UHPC concrete for precast production

UHPC concrete has many commercial as well as technical

advantages over standard concrete for the production of 

precast concrete elements.

More and more architects are specifying UHPC concrete 

as a standard material for their façade design. There are 

no design limits for façade constructions.
In recent years, we have developed UHPC binder systems 

that can be processed into lightweight concretes or 

insulating concretes, especially for façade construction.

- We produce UHPC materials with a strength of

   40 MPa to 240 MPa.
- Our UHPC materials reach 70% of their maximum

   nominal strength within 48 hours. Faster strength

   developments are possible on customer request.
- We only need sand, not gravel, to process UHPC

   concrete.
- With our UHPC Desert Sand Binder, desert sand

   can also be processed without any problems.
- All of our UHPC materials are self-compacting

   and need no or very little vibration.
- Our UHPC materials have extremely little to no pore

   development.
- The nanotechnology development of our UHPC

   binders enables extremely fine surface structures to

   be created.
- With the use of fibre reinforcement it is possible

   to create very thin structures of high strength.

- For prestressed elements, the pre-tensioning force
   of UHPC material can be chosen to be much higher
   due to their very high strength than standard concrete.

- Very good flow properties for casting complicated

   geometry and filigree surface structures.

Processing of UHPC binders
Only a shaft or pan pot mixer is required for

processing.
The UHPC binder is mixed with sand or desert

sand and a very small amount of water.
It is not necessary to add additives.

Applications

• Double walls 
• Pre stressed elements 
• Tubes
• Bridgedeck elements
• Stairs
• Piles
• Supports
• Tunnel segments
  
• Facade elements
  
• Balconies
• Sea defence units
  
• Floor tiles in large geometries                
  
• Security
  
• Vertical garden (facade) elements
• Sewage pipes and box culverts
• Floating elements
  

UHPC Rehabilitation of concrete structures

Due to the old age and the increased and
rapidly increasing loads, for example due
to traffic and environmental influences,
an enormous number of concrete structures
are in need of renovation or have to be
completely replaced by new, more robust
structures. The renovation effort in the
infrastructure area is gigantic worldwide.
The focus here is on bridges.

UHPC Ultra High Performance Concrete
materials have many decisive advantages
over standard concretes when renovating
concrete structures. By using UHPC concretes,
material costs, assembly costs and assembly
times can be reduced and the service life of
the repaired concrete structures can be
extremely increased. Standard construction
machines can be used when installing UHPC
concrete.

The goals of repair or repair assembly are in
general

The restoration of stability and a stable concrete 
cross-section
Due to the enormously high strength values ​​of
UHPC compared to standard concrete and its
very fast strength development, the stability of
the construction can be quickly restored.
UHPC mortar, castable and shotcrete materials
can be used.

Increasing the load capacity
UHPC materials offer the structural engineer and
bridge designer the option of significantly
strengthening areas of the bridge structure that are
subject to high loads.

Maintenance or restoration of corrosion protection 
and frost resistance
UHPC is an almost non-porous material that is
absolutely frost and de-icing salt resistant, even
with a very thin layer of material. UHPC is also
absolutely seawater resistant and can also be
processed underwater. Thanks to these properties,
the repair effort for exposed reinforcements is
significantly lower than for standard concrete.
Only half of the material coverage is required
compared to standard concrete

Restoring or increasing the frictional resistance of 
the concrete surface
Through the addition of ceramic or mineral additives
and their very high adhesion to the UHPC material,
any friction coefficient can be guaranteed over a very
long period.

Restoring or increasing the fire resistance of components
UHPC HT (high temperature resistant) materials are
endurance-resistant up to over 1000°C /1832°F. All UHPC
materials are extremely resistant to shock temperature loads.

Increase thermal insulation
UHPC and UHPC HT in combination with extremely
thin high-performance insulating materials can lead to
high-strength and highly insulating structures.

Permanently closing cracks with a static and sealing function
UHPC Castable are based on nanotechnology, they are
extremely thin and penetrate into the smallest pores or
cracks and seal them permanently.

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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



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UHPC - Alternative engery power plant

UHPC Ultra High Performance Concrete products used as wear and corrosion protection for all kind of alternative energy production plants.
All of our UHPC special concrete products have a minimum compressive strength of 120 MPa / 17400 psi. UHPC concrete can install on concrete and steel structures, for new constructions as well as for repairs. UHPC concrete for wear and corrosion protection can be processed as mortar, grout or shotcrete.

UHPC HT High Temperature wear and corrosion resistant material can also applied in a combination with a thin high effective insulation
material. This combination can reduce the amount
of refactory material by approx. 50%

Benefit of UHPC lining systems

 - Smooth surfaces
 - Jointless surfaces
 - Resistant to rapid temperature fluctuations
 - Temperature resistance up to 1.000°C/1832°F
 - High compressive strength
 - High wear resistant
 - Good thermal insulation
 - Flexible layer thicknesses
 - Good chemical resistant
 - Very good corrosion resistant
 - Good resistance to mechanical loads

Incineration power plant

Incineration plants have beside wear problems
also corrosion problems. Waste burning creates
a aggressive atmosphere.

Standard application:

• Ash system
• Dedusting system
• Rubbish bunker
• Pneumatic pipeline system
• Burner feeding system
• Roadway redevelopment 

Biomass power plant

Here mostly it is all kind of wood and bio waste which is used as firing material. In the complete material handling process you will find wear and corrosion.

 

 

 Biogas power plant

We offer for corrosion and wear problems in the gas production process UHPC linings for:

• Bunker
• Shredder
• Dewaster
• Material transport system
• Mixtank
• Fermentation tank
• Storage tank

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UHPC - Wear and corrosion protection in incineration plants

In modern incineration plants today large quantities of household rubbish and industrial waste are burned for the purpose of extraction process steam and energy.

The burning of waste considerable demands on the process equipment and their construction material by the discontinuous garbage quality a very high material quality.

For some years, UHPC material has been used as wear protection with and without thermal insulation in waste incineration plants. The advantage of UHPC is the unique combination of temperature resistance, 
very good wear protection and very easy 
processing. UHPC is equally suitable for 
new constructions as well as for repair work. 
UHPC HT wear protection material can also 
be used on refractory linings in a fast-curing 
version for short-term repairs.

Benefits of UHPC lining material

• Easy installation method
• No special tools are necessary
  
• Flexible layer thickness
• Overhead installation possible
• Jointless installation
• Extreme compressive strength
• Very high wear resistant
• Very good corrosion resistant
• Very good thermal shock resistant
• Adapts each of surface geometry
• Fast curing at ambient temperature
• High temperature resistant

Lining areas

• Routes of waste collection vehicles to discharge area in the waste bunker
• Waste bunker ramps and walls
• Waste feed hopper
• Waste conveyor duct to the burner grate
• Ash handling systems
• Dedusting systems

Special UHPC materials are virtually the bridge material of the future

Bridges are among the oldest, most important and most prominent construction tasks of humanity. For a long time, bridge construction was mainly characterised by functional criteria, but nowadays more and more attention is paid to visual appearance. Highly developed building technologies can be used to create exciting, previously unimaginable constructions.


Several characteristics of UHPC make it a desirable construction materials. With increased compressive (more than 200 MPa) and tensile 
strengths, the material lends itself well to 
structural applications by allowing higher loads 
to be supported. By utilising the higher strengths, 
traditional structural components can also be 
reduced in size and weigth.
Another benefit of UHPC is the high density and
none porosity of the material making it essentially 
impermeable to water and chlorides, thus making 
the material highly durable. Both characteristics 
also make UHPC attractive in areas of high impact 
and where water or chloride ions can corrode steel 
reinforcement. 

Advantages

• High compressive strength
• Fast development of compressive strength
• High wear and impact resistant
• Absolute frost and thaw resistant
• Impermeable to fluids but still vapour permeable
• Anti corrosive features
• Good bonding to sub-bases, aggregates and reinforcement
• High temperature resistant
• Fast curing
• Sort repair stops
• Jointless lining

Elements of a bridge that can be executed with UHPC

• Bridge foundation 
• Bridge bearings
• Bridge supports
• Bridge deck and bridge deck pavement
• Prestressed concrete foundation 

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UHPC Hot gas slide system in a cement plant

A customer from the cement industry had permanent problems with a hot gas gate valve. The gate valve was made of a stainless steel construction with a refractory heat protection lining. The average gas temperature is in the pipesystem is 800°/1472°F - 1000°C/1832°F.

The problems in detail were

• Significant wear due to high dust loading in the gas flow
• Heat exchange problems arose as a result of temperature changes and the result was breakdowns in the refractory lining and problems with the movement of the slide.

We engineer a slider made complete of UHPC HT (High Temperature) with the following characteristics

• High thermal shock resistance
• Thermal stability up to 1100°C/2012°F
• Very high wear resistance
• High impact resistance
• There was no metallic reinforcement used, so there was no metallic thermal expansion
• Due to the very high strength values ​​of the UHPC used, the board thickness could be reduced by more than 60% compared to the old refractory construction.
• This resulted in a weight reduction of almost 50%, which also reduce power consumption.
• a drastic reduction of the idle time and better movability of the gate valve resulted in a 16% better production.

Here are a short video to show the impact resistance of the gate plate

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UHPC Supervisor projects worldwide

Today we completed our 100th Supervisor project

Since the first customer request more than 20 years ago, we have meanwhile completed projects with UHPC materials in more than 35 countries around the world. We looked after offshore, corrosion, wear protection, concrete rehabilitation, architecture, hydraulic engineering, road construction, etc.
On behalf of our customers, we have carried out assembly projects, trained fitters on site, carried out complete assemblies independently, assessed damage, worked out repair solutions, etc.
Our current project was the rehabilitation of 10 km of lanes at Europe's largest flower auctioneer.

Here some impressions of our worldwide jobs

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The future of offshore wind energy with UHPC

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 is used in all foundation techniques.

Monopiles

UHPC grouting material is used for the connection between monopile and transition pieces.
Monopiles have been deployed with even larger turbines in even deeper waters, currently up to 41 meters. 9 diameter monopiles are now in production. We estimate that more than 2000 monopiles worldwide have been installed with UHPC grouting and transitions pieces.

Benefits

• 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

Jackets
Jackets are generally considered to be better than monopiles for seabeds where the substrate is poor or deeper water. So here UHPC 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

The future - with floating foundation design

This includes

• Spar
• Semi-submersible
• Barge
• Tension-leg platform

Spars
First systems are already being tested. In the near future, a wind farm with spar systems is to be built off Scotland.
These systems can reach total lengths of over 90 meters, with about 75 m of them underwater. The entire underwater area can be made of UHPC.

Semi-submersible
Similar to the Spars, the whole underwater construction can be made of UHPC.

Barge
Barge systems are actually classic pontoon systems. There are now UHPC concrete available which in addition to their high strength also swim without the large cavities inside the barge must be generated.

 

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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.


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