UHPC Spray Projects in a Northern European Ore Mine

An ore mine operator in Northern Europe has commissioned one of our customers to install a UHPC wear lining on several cyclones. 

The installation was to take place on site at the ore mine. A UHPC wear protection layer of 25 mm was to be installed. The time frame for the installation was very tight due to the mine. For this reason, a UHPC spray installation was chosen. UHPC spray wear protection is sprayed on using a wet process. This has the very great advantage of a controlled and uniform material quality. Since UHPC spray only produces a maximum rebound of less than 2%, there was also no material loss during the spray installation.

Our customer first sprayed half the circumference of the cyclone parts on site and then the other circumference of the cyclone parts. Due to the ambient temperatures, the lined parts could be transported and installed without any problems after 48 hours. directly after installation, this part of the plant could go into operation.

 

 

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.

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