Short time repair story of a oil rig with UHPC

An oil company had very big problems with an old pumping station in the Bay of Bengal. Due to
massive corrosion on some columns, the entire statics of the conveyor station was endangered. It was expected that they have to give up the station in a short term.

The only technically feasible solution that offered itself at short notice was the filling of the columns with UHPC concrete. A demand of approx. 600 tons of UHPC material was determined by the oil company. Within a week, the 600 tons could be produced.

The procurement of raw materials was the time factor here. The actual production did not take more than 1.5 days.
There was no time to ship the UHPC material to the Bay of Bengal. The oil company rented Anotonow AN 124 aircraft for direct transport.
On site, a ship was chartered for the material and the mixing systems. On the ship, the UHPC material was mixed by specialists and pumped into the columns.

What were the reasons why the oil company chose UHPC?

1. The fast availability
2. The fast strength development
3. The absolute sea water / corrosion resistance
4. The fast processing, even on the high seas
5. A long-term technical solution

New use of recycled windmill rotor blades as aggregate for UHPC concrete

UHPC grouting material is used worldwide in the

in the offshore and onshore industry worldwide for more than 25 years. 

Mostly, UHPC Grout has been used to make transition pieces and foundation systems for wind energy, oil production, tidal power plants and floating windmill platforms. There are also plans to use UHPC concrete as corrosion protection for the systems in these areas. It would be a safe, easy to install, cost effective and durable solution. Another development for the future is the combination of UHPC concrete and recycled rotor blade material. Several thousand used rotor blades from offshore and onshore wind turbines are lying on the ground around the world to be recycled or disposed of. Storage has become a very big problem in some countries. In many industrial
applications we use glassglass fibres, carbon fibres or plastic fibres asaggregates to our UHPC concrete. 

 

In order to carry out reuse, recycling and upcycling as standard in the near future, special UHPC concretes are the ideal combination partner. It should also be possible to add construction material from wind turbines to our UHPC with appropriate processing. This could then possibly be used again as foundation material for new onshore or offshore wind turbine.

UHPC design for Gas, Hydrogen and E- loading station

Gas, Hydrogen and E-loading stations should get a UHPC concrete design. Every future energy filling station design should be unique.

We want to get away from the standard unit sheet design. The idea is to create bold, curved, interesting roof structures, possibly greened and provided with solar panels made from our UHPC concrete. 

No armada of petrol pumps, which you will not need in the future,
but a few dispensers in combination with e-charging stations, for cars, trucks, motorcycles and e-bikes. The petrol pumps / charging stations are to get a design from historical to futuristic. In addition to a bar, would be possible, for example, a sports bar or snack bar after American Hard Rock Style or French Bisto. No supermarket where you can
chance to refuel. In addition to the bar, a workshop should be connected for special vehicle types, perhaps historic vehicle types. No mass repair, the vehicle owner may be present during the repair and possibly see from the sports bar howhis vehicle is being repaired.

Our UHPC team will create a gas stationthat is not a fast transit station, but a place to stay and meet, built with the utmost sustainability.

The first specifications are about to be completed, some architects have alreadysent their ideas and the first interested parties and investors have invited us to talks.

The gas station of today, is a dying system, which will not survive. In a very short time, there will be fewer and fewer gasoline powered vehicles in many countries. The new vehicle types will be powered by electricity or hydrogen. The gasoline powered vehicles will then be more and more vehicles, which one will call historical vehicles. These historic vehicles will, as they always do today, have their fans and drive on the streets.

UHPC Helicoper landing pads concstructions

For more than 20 years, UHPC Ultra High Performance Concrete has been used as a
floor covering at airports worldwide.

UHPC as a concrete floor covering or in combination with asphalt (UHPC Phalt) are extremely resilient floor coverings for runways, hangars, aprons and warehouses. In terms of their technical properties, they exceed the existing standard coverings several times over, especially with regard to compressive strength, temperature resistance, corrosion resistance and wear resistance.

Helicopter landing pads for civil and military helicopter are rarely made from high performance UHPC unless the landing pads are to be created in exceptional locations or under exceptional environmental conditions, such as in extreme altitudes, extreme climatic conditions, offshore platforms, exceptionally low ground structures, civilian and military vessels.

Certain UHPC material combinations have ductile properties which have proven to be
particularly suitable for moving steel
constructions in many industrial sectors.

UHPC in combination with steel constructions can increase the load bearing capacity of the steel constructions while protecting them from all extreme environmental influences.

In addition, our UHPC concrete or UHPC Phalt  has an extremely fast strength development, so that the landing area can be used after a short time.can be laid very quickly and the  and can be used in a very short time.

Green bus roofs made of UHPC design

Insects are essential for the survival of humans and
nature. The cycle of nature would be decisively
disturbed, if not interrupted, by the death of many
species of insects.
The idea of ​​us and more and more architects was
the insects to rebuild a habitat in the cities. One
possibility is the vertical gardens or green facades.
In our opinion, quick support for the insects is the
greening of roofs of bus stops. They are small areas
but they are spread all over the city and not like a
facade in one place.
Architects find the idea incredibly good, as the bus
stops usually have a bad design. Roof greening
makes it possible to make bus stops an interesting
design element in the cities. Meanwhile, there is a
veritable ideas hype.


Why UHPC Ultra High Performance Concrete?
1. UHPC can be used to produce UHPC precast
concrete elements with a minimum thickness of
10 - 15 mm / 0.4 - 0.6 inches.

2. UHPC achieves 70% of its nominal strength
in just 48 hours, which means many advantages
for finished element production.

3. UHPC elements are absolutely corrosion
resistant

4. All design ideas can be realized with UHPC

5. Due to the low weight, the assembly can be
carried out quickly and without effort

6. Our UHPC concrete can be easily combined
with a variety of other materials such as glass,
metals and wood combined.

7. We intentionally do without the use of plastics
in our design

8. The stops can reach a lifetime of at least 60 years

9. Our UHPC is absolutely resistant to de-icing salt.

10. The bus stop area is filled with a combination
of asphalt and UHPC. This makes this area highly
wear-resistant even at temperatures up to 90°C / 194°F



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

UHPC concrete and optical fiber for Media Architecture

Some years ago, a customer approached
us with the problem that he needed a
wear lining in a brown coal dust silo and,
if possible, in combination with a lighting system. The problem was that lignite
dust is highly explosive.

The solution we offered and executed
was a UHPC® wear protection liner in
which we inserted optical fibers. With
optical fibers we could have solved two
problems at once; first, the lighting and
second, the existing wear can not interfere
with the function of fiber optic lighting.

This combination UHPC® / optical fiber
was also used by a customer for illuminated
facade elements.

2001 First tests with UHPC / optical fiber elements

Here, too, environmental influences could
not hinder the function of optical fibers as
lighting. This system is completely
maintenance free.

Similar application ideas already had architects and designers for UHPC® ceiling panels and
wall panels. The advantage is architectural
and designer's view is that the lighting is not visible during the day. No matter which
geometry or surface structure the UHPC®
element has, the optical fibers are not visible. Another advantage is that optical fibers do
not generate heat.

Lamp design made of UHPC® with optical
fibers have already been manufactured.
Interior architects have designed bar counters
made of UHPC® and optical fibers.

Today, these solutions are used and further
developed, among other things, in Media
Architecture.

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

 

UHPC Navy Concrete - Ferrocement

The technique of using fine wire mesh as a 
reinforcement for concrete (ferroconcrete) 
structures is already very old. This 
technique has been used above all in the 
manufacture of boat and ship hulls, simple 
construction elements and in the design 
sector.

Today, less so-called chicken wire mesh is 
used and more plastic and ceramic mesh is 
used, which exceeds the tensile strengths 
of steel several times over.

With UHPC (Ultra High Performance 
Concrete) Navy binder it is also possible to 
use very fine aggregates, which in turn make 
it possible to use very fine meshes. Modern 
high quality UHPC Navy materials are a 
multiple times superior to standard concrete 
in all technical values.


UHPC has been used in the offshore industry 
for more than 25 years as a construction 
material and as a corrosion protection material 
under the harshest environmental conditions. 
In many areas, UHPC is superior to steel and 
replaces it there.

UHPC Navy offers the professional navy 
architect, boatbuilder and shipyard a more 
than interesting alternative to steel, plastic 
and wooden constructions.
Production methods such as casting and 
spraying and the rapid development of 
strength can save enormous costs.


This new development also makes it possible 
to manufacture boats or ships in series. 
Special hulls are possible. UHPC designs for 
floating windmill systems are in production today.

 

Statement on Ferrocement	Statement on UHPC Navy
Ferrocement = Steel reinforcement plus   mortar concrete   Small dia high tensil steel rods sandwiched   between layers of wire mesh (chicken mesh)	UHPC Navy = Steel, cermic fiber or plastic fiber   reinforcement plus   Ultra High Performance Concrete   Extreme high tensil strength ceramic or glasfibre   mesh and ceramic rods
The shell structure of mortar and steel would   be sufficiently impermeable, strong and   impact resistant and with the right degree of   flexibility	The shell structure of UHPC Navy and   reinforcement would be high sufficiently   impermeable, extreme strong, very high impact   resistant and with a extreme high flexibility.
Ferrocement boats are produced in Britain,   Canada, South Africa, Hong Kong and USA	Hong Kong, Singapore, United Arabs Emirates
Ferrocement hulls do not rot, nor do such   marine animals as bores and tered worm   have any effect on the mortar	UHPC Navy hulls are absolutly sea water resistant, absolutly restinstant      against marine animals high dense structure and extreme high corrosions resistant
Ferrocement hulls are stronger than hull    build in wood or glassfibre	UHPC Navy hulls are much stronger than hulls in wood or glassfibre
A partical characteristic of ferrocement,   unlike others, is that if gains strength with   age rather than loose it.	UHPC Navy already reaches more than 70% of final strength after 48 hours and gain strength with age.
Ferrocement   Tensil strength 37 MPa   Compressive Strength 83 MPa	UHPC Navy Tensil strength 52 MPa+ or 755 psi (depends on reinforcement system)   Compressive strength 140 MPa+ or 2300 psi   (depends on reinforcement)
Ferrocement is high temperature resistant	UHPC Navy is very high temperature resistant. In a special high temperature resistant version UHPC Navy it temperature resistant up to 1200°C or 2192°F
Ferrocement has a very low thermal  conductivity	UHPC Navy has a low thermal conductivity in   combination. With special insulation aggregates   UHPC will have a extreme low thermal conductivity
Absence of maintenance cost for the hull	UHPC Navy hulls are maintenace free
A problem would be the difficulty of   achieving complete penetration of mortar   through the mesh matrix	UHPC Navy mortar, spray and castable products are selfcompacting. The penedration through the mesh is nearly to 100%
Portland cement, Slag cement	UHPC Navy Binder
Water/cement ratio 0,35	Water/ cement below 0,25
Aggregate: Sand which pass 3/16 in sive	Aggregate: 0 – 3 mm Quarzsand or insulation   material in the same grain size or desert sand
Mixing ratio cement : aggregates 1:2	Mixing ration UHPC Navy binder : aggregates 1:1
Density 2400	Density 2400
Admixtures: for improve workability,   durability, acclerate or retard setting and   hardening   Such admixtures are only introduced in   minute qualities to produce the desired   effect, therefor the degree of control must be   very high.	Admixtures are not necessary for UHPC Navy
Recommended mixer is that which has a   paddle attached to the inside of the drum to   keep the mortar mixing evenly.   The mixer is often referred to as a plaster´s   mixer	Pan pot mixer or shaft mixer
Min. boat size approx. 18 ft	Not known
Hull skin thickness 3/4 in	Hull skin thickness max. 3/4 in
Salary rates for mortar work very high	Labor costs much lower, installation as shotcrete, casting and mortar possible. UHPC Navy material is self-compacting.
No serial production possible	Series production easily possible

 

 

 

 

 

 

WPE DK International

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

Unusual material with unusual residental solutions for unusual residential areas

Unusual material

With our UHPC binder + desert sand + very little water we can produce a concrete with a compressive strength of up to 100 MPa. So better than many standard concrete qualities. UHPC desert sand concrete is completely waterproof, corrosion-resistant and rot-proof. Desert sand concrete can be easily made with most desert sands. Desert sand is currently free.

Unusual living solution

The stone system is a building system for small children. With this fantastic system, you can intuitively build without having special knowledge, that is already shown by our children.
If you enlarge this system and the stones made of UHPC desert sand concrete, you can easily build simple and, if necessary, complicated constructions quickly without blueprint and remove again. With standard concrete such stone systems are not possible because they are not sustainable enough. With the high strength UHPC desert sand concrete, even very thin-walled load-bearing stones are possible. For the production of the stones only a few different cast forms are necessary.

Unusual residential areas
UHPC building block systems can be used without any problem in all areas of the world. Due to the

large cavity volume of the stones they are extremely well insulated against cold as well as against heat. They can be used in the desert, in the damp jungle and in extremely cold environments.

UHPC Binder systems development for customer

Experience and Know how - Everything from one source
We develop new innovative UHPC binder systems for a wide range of requirements for our customers. These materials developments incorporate more than twenty years of worldwide experience in the development, production and application of UHPC materials.
We have developed, produced and applied UHPC products for architecture, design, facades, offshore, anti-corrosion, wear protection, flooring, power plants, steel mills, mining, shipping, military, engineering, airports, port facilities, etc.

You would like to have your own UHPC binder production?
We advise and assist you

• In the design of the production plant
• Raw material evaluation of local raw materials
• Research and selection of alternative raw materials
• Assistance with the procurement of production facilities
• Production preparation and production start
• Accompaniment of local production by our specialists
• Training of local staff through workshops
• Introduction of a material and quality inspection

We develop according to your requirement specification for you

• UHPC binder systems for use as mortar, casting compound, shotcrete products
• UHPC binder systems for continuous temperatures up to 1200°C
• UHPC binder systems with fast-curing properties
• UHPC binding systems as lightweight concrete
• UHPC binder systems, impermeable to water and underwater applications

We produce for you according to your recipe your UHPC quality as ready mix in standard paper bags, plastic containers, bigbags or silo trucks in any quantity you want.

We can be your development partner
You have innovative, extraordinary UHPC material, product or application ideas and are looking for a development partner. Please contact us at any time. With your ideas and our experience, interesting future-oriented products should be created for you.

UHPC Construction test for the deep sea use

Research in deep sea construction

For more than a year, we participated in a research project of a German university. It was about the exploration of future concrete constructions for the deep sea.

For a few weeks, the result is available. The UHPC Binder material manufactured by us passed the tests by far from other binder materials.
The reasearch team of the university did models made of different concrete materials The models have been tested for corrosion, leaks and pressure resistance. The compressive strength should be so high that the concrete construction can withstand a sea pressure of 3500 m /2.17 mi permanently.

 

At the end of the long-term test, there were no cracks or other damage to the UHPC concrete construction.

 

Research in deep-sea energy storage
Another interesting research project is the construction of compressed air storage balls for the deep sea. The first concrete ball was manufactured in Germany by the Hochtief company and successfully tested as part of a research program. A very good standard concrete quality was used, but it reaches its material limits with a diameter of over 3 m.

One problem that still needs to be solved is the limited transportability of such hollow spheres due to their diameter.
For commercial use, the diameter must be larger. This means that the hollow spheres have to be manufactured on site, which is very costly, or the hollow sphere is manufactured from several prefabricated UHPC concrete elements, similar to the tower elements in wind power plants.

UHPC Offshore grouting could be an interesting alternative solution to this standard concrete here.

Why?

UHPC has a very high compressive strengt of over 200 MPa / 29000 psi
UHPC has been used in the offshore sector for more than 30 years.
UHPC is absolutely resistant to salt water
UHPC is easy to pump and is self-compacting
UHPC constructions can withstand much greate external and internal pressure loads than standard concrete. Due to the enormous compressive strength, the necessary wall thicknesses can be reduce  depending on type of construction
UHPC is waterproof from 10 mm thickness. Steel reinforcement is much more corrosion-proof in UHPC than in concrete
UHPC has an extremely low to no pore volume.
As far as the heat development during pressure build-up is concerned, the standard version of UHPC is temperature resistant up to 450°C. In the high temperature version, UHPC is permanent temperature resistant up to over 1000°C / 1832°F.

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.

UHPC Bridge Deck Joint Filler BF

In many prefabricated concrete bridge constructions, the joints between the individual elements are filled
on site with a UHPC joint filler after the concrete elements have been installed. This creates a continuous concrete bridge deck.
Our BF joint filler systems have compressive strengths of 150 MPa - 220 MPa and flexural strengths of 14 MPa - 21 MPa.
The water to cementitious ratio is less than 0,22
Our BF System joint fillers can be processed on site with pan pot mixer, shaft mixer and horizontal mixer.
For very large sites with very large UHPC binder requirements we have mobile production plants for the binder and mobile mixing plants for the UHPC concrete. All plants are housed in containers and are therefore independent of weather conditions. With our mobile production plant for our UHPC joint filler systems, we are able to use local raw materials if suitable.

 

The joint filler BF systems can be used for all connections between adjacent box beams, next D beams, precast deck panels and beam haunch connections.
There is a wide range of concrete element connections. Each state in the USA and therefore DOT has its own specifications for these.

WPE DK International

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

UHPC Desert sand binder - Local Concrete for Africa

Almost four years ago we developed a UHPC Desert cement binder to process desert sand into a concrete with very high strength values. Only cement binders, water and desert sand are necessary for this. For mixing a standard concrete mixer is needed. The focus of binder development two years ago was on the professional construction industry.

In discussions with architects and organizations operating in Africa we were asked, if we could develop a simple, not so high-quality version of this binder that can support the traditional simple
constructions of the rural population. After some
discussion, a list of requirements for this new
binder was created with which we now work in
our lab. UHPC binders were originally developed
with the aim of achieving an extremely high level
of strength. Then we discovered with our UHPC
binder the incredible combination possibilities
with a variety of natural materials.


Our UHPC binders can perfectly support or
replace wood, straw, loam and clay constructions in terms of their strength and resistance to high
UHPC can also be easily combined with recycled material. It can be made of furniture and sanitary equipment. UHPC concrete is not flammable, which contributes to the safety of the accommodation.

The aim of our current binder development is to
drastically reduce binder costs, to keep the
mixing procedure as simple as possible, to
drastically reduce the proportion of binder in the
overall mix, to reduce possible material transports,
to enable new material combinations with local
raw materials and to preserve as many
properties of UHPC as possible, temperatures and high solar radiation. UHPC binders are completely waterproof, even in very thin layers, do not rot and provide safe protection against termites.

There is also the possibility to use local cement for the production of UHPC Desert Sand Binder in addition to the local desert sand. For this we would have to test local cements for their suitability for our UHPC binder.