichkeiten mit alten und hochmoderen
Werkstoffen anbieten.

UHPC concrete with rubble or demolition material

Building rubble or demolition material is a very valuable raw material today, its reuse (upcycling), in our opinion, a very important step for sustainability, reduction of raw material requirements, energy reduction in production and reduction of CO2.

Many architects and designers already work in their designs with materials that have become interesting building materials again through upcycling. Old makes new.

 

In Europe there are more and more companies that have specialized in the processing of used building materials. You are preparing demolition material for a new use in your own plant or already on the construction site. The demolition material is sorted and broken according to quality and color.
In conjunction with our HPC or UHPC binder systems, old building materials obtained through demolition are transformed into interesting new building materials with amazing properties.
The sorted and broken waste material is processed with an HPC binder material for later use as an aggregate in a very simple work step. After processing, the demolition material is suitable for processing with HPC or UHPC binder material and water into high-quality concrete, mortar and floor coverings. Plastics, rubber, porcelain and glass can also be processed as aggregates.

With HPC or UHPC casting binder systems, prefabricated elements or bricks can be produced.

New floor coverings can be produced from milled asphalt road surfaces in a few simple operations. This
processing process could be carried out directly on site with the appropriate screening and mixing machines.

 

 WPE DK International

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

Pipeline repair in a potash mine

When I visited a potash mine, I noticed this "cemetery"

of used pipe parts for the hydraulic potash extraction.

There are around 200 pipe parts of different diameters,

lengths, angles and radius. All parts that were specially

manufactured for this production. The pipe parts are all

lined with cast basalt and have a 3-component

anti-corrosion coating. On average, these new pipe parts

cost EUR 700.00 / piece. So there is a value of at least

EUR 140,000.00. Since the pipe parts show more or less

wear damage, all should be disposed of. The disposal

costs amount to at least EUR 12,000.00. The new price

for the pipe is approx. 156,000.00 EUR and the delivery

time is at least 3-4 months.

I explained to the plant management that we can repair

all the pipe parts. We would remove the existing and

partially worn cast basalt lining and replace it with a

new UHPC wear protection lining. I calculated the

budget costs for this at EUR 66,000.00. The repair work

takes approximately 2 months. Here, however, we could

orient ourselves according to the wishes regarding the

installation sequence to the customer and always repair

the pipe parts that he needs at short notice.

Our customer decided on a new lining instead of a new

production and saved 90,000.00 EUR and at least 1-2

months delivery time.

Today there are no more "cemeteries" for used pipeline

parts in his plants.

www.hhbc-consulting.de

info@hhbc-consulting.de

Recycling of old building materials with HPc and UHPC bindersystems

In our fast-moving times, old houses, some of
them historical houses, are being brutally torn
down to make room for new, more modern,
larger, higher and often not more beautiful but
more effective new building designs. Very
often there is no time left and there is often no
will to secure the valuable and reusable old
building material.

The end of an old building is a heap of rubble
that is only suitable as gravel material for the
subbase material of streets.

The architects in particular could campaign
for the reuse of such materials. It would be
entirely possible to reuse these old materials
in modern design concepts and to save some
valuable raw materials.

This year we will start some attempts to
combine UHPC with a variety of old used
materials. We are very sure that this is
possible without any problems, both in terms
of statics and construction. Of course, with
UHPC we can copy old materials in
appearance and design extremely precisely,
in some cases this is certainly sensible and
necessary. However, we want to reuse old
materials and hand them over to a new
design function. Even building rubble could
become a very interesting concrete material

in combination with UHPC. We also want
to give architects and designers new design
options using old and ultra-modern materials.

Recycling of UHPC concrete compared to standard concrete

Our UHPC concretes are far superior to standard concretes in all technical properties and actually
make them a competitive material for steel. Also in this comparison, UHPC concretes have advantages such as corrosion resistance and temperature resistance, etc.

UHPC concrete constructions achieve a multiple service life of standard concrete in comparable constructions. This means standard concrete structures are demolished much faster and the debris has to be recycled. The demolition material is used as gravel. It is currently trying to recycle this demolition material as a building material.

In addition to a longer service life compared to standard concrete, UHPC also has many advantages here.

1. UHPC concrete has a very high compressive strength which is similar or better to many standard aggregates of standard concrete.

2. UHPC concrete granules have no to extremely low porosity. Thus, UHPC Granules does not absorb very little water.

4. UHPC concrete granules are corrosion and seawater resistant. UHPC concrete granules can be easily processed with standard concrete or UHPC concrete.

6. At the moment we are working on trying to prepare standard concrete material granulate, so that it can be used as a fine aggregate for some UHPC grades.

7. We also plan to use recycled UHPC high temperature material. It could very well be used as aggregate for UHPC HT or for refractory materials.

New use of recycled windmill rotor blades as aggregate for UHPC concrete

UHPC grouting material is used worldwide in the

in the offshore and onshore industry worldwide for more than 25 years. 

Mostly, UHPC Grout has been used to make transition pieces and foundation systems for wind energy, oil production, tidal power plants and floating windmill platforms. There are also plans to use UHPC concrete as corrosion protection for the systems in these areas. It would be a safe, easy to install, cost effective and durable solution. Another development for the future is the combination of UHPC concrete and recycled rotor blade material. Several thousand used rotor blades from offshore and onshore wind turbines are lying on the ground around the world to be recycled or disposed of. Storage has become a very big problem in some countries. In many industrial
applications we use glassglass fibres, carbon fibres or plastic fibres asaggregates to our UHPC concrete. 

 

In order to carry out reuse, recycling and upcycling as standard in the near future, special UHPC concretes are the ideal combination partner. It should also be possible to add construction material from wind turbines to our UHPC with appropriate processing. This could then possibly be used again as foundation material for new onshore or offshore wind turbine.

Sound barrier systems with UHPC and recycling aggregates

Highway noise barrier

There are a variety of sound barrier systems.
Soundproofing systems made of precast concrete
parts is one possibility.

Precast concrete walls are used especially as a
noise barrier on highways and railway tracks.
They can be made in any size and geometry,
adapting perfectly to noise protection and local
conditions.

UHPC Ultra High Performance Concrete
UHPC fiber reinforced concrete has a lot of
advantages compared to standard concretes
that already start with the production.

Recycled asphalt

Due to the extremely high strength values, the
elements can be designed leaner, resulting in
lower material consumption and final price.

Furthermore, UHPC materials reach their strength
in less than 24 hours, enabling them to be removed
from the molds. After less than 48 hours, already
70% of the maximum final strength is achieved.
UHPC is a concrete material with almost no pores.
This makes UHPC extremely corrosion resistant
and resistant to all environmental influences.

Of course, due to its extreme corrosion resistance,
UHPC concrete is ideally suited as a construction
material for soundproof walls that are to be planted.
The root system or frost cannot harm UHPC

Recycled rubber

constructions.
We also have experience of producing of UHPC
lightweight concrete for facade andwall construction.

A regular inspection of UHPC walls is not required.
The expected service life is approx. 100 years.

The future 
Use of all kind of recycling material as an aggregate 
to UHPC Binder
Our goal is to provide our customers with a material
that is not only recyclable but also largely made from
recycled materials such as plastic, rubber, asphalt,
concrete, glas, wall stones, all kind of bricks and
other mixed products. Through this use, the material
costs per ton concrete are drastically reduced. UHPC
is the perfect binder for these aggregates.

UHPC Desert sand binder - Local Concrete for Africa

Almost four years ago we developed a UHPC Desert cement binder to process desert sand into a concrete with very high strength values. Only cement binders, water and desert sand are necessary for this. For mixing a standard concrete mixer is needed. The focus of binder development two years ago was on the professional construction industry.

In discussions with architects and organizations operating in Africa we were asked, if we could develop a simple, not so high-quality version of this binder that can support the traditional simple
constructions of the rural population. After some
discussion, a list of requirements for this new
binder was created with which we now work in
our lab. UHPC binders were originally developed
with the aim of achieving an extremely high level
of strength. Then we discovered with our UHPC
binder the incredible combination possibilities
with a variety of natural materials.


Our UHPC binders can perfectly support or
replace wood, straw, loam and clay constructions in terms of their strength and resistance to high
UHPC can also be easily combined with recycled material. It can be made of furniture and sanitary equipment. UHPC concrete is not flammable, which contributes to the safety of the accommodation.

The aim of our current binder development is to
drastically reduce binder costs, to keep the
mixing procedure as simple as possible, to
drastically reduce the proportion of binder in the
overall mix, to reduce possible material transports,
to enable new material combinations with local
raw materials and to preserve as many
properties of UHPC as possible, temperatures and high solar radiation. UHPC binders are completely waterproof, even in very thin layers, do not rot and provide safe protection against termites.

There is also the possibility to use local cement for the production of UHPC Desert Sand Binder in addition to the local desert sand. For this we would have to test local cements for their suitability for our UHPC binder.

Aggregate, fibers and reinforcements for UHPC

Over the course of more than 25 years, we have combined and applied a large number of materials with our UHPC materials. The material combination was used as wear protection material, offshore material, floor material, building material (for buildings, bridges, halls, etc.), safety technology, shipbuilding, tunnel construction, etc.

We would like to show a small selection of aggregates, fibers and reinforcements, which we have used. The aim of our development work in the combination of UHPC with other materials is the possibility to create country-specific materials with UHPC.

For each of these aggregates, fibers and reinforcements, there is a little story why we chose the combination, how we processed it and the results. if you are interested write us and we will send you this collection of little stories.

Further information on the aggregates, fibers and reinforcements


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

UHPC - Environmental and Sustainability

The hhbc-consulting and WPE DK Team feel responsible for
working in close cooperation with architects,
designers, engineers, urban planners and
construction companies for a more sustainable
future.

Development of UHPC

Already during the development of UHPC Binder,
our goal is to use raw materials that are as
environmentally friendly and energy-efficient
as possible in production. At the suppliers of
cementitious binder systems, we pay attention to

their activities regarding environmental protection
and sustainability. Microsilica as well as fly ash
are waste products that we reuse but they come
from processes that consume enormous amounts
of energy. That is why we use these products in
very controlled quantities. In some of our UHPC
products we have been able to do without
microsilica or fly ash.
We plan to set up production facilities in Asia,
North America, South America and Africa in
order to use local resources and to limit
transport routes to a minimum.

Processing of UHPC

Our UHPC products can be mixed with 50% less
water than standard concretes. The water cement
value in our products is 0.2 to 1.8. In some
countries of the world there is a permanent lack
of water, which is only balanced with seawater
treatment plants that consume considerable
amounts of energy. If less water is needed for the
inforastructure, there is more drinking water for
the people.
Only sand is required for processing our UHPC
binders to concretes with a compressive strength
above 100 MPa and no gravel.
Due to the low precast weights the energy
consumption to the transport of production to site
is much lower.
As a substitute for the admixture of sand, a wide
variety of recycled materials can be used. Our
UHPC binder systems are ideal combination partners.

We have developed a new UHPC binder system that

can completely dispense with the previously
required sand and gravel qualities. Which will
drastically reduce the depletion of sands in the river
and coastal areas and the high-energy international
export.
In the future, we plan to drastically reduce the
production of UHPC materials in accordance with
our quality guidelines to various countries with
local raw materials in order to reduce the
high-energy material transports.

Application of UHPC

Due to the high compressive strength, the component
geometries can be selected smaller compared to
standard concretes, which leads to lower material
consumption and thus to lower component weights.
Our UHPC materials are many times more resistant to
all environmental influences than standard concretes.
Thus, the expected lifetime is several times higher than
standard concrete with almost no repair.
Even today, UHPC materials can completely replace
steel constructions in many areas and achieve a multiple
service life without corrosion protection and repair work.

From our high-density, buoyant UHPC concretes, ships
or islands with high load-bearing capacity and service
life can already be produced today. UHPC materials
are absolutely resistant to seawater.

The better the concrete quality is and with UHPC concrete
it is many times better than with standard concrete, the
longer the usage phase.

UHPC - Use in recycling plants

UHPC Ultra High Performance Concrete
application in recycling plants for

• Synthetic substance - Recycling
• Plastic - Recycling
• Military equipment - Recycling
• Paper - Recycling
• Metal - Recycling
• Precious metal - Recycling
• PCBs - Recycling
• Nuclear - Recycling

The reprocessing of paper, plastic, chemical 
waste, rubber and metals has become an 
extremely important commodity market for 
the producing industry. Much more metal 
raw material is recovered from reprocessing 
than mining.
The material required for reprocessing is 
stored on large exterior and interior surfaces. 
Here, the bearing surfaces are mechanically 
attacked as well as the corrosive liquids 
extremely.
Many existing concrete surfaces show 
considerable damage, which does not 
guarantee the smooth and safe transport 
of the stored goods for reprocessing.
UHPC floor systems are best suited for 
these loads due to their hardness and 
wear resistance. These floor systems are 
laid without joints. Due to the very high 
material density, penetration of corrosive 
liquid with professional installation is 
almost impossible.

UHPC floor and pavementsystems are 
UHPC Phalt and UHPC TopLayer.

UHPC Phalt is a combination of traditional
asphalt with UHPC concrete. The result is a
ground or street blast with the flexibility of asphalt 
and the very high compressive strength and 
wear resistance of UHPC concrete. The 
processing and processing time is extremely 
easy and cost effective.
UHPC TopLayer are floor coverings made of 
UHPC concrete for very high mechanical loads. 
The material thickness is only a fraction of 
standard screeds or concretes.
UHPC TopLayer are extremely corrosion 
resistant and can be installed almost on any 
flooring. UHPC TopLayer achieve compressive 
strengths of far more than 140 MPa


Applications
- Indoor and outdoor pavements in storage areas
- Roads
- Material bunker
- Chutes
- Pneumatic transport systems
- Scrapyard pavement
- Dedusting systems

Benefits for UHPC Wear Protection
- Flexible layer thickness
- Overhead installation possible
- Jointless installation
- Extreme high compressive strength
- Very high wear resistant
- Very good corrosion resistant
- Adapts each of surface geometry
- Fast curing at ambient temperature

Benefits UHPC Phalt and UHPC Top layer
- Extreme high tensile strength
- Extreme high impact resistance and ductility
- The jointless surface prohibits damages on trucks
- Can be applied thin on even the weakest base
- Freeze/thaw resistance
- Fast curing -short stop time
- Cost efficient alternative where a weak base
  requires a change in both wearing course and
  course



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