Mixing UHPC Concrete - A simple process

A real UHPC (Ultra High Performance Concrete) 
consists of a maximum of three components:

• UHPC binder
• Water
• Aggregates, such as quartz sand with a grain size of 0-3 mm

Nothing else is necessary. No further additives.

UHPC concrete of exceptional quality is an
easy-to-manufacture material, provided you have
the right high quality components. For more than
25 years our UHPC Mortar, UHPC Cast, and

UHPC Shotcrete have been mixed by specialists

and amateurs around the world.

 
Let's start with the most important thing, the mixer.
We need a compulsory, pan-pot or shaft mixer for
small to medium UHPC concrete volumes.
For larger UHPC concrete quantities, the use of

continuous mixer is recommended.

If you are not sure whether your mixer is suitable

for processing please contact us, we will be happy

to help you.

1st operation
Mix UHPC binders and aggregates, such as quartz
sand, in a proportion of one bag of binder (25 kg)
and one bag of quartz sand (25 kg) dry for
approx. 3 minutes.

2nd operation
Add water, add approx. 3.8 liters per 25 kg UHPC
binder and mix for at least 7 minutes.

3rd operation
Install the material. For the installation by a average
ambient temperature of 18° - 25° you have about
45 minutes time.

4th operation
Seal the newly laid surface with a suitable wax liquid
such as UHPC curing compound or a suitable foil.

That's it.

All our UHPC materials are mixed in this way. If you 
have mixed one UHPC material quality, you can mix 
all other UHPC material qualities as well. 
Simple and easy.

We also provide a detailed Mixing and processing 

manual for UHPC Cast, UHPC Mortar and UHPC

Shotcrete, with many practical tips

You can order this manual at the following e-mail address 

service@hhbc-consulting.de and 

password "UHPC mixing and application manual."

At this address, we also answer all your questions about our
UHPC technology mixing and applying UHPC under normal
conditions and under extreme conditions.


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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.

Fast - Faster - UHPC Rapid for new installation and repair

For very fast assembly in the taxiway of an airport
we have delivered a special UHPC (Ultra high
Performance Concrete) Cast.

Last Airport project:
There had to be laid cable protection pipes in the
area of ​​the taxiway. For this purpose, a slot of
20cm / 7,87in wide, 100cm / 39,37in deep and
100meters /109yd long in the existing concrete
floor had to be milled. For the filling of the slot
after the cable protection pipes had been laid,
we delivered a quick-hardening UHPC Rapid
Cast. The setting time of this special UHPC
is 2-3 hours, depending on the environmental
conditions. After this time it reaches a strength
above 20 MPa / 2900 psi. The final strength
after 48 hours is about 80 - 100 MPa /
1160 - 14500 psi.


Originally the UHPC Rapid product series
was developed about 20 years ago for wear
protection repairs in steel plants, power plants,
mining plants and cement plants.
Later, the UHPC Rapid was used not only as
a mortar but also as a cast and shotcrete. The
UHPC Rapid shotcrete was particularly used
in mining tunnels and the UHPC Rapid Cast
was used in the new lining and repair of
roadways, roads, storage areas and industrial
floors.

Meanwhile, it is also used as repair material
in airports, on highways and bridges.

Railway bridge repair or new construction with UHPC concrete

One of our many bridge projects we have this year. They are highway bridges and railway bridges. In this case, a railway bridge that was built shortly after the war from simple steel girders and heavy concrete. There are up to 65 freight trains passing this bridge daily.

It is not yet clear if the bridge can be repaired with UHPC or if the bridge has to be completely rebuilt from UHPC. There are still some reports necessary.

The advantage of UHPC in a repair is the UHPC as corrosion protection, as joint and crack filling and as additional static reinforcement can be used easily. The repair time can be minimized by the extremely fast setting time.
In the case of a new building, the size of the bridge can be easily used with a UHPC precast technology, which also reduces the blockage of the rail track to a minimum.

Brighter and cooler city centers and brighter in tunnels with UHPC

An article reported on the increasing warming of

inner cities and possible future measures to reduce
heating.

City roads

In a test, some asphalt road with a specially
developed soil color was colored white as much
as possible and the temperature differences in
this road were measured over a summer period.
It turned out that the light road surfaces reflect
significantly more solar radiation and were
therefore "cooler" than the traditional asphalt
pavements.

Of course the pavement painting, the traffic and
thus exposed to wear and it would be necessary
to renew the floor paint at regular intervals.

A simpler and much more durable method is
the combination of asphalt and UHPC Ultra
High Performance Concrete binder. This
combination is used in many areas such as
industrial flooring, aircraft hangars, runways
and roads. This combination has a variety of
technical and cost advantages over standard
asphalt. Its main advantages are its extreme

resilience at any temperature and the much

higher compressive strength than Asphalt

alone.

The lifetime of this material combination is
several times higher than standard asphalt.
Likewise, this coating can easily withstand
the future traffic through its significantly
higher pressure resistance

The UHPC binder content can also be produced
on a white cement base. As you can see in the
photo, the binder would stain over the entire
layer thickness without the need for special
"coloring" measures.

Tunnel

In addition to reflecting solar radiation, very

light asphalt / UHPC surface has many other

advantages over traditional asphalt surfaces.
When used in tunnels, the light-colored road

surface reduces the energy costs for lighting,

the floor areas are evenly light, which increases

safety, and the surface is considerably less

flammable than standard asphalt surface. The

surface has a much longer service life with high

traffic loads than standard asphalt, which

drastically reduces repair times and repair costs

and increases traffic safety.

It can become very bright on the streets

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UHPC/Asphalt system versus concrete for pavement, industrial flooring and roads

What is UHPC Phalt?

UHPC Phalt is a grouted macadam comprising 
an open graded asphalt that is flooded with high 
strength microsilica based mortars. The open 
graded asphalt is mixed to a design mix at a 
local asphalt plant and delivered to site in tipper 
trucks. It is placed via traditional paving techniques.

The UHPC Phalt mortars are delivered in 
1 tonne bags and mixed via a continuous flow 
pump machine. The mortar is mixed for a certain 
amount of time to achieve correct viscosity then 
flooded via a large hose onto the asphalt matrix.

How does the whole construction 
thickness fit together?

UHPC Phalt can be laid at depths of 30 mm / 
1,18 in upwards (typically maximum depth used 
is 40 mm / 1,57 in). UHPC Phalt is the top layer 
of the pavement that is supported by a basecourse 
layer. The basecourse layer can vary dependent 
on environment and loadings, internal or external 
applications. Preferred basecourse materials to 
support the UHPC Phalt topping are high modulus 
macadam basecourse or Foamix recycled binder 
course. CBM bases are ideal for use for large 
internal areas. 
The UHPC Phalt pavement structure (DPH + 
Basecourse) is laid onto varying depths of Type 1 stone/capping dependent on the CBR value of 
the sub-grade. 

Advantages of UHPC  Phalt

• Very high load carrying capacity

• Frost and rew resistant

• Jointless laying

• Quick installation

• High early strength

• Temperature resistant from - 60°C/-76°F - 90°C/194°F

Where is UHPC Phalt used?

• Airports
• Ports
• Lorry marshalling areas
• Service yards
• Acces roads
• Bus stations / depots
• Waste management facilities
• Car parks
• Indoors for warehouse floors
• Anywhere that concrete is conventionally used 
  
  
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Heat problems with concrete and asphalt highways

Problem asphalt roads
Asphalt streets lose their strength very quickly
as the temperature rises. Many highways, for
example, lead through desert areas in the USA
and Australia.
Driving heavy trucks in such areas push the
soft asphalt ahead or aside. The result is that
the trucks have to drive slower because of the
uneven road, which can certainly lead to
logisticalproblems and motorists who have to
drive in truck asphalt trails do not feel this as
a rest and drive slower. In residential areas,
out-of-the-way asphalt tracks cause noise
pollution as cars literally jump over these
tracks. If buses or trucks pass through these
streets, you can hold your cupboards in the
living room.

Depending on the quality of the asphalt, it is
tacky even at slightly higher temperatures and
at very high temperatures these surfaces can
neither be entered nor driven on without causing
damage.
A UHPC®-Asphalt combination can be thought
of as an asphalt matrix filled with UHPC®Ultra
High Performance Concrete. Thus, a large
proportion of this lining is UHPC® concrete,
which does not stick and temperature resistant
is well over 200°C/392°F. This combination is
still very stable even in extreme temperatures
up to 90°C/194°F in desert areas.

Problem heating asphalt roads and 
adjacent houses
There is an interesting article from a company
that measured the heating of an asphalt road
andadjacent house walls in a residential area.
Then they have provided the black asphalt
pavement with a white topcoat. The road
temperatures and house wall temperatures
were measured again. The result of this
temperature measurement was much lower
than the first measurement without coating.
If the walls of houses also get a light coat the
sunshine reflection is even better. We see this
idea as a solution but not a lasting, economical
solution.


Solution heating of the asphalt surface 
and adjoining houses
As for the heating of the road surface we work
with a UHPC® binder with a very high degree of
whiteness, which makes the road seem much
brighter than the standard asphalt surface. It is
used in tunnels or production halls to save energy
for lighting. Compared to the two-layer solution
standard asphalt and white coating layer, everything
is in one system and the UHPC® Phalt system is much
more durable and more economical than the
two-layer model.


Solution concrete highway
Many kilometers of roads have already been laid
with fiber-reinforced UHPC® concrete in Europe. In
addition to the extremely high strength values, which
are far above that of standard concrete, they also
achieve extremely low abrasion and are absolutely
frost and salt-resistant. The thermal stability in both
the minus and in the plus range is a lot better
compared to standard concrete. During processing,
of course, the same machines can be used as in a
standard concrete processing. Such lining is used
today on airports, highways, harbor area etc.

Solution asphalt roads

About 15 years old asphalt roads or asphalted
areas are lined with a combination system made
of asphalt and UHPC® binder. This ideal
combination of an asphalt matrix that is cast
with UHPC® Binder achieves a significantly
higher load resistance even at ground
temperatures of up to +90°C / 194°F compared
to a standard asphalt. Abrasion resistance is
much higher than standard asphalt. Such
lining is used today on airports, highways,
harbor area etc.

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