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 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.

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

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


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

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


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 


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

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



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


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

















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

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.

 

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

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.