UHPC Grouting of Pile Jacket Annulus at RS 16 Platform, for ONGC, Bombay High, India

Larsen and Toubro Ltd  was engaged in installing two new platforms in the Bombay High field, but due to issues with the specified pressure grouting technique, the jacket pile connection could not be completed on the last remaining leg on the RS 16 platform.
A Danish company was contacted in April 2009 and immediately mobilised all their grouting equipment and personnel together with around 80 tons of special UHPC grouting materials to Mumbai.
UHPC grouting material was specified due to its high compressive strength and modulus of elasticity in the region of four times higher than conventional grouts. In addition, the highly viscous and cohesive nature of UHPC prevents the risk of cement particles washout or being mixed with
water, making UHPC grouting material ideal for use in underwater conditions.

Working from Sapura 3000, a DP Heavy Lift and Pipe laying Vessel, grout hoses were connectedby divers to the pile grout inlet underwater at a depth of 46 meters. Grouting works were carried out 24 hours to expedite completion and all grouting works were
completed within 16 hours. The topside was installed 36 hours after completion of the grouting.


The use of UHPC materials have been proven to provide fast and efficient solutions to structural installations and repairs in the offshore environment.

Repair and new construction of concrete structures at coastal areas with UHPC

The splash zone is without doubt one of the more 

aggressive environment for wood, concrete and/or 

steel. Here you have the movement of the water 
inducing wear on the structures, high level of 

oxygen inducing a perfect corrosive environment. 

In salt water chlorides are present all over but 

combined with good access of oxygen this zone is 
where the problem is.
 In icy regions ice sliding by 

a structure will tear and wear the structure. 

UHPC Ultra High Performance Concrete is here 

an ideal construction material or protection layer.

Sea level rise
It is likely to lead to greater flooding, 
salinisation and erosion in coastal areas, 
affecting millions of people worldwide and 
costing billions of dollars of damage.
Today, a lot of big cities are right on the 
coast or at estuaries. Changes in sea level 
or in severe storms or torrential floods 
directly hit these cities. Most cities have
not yet realized this danger and have not 
yet taken any protective measures. Such 
safeguards include raising defenses, 
implementing flood storage and construction 
of new river barrier systems.

Many important industries are located 
particularly in Asia directly on the coast. 
Without future active coastal protection, 
this industry will be a major problem for the 
respective country.

Prefabricated concrete elements made of 
special UHPC concrete are ideal for effective, 
long-lasting coastal protection.
The elements can be made slim and light due 
to the enormous strength. They are easy to 
transport and assemble. They are extremely 
corrosion resistant and virtually repair-free. 
The expected lifetime far exceeds that of 
standard concrete elements.

Areas of application are

• Marine structures
• Coastal protection
• Quay construction
• Weir, dock and wharf construction
• Jetty construction

In many coastal industries seawater is used for 
process cooling. In steel or concrete pipes, the 
water is pumped directly from the sea into the 
corresponding production.

To ensure the necessary process cooling 
permanently, it is extremely important that the 
water supply is always constant. A reduction 
by the flow rate, for example, a reduction in the 
conveying cross section of the pipeline can 
result in the worst case to a stop in the production 
or cause damage to the system due to overheating.

In most cases, standard concrete qualities is used 
in the manufacture of concrete pipes.

These tubes have a rough and porous surface. 
Shells of all kinds can be very firmly and 
permanently anchor on the basis of porosity in the 
concrete structure. Especially pipes in cooling 
water or cooling water channels must regularly 
notify the mussel case be removed.

In the removal the firmly anchored mussel beds a 
part of the concrete surface is also always removed, 
which can cause the concrete reinforcement may 
corrode. The result is a time consuming and costly 
repairs to the existing concrete structure.

UHPC concrete has a compared to standard concrete 
extremely low porosity and a very high wear resistance. 
These characteristics make it is not possible to 
permanently anchor the shells in concrete. Removal of 
the mussel beds is quick and does not damage the 
concrete surface.

Standard concretes can effectively protected with a 
10 - 20 mm UHPC layer for a very long time.


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

UHPC - 3D Printing

At the moment we are trying to develop the printing of concrete more professionally worldwide, so that all imaginable constructions can be printed out of concrete. Here, in my opinion, the interaction of printing system and printer material is the deciding factor, similar to an inkjet printer. If you have the wrong ink quality, there can be significant difficulties.

With standard concretes or improved standard concrete, good to good results can be achieved with concrete walls. But what if a combination of insulation and concrete is required, as well as high strength for the printing of high-rise buildings or filigree structures? Here the standard concrete comes quickly to its material limits abuts.
In addition, the printheads are moving faster and faster in all dimensions - so an extremely fast strength development in conjunction with high adhesion is necessary.

In our opinion, all these requirements can only be achieved with extreme UHPC material qualities. We are currently working on these materials. At the moment we also process a wide variety of material combinations to make them printable. In doing so, our over 20 years of experience in the development of UHPC casting and injection materials, production and application experience in a variety of industries around the world are key to our success.

Not to mention a very good pumpability with low load on the pump or the printer system.

We are not looking for the standard - we are looking for the extraordinary. Do you want to accompany us?

Desig

In the field of design, we believe that we will be printing extremely fine filigree structures using special UHPC grades. Today wall thicknesses in the design range of less than 10 mm can be achieved with UHPC design qualities. First attempts are currently running at us to drastically reduce the wall thicknesses.
In our design workshop, we "play" with the most diverse combinations of materials, sometimes with amazing results.

 

WPE DK International

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

UHPC Workshop in Germany

Our manufactory is not very big. Here we
playfully develop new design ideas, new
material combinations and, if necessary,
develop new UHPC Ultra High Performance
concrete mixing recipes.

Our manufactury is to transform the
advantages and peculiarities of our own
UHPC material creations into design
designs. We also develop special material creations for designers, similar to those in the textile industry.
Our UHPC material qualities are used from the smallest jewelery to complete house interiors.

We have the possibility for interested parties outside of Europe to connect directly to our UHPC development laboratory via TEAM, SKYPE etc.. After making an appointment, we will then be available for you.

We only produce UHPC design material of the highest quality for designers.

Some of our qualities can be processed
with standard mixing machines.

We are working on a new cast process
in order to be able to achieve even finer
wall thicknesses and structures, or to be
able to use previously used processing
techniques in the field of clay processing
and plastering for our material. We are
currently working on a material quality
that can be processed like clay on the
turntable.

We plan to move our manufacture
workshop this year in an old farm
with big barns.
Here, we want to invite students and
designer from all over the world to
work together with us to develop new
design ideas and put them to practical
use, which requires more space.


You want to try out our UHPC design
material?

We ship 5 kg plastic containers free of
charge within Europe.
Outside of Europe, unfortunately, we
have to take a very small freight surcharge.

WPE DK International

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

UHPC - Standard concrete comparison

Standard concrete
A mixture of cement binder + sand + gravel + water

UHPC concrete
A mixture of UHPC binder + sand + water

One of the most important quality parameters
when comparing standard concrete and UHPC

Standard Cement Binder                         UHPC Binder         

is water/cement ratio and compressive strength.

The water/cement ratio is the ratio of the weight of water to the weight of cement used in a concrete mix.
A lower ratio leads to higher strength and durability, water/cement ratios of 0.4 to 0.5
are more typically used for standard concrete qualities. For higher-strength concrete, ratios of 0.20 - 0.18 are used.

Despite the extremely low w/c value, UHPC materials of high production quality 

can be processed in much the same way as 

concrete.

Among other things, the low w/c value
means that the pore volume is extremely low
or even absent, which leads to very high
compressive strength (up to 240 MPa) and
very high corrosion resistance. UHPC is also
self compacting.

Another effect of the low pore volume in UHPC
is the extremely high content of wetted surface,
e.g. on steel reinforcements against concrete.
This leads to very strong connection of steel
and UHPC. If you wanted to pull a standard
reinforcing steel out of a UHPC block you
needed enormous tensile forces compared to
a standard concrete reinforcement.

Due to the extremely low pore volume and the

high pressure and tensile strength combined
with the exclusive use of sand as aggregate, the coverage of the reinforcement can be reduced. Likewise, the distance between the reinforcing bars could be reduced.

In this context, UHPC can be used to make
concrete structures that are closer to steel structures than the ones in their dimensions
and bearing capacities.

 

 

 

 

 

 

 

 

WPE DK International

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

 

UHPC - Wear protection system for coal fired power plants

Large quantities of materials like hard coal,
lignite and ash are handled in a coal fired
power plant. To ensure a constant production,
most of the conveying (hydraulic or pneumatic),
storing and production equipment must lined
with wear protection products.

Based on the long experience in wear
protection system engineering for the most
of the OEMs of grinding and mill systems
like impact mills, vertical roller mills,
hammer mills etc., together with our
partner WPE DK we can offer standard and
custom made UHPC wear protection lining
systems.

We supply custom made solutions and
engineered systems like pipe components
with electrical wear control or pipe
components with a combination lining of
wear and heat reduction linings.

For circulation fluidised bed steam power
plant we engineer and install dedusting and
ash transport systems with a high quality
wear protection linings or combination
linings of wear and insulating material.

We deliver and install special custom
made wear linings for different burner systems.

We engineer and produce 
lining systems for mill suppliers like: 

Loesche            LM Verical Mill
Gebr. Pfeiffer   MPS Vertical Mill
ALSTOM         SM Mill, Raymond Roller Mill
HITACHI         Vertical Roller Mill
FLSmidth         ATOX Vertical Roller Mill

UHPC Installation areas

Cyclones                                                                        Cellular wheel sluice
NID-Systems for flue gas cleaning                                Chutes  
GSA-Systems for flue gas cleaning                               Pumps
Pneumatic transports systems                                       Ventilator housing and blades
Hydraulic transport systems                                          Coal mill
Trough chain conveyors                                                Burner systems
Submerges chain conveyors                                         Ash silo
Apron conveyors                                                           Coal bunker

 

WPE DK International

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

UHPC - Wear protection in cement plants

Large quantities of materials like clinker, cement,
lime and granulated slag are handled in a cement
plant. To ensure a constant production, most of
the conveying, storing and production equipment
must lined with wear protection products.

UHPC (Ultra High Performance Concrete)
wear protection systems are engineered for wet
and dry system cement plants, grinding
clinker or grinding slag plants.

Til today the most of the interantional OEMs like
Polysius, FLSmidth, Loesche, FCB, Gebr. Pfeiffer,
KHD, IKN, etc. use UHPC wear protection systems
in their machines.

There is a 25 years long experience in engineering of
UHPC wear protection systems for dynamic and static
seperator systems, clinker cooler and grinding systems,
like hammer mills, vertical roller mill, high pressure
mill and crusher.

Mill systems in which UHPC wear protection 
systems were used

FLS ATOX coal mill

FLS OK mill
Gebr. Pfeifer MPS mill
Claudius Peters EM mill
Polysius QUADROPOL mill
Polysius DOROL mill
Loesche LM mill
Christian Pfeiffer QDK separator
KHD SKS Sepmaster separator
KHD V-Separator
Polysius SEPOL separator

Standard application areas for UHPC 

wear protection systems

Cyclones  Seperator
Pneumatic transports systems

Hydraulic transport systems
Mechanical transport systems
Chutes
Chain conceyor systems
Slide gate valves
Ventilator housing
Coal, cement and clinker mills
Flash dryer system
Coal bunker
Silos
Dedusting systems

WPE DK International

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

UHPC - Offshore structural repair

UHPC (Ultra High Performance Concrete) offshore grouting products are a pumpable and developed for all kind of offshore application and has been used widely in connection with structural strengthening and corrosion protection of offshore platforms.

Such UHPC grouting products have been used offshore in connection with

• Strengthening of intact tubular members
• Reinforcement of joints
• Repair of damaged members
• Pile-sleeve connections
• Strengthening of double skin sections

An example of a spectacular application of such solutions with respect to member repair is for a
member having experienced hydrostatic collapse,
where the member was re-inflated and filled with
ultra high performance grout. In another case
our solutions were applied in connection with a
pile-driving refusal (changing the intended shear
key connection to a plain pipe connection).
UHPC grouting high strength material was used
as grout material in stead of the intended
conventional grout. In the above selected cases
the design strength of the members was
re-established due to the extreme effect offered
by high strength materials and at the same time the solutions was economically attractive.

One of the main advantages of using UHPC grouted solutions in connection with repair is the easy accommodation of geometrical irregularities. Structural components subjected to some kind of damage
(from installation, impact or accident) often
show some dents or imperfections. The use of ultra high
performance grout in connection with repair
improves the performance hereof as the UHPC
grout serves not just as a filling material but
as a strong structural component.

UHPC grouting materials are suitable for

casting both above and below water. Due
to viscous consistency of the mixed materials
there is no risk of washing out cement
particles or mixing with water when cast
below sea level. 

The UHPC grouting products for offshore
have been developed having very low
shrinkage so that the grout and surrounding
steel remains in physical contact after curing.
Further, these products has been developed
to show limited heat development during
the hardening process eliminating the risk
of thermal cracking. 

WPE DK International

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

UHPC - a material for many applications in onshore and offshore wind energy production

UHPC Ultra High Performance Concrete has been used for many years in offshore wind

and onshore wind energy production.

We produce our UHPC for these applications. The new grades UHPC are currently being tested and will be available to the market later this year.

Monopile wind turbine designs are still the most widely used standard foundation design in many coastal areas. Jackets -, Gravity base -, Tripods - and Tri-piles systems are also used depending on requirements and needs.

UHPC grouting is used in all foundation techniques.

Monopiles

UHPC grouting material is used for the connection between monopile and transition pieces.

We estimate that more than 2000 monopiles worldwide have been installed with UHPC grouting and transitions pieces.

At the moment we are working on the 4th generation of grouting material. In addition to the technical improvements, the fulfillment of a wide variety of environmental requirements is the prime objective of the development.

Benefits of using UHPC grouting material for the transition piece

• Extremely high strength
• Very good fatigue properties
• Minimal shrinkage
• Extreme bond between UHPC grouting material and steel
• Fast setting development
• Very high inner cohesion
• No mixing with sea water
• Absolutly seawater resistant
• Very low hydration heat
• No corrosion

Tripile

A Tripile foundation consists of three steel piles driven into the seabed after which a three-legged transition piece structure is slid into the three piles. The overlaps between piles and transition piece are grouted with UHPC concrete.

The UHPC concrete connections evenly distribute the forces from the three-legged transition piece to the piles

Tripod

A Tripod support structure/foundation is secured in place by driving three piles into the seabed through a sleeve in each of the three corners.

UHPC concrete is pumped into the annuli between pile and sleeve to ensure a strong and durable connection.

Jacket

Jacket foundations are secured to the seabed by four piles placed in a sleeve in each corner and driven into the seabed. Jackets are generally considered to be better than monopiles for seabeds where the substrate is poor or deeper water. So here UHPC grouting can be used in the "transition piece" and in the lower foundation.

Gravity foundations

Are well suited for rocky sea beds. The complete foundation system can be manufactured on land and then pulled into position with a ship and then sunk. Depending on the design, the entire foundation piece can be made from UHPC. UHPC will be perfect for slip casting the entire foundation.

                                                       
After the use of UHPC grout in offshore wind energy generation, the experience gained in onshore wind energy production has also been exploited.

Steel Tower

So far, steel towers in cylindrical or conical segment construction have been the state of the art.

Depending on the required hub height, up to five segments were mounted on top of each other. With the new tower heights, the segment diameters are getting bigger and bigger and the road transport between production and the site is becoming an ever greater problem.

Concrete Tower

More and more, as an alternative to steel towers, concrete towers are also produced and assembled in cylindrical, conical or polygonal segments. A disadvantage compared to the steel towers is the high wall thickness, which makes larger foundations necessary

The advantage is

• Favorable vibration characteristics, which leads to reduced noise emissions.
• Long life expectancy
• An ideal solution for high tower high and large rotor diameter
• Transport cost savings due to possible on-site manufacture
• The use of special UHPC concrete grades can lead to slender constructions and thus rougher component weight.
• Lower component weight can also make the foundation dimensioning more favorable, which can lead to cost reduction. The material experiences in the offshore transitionpiece technology can also be of advantage when using UHPC grout in the imbed ring assembly (connection tower / foundation).
• Since UHPC concrete of high quality have virtually no pore formation, they are extremely resistant to corrosion.
• There are little or no maintenance costs.
• The individual segments can be transported more cheaply than is possible with the steel segments.
• On-site fabrication is the use of slipforming is another option including the use of local concrete raw materials for the production of high-quality UHPCs.
• Furthermore, it is possible to produce extremely exact segments with UHPC grout material, which requires no or very little post-processing of the segment abutment surfaces.
• Our UHPC materials reach at least 70% of their rated strength in less than 48 hours, which can lead to lower manufacturing costs for segment production and delivery times can be drastically reduced.

Hybrid towers

This type of tower construction is a combination of concrete (lower part) and steel construction (upper part). IT combines most of the advantages of steel tower and accentuated tower technology. Here, too, the use of UHPC can lead to additional benefits and savings in terms of material and financial resources.
A segment construction or on-site casting by slipforming are possible. This reduces the costs of transport and reduces the foundation geometries.

 

WPE DK International

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

                                                        

HPC and UHPC Facade elements

In modern architecture, facades and wall elements made from a wide variety of materials today.

The classic is still Italian marble like carrara, lasa bianco classico, lasa bianco vena oro.

The beauty of these natural stones is undisputed but the processing of these natural stones is very expensive and also has its limits in durability and plate sizes. The larger the façade or wall panels are desired by the architect, the thicker the panels become, the higher

the weight of the single panel becomes, the more complex
the handling becomes during assembly on site.

The future of the facade architecture is designed with UHPC 
(Ultra High Performance Concrete). UHPC fiber reinforced conctrete is a material with outstanding properties compared
to today's standard concrete.

We produce the highest quality UHPC binders worldwide. With more than 30 years of experience in research, development and production, we can meet a variety of customer needs.

Our UHPC binders can be combined with almost all mineral
and metallic materials.

With our service team we support precast plants worldwide
in the optimal handling of UHPC.

Facade and wall panels can be produced as sandwich
panels in a wide variety of material combinations.
Examples would be
UHPC / insulating material
UHPC / wood
UHPC / glass
UHPC / gypsum
UHPC / metals
UHPC /minerals

We can not only reproduce a variety of natural stone 
structure and color with pigments and special mixing 
technology, it is also possible to produce a variety of 
surfaces from polished to various roughnesses to 
coarse structures.

Depending on the combination material, UHPC
layer thicknesses of less than 15 mm are possible.
We have already used UHPC layer thickness of
less than 5 mm on wood.

Complete UHPC seamless frames can be made
for any kind and geometry of façade openings.
This kind of seamless facade element
construction in any geometry, design and size
is not possible with natural stones.

Due to the significantly higher compressive strength 
(100 - 160 MPa / 14500 - 23000 psi), much thinner 
and more elegant load-bearing structures, like frames 
for glass facdes are possible. Likewise, considerably 
higher spans of prefabricated parts are possible.
UHPC is fire-resistant up to 450°C / 840°F. In the high 
temperature resistant version UHPC HT a permanent 
temperature resistance up to 1200°C / 2190°F can be 
achieved.

Facade construction can be produced with UHPC in a 
fineness which until now was not possible with 
standard concrete.

The finished elements produced with UHPC casting 
compound do not require any or very little surface 
finishing. The dimensional accuracy is so exact after 
hardening that it is only necessary in extreme cases 
of extremely high production accuracies in the 
hundredth of a millimeter range.

Due to the extremely fine components, fine or smooth 
surface structures can be produced. Only the quality 
of the mold limits fineness or smoothness. 
UHPC can be casted almost poreless and capillary-free. 
Therefore all products made from UHPC are extremely 
resistant to any environmental 
influences. For this reason, UHPC is 100% seawater 
resistant.

 

 

WPE DK International

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

Modern interior design with UHPC concrete

Modern interior design is increasingly associated
with UHPC Ultra High Performance Concrete in
hotels, restaurants, offices and homes.
Due to the enormous strength extremely fine
structures can be achieved which is not possible
with standard concretes. UHPC surfaces are virtually
poreless and can withstand even the harshest
mechanical, temperature and corrosive stresses.

Floor design

UHPC concrete floors systems are popular thanks
to the stunning contemporary finish they offer.

Available in variety of textures colours and
combination with glass, wood, minerals and metalls,
there are endless design options for floor design.
Polished concrete achieves a fantastic finish not
unlike marble, ganite sandstone etc., while etched
UHPC concrete can be used to create any desired
pattern or design on the floor similar to tiles.
Floors made in a combination of UHPC materials
and woods look noble and elegant. With UHPC
materials almost all stone structures can be
reproduced.

Wall design

UHPC concrete walls is another example of how
effective the material can be when used in interior
design. UHPC concrete walls work well in any
room, and there is a wide selection of surface
design that can be archived using various application
techniques. For example, shuttered concrete uses
moulds to create a stylish finish featuring imprint
designs that are used to resemble wood board effects
on the surface.

Countertops and counter design

A hallmark of the industrial look, UHPC concrete
countertops not only look fantastic but are
low-maintenance, durable, very hygienic and
produced custom made in any conceivable design.

They can also be treated with various colours and
finishes, while being easy to mould and shape into
the required size. UHPC countertops can be
manufactured from a plate thickness of 15 mm / 0.59 in.

Lighting

As one the more recent design trends, concrete
lighting has become massively popular in recent
years, which is little surprise when you see the
stunning aesthetics produced from this simple
yet effective use of concrete.

Minimalist in design, various light shades and
fixtures are being created from concrete moulds
 to great effect, with some of the top lighting
manufacturers looking to take advantage of this
trending design feature.

It can be achieved layer thicknesses of less than
6 mm in some designer pieces.

Completely new lamp and lighting systems with
glass fibers laid in thin-walled UHPC materials
are possible.

Furniture

While more unique than most other modern uses

of concrete, more people are looking to create
stylish design features through concrete furniture.

UHPC concrete allows infinite variations in
furniture, such as armchairs, tables, lamps, chairs,
in terms of design, size, colors, fineness of structure,
surface and enormous strength. The same diversity
also applies to the ability to be combined with
other materials such as precious woods, glass,
minerals, metals, etc.

The demands on concrete materials in the interior
sector are several times higher than in architecture.
This is mostly about milimeter work. UHPC
castings achieve an extremely low tolerance of
just a few tenths of a millimeter out of the mold.
In most cases, post-processing is no longer necessary.

We do not compare UHPC with standard concrete
design of conventional brands. UHPC is much
more than just concrete. UHPC materials are noble
in design, are light in weight, can withstand the
toughest demands such as hot pots and cutting tools
and there are no limits in design.

Bathrooms, saunas, wellness areas, pool areas can
all be produced by UHPC concrete in a variety of
designs.

For the special and extraordinary, we offer architects,
designers and artists our UHPC desert sand concrete.
This UHPC concrete is unique. It can process natural
desert sands from different deserts.

WPE DK International

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