Pipeline repair in a potash mine

When I visited a potash mine, I noticed this "cemetery"

of used pipe parts for the hydraulic potash extraction.

There are around 200 pipe parts of different diameters,

lengths, angles and radius. All parts that were specially

manufactured for this production. The pipe parts are all

lined with cast basalt and have a 3-component

anti-corrosion coating. On average, these new pipe parts

cost EUR 700.00 / piece. So there is a value of at least

EUR 140,000.00. Since the pipe parts show more or less

wear damage, all should be disposed of. The disposal

costs amount to at least EUR 12,000.00. The new price

for the pipe is approx. 156,000.00 EUR and the delivery

time is at least 3-4 months.

I explained to the plant management that we can repair

all the pipe parts. We would remove the existing and

partially worn cast basalt lining and replace it with a

new UHPC wear protection lining. I calculated the

budget costs for this at EUR 66,000.00. The repair work

takes approximately 2 months. Here, however, we could

orient ourselves according to the wishes regarding the

installation sequence to the customer and always repair

the pipe parts that he needs at short notice.

Our customer decided on a new lining instead of a new

production and saved 90,000.00 EUR and at least 1-2

months delivery time.

Today there are no more "cemeteries" for used pipeline

parts in his plants.

www.hhbc-consulting.de

info@hhbc-consulting.de

Repair with UHPC wear protection systems

UHPC wear protection material has been used for over 25 years in all industrial sectors worldwide, such
as the cement industry, power plant industry, steel industry and mining industry. A large part of the projects we carry out are repair orders. In recent years, the share of repair orders has risen sharply. Our customers want fast, flexible and cost-effective repairs. A decisive advantage for UHPC wear protection material is the very high protective function against wear and corrosion, the high flexibility in layer thickness and the simple. Assembly. With UHPC wear protection, existing wear protection systems can be quickly repaired. There is no need to order special plates or cylinders with long delivery times. No installation plan is requested.

More and more of our customers order UHPC wear protection in 25 kg paper bags and process the material themselves in order to have the greatest possible flexibility and very short downtimes for the repair.
We define our wear protection material for plants and floor areas. UHPc wear protection material can be processed as mortar, castable and shotcrete.

You need detailed information? Please contact us via: info@wpe-dk.dk

We increase the sustainability of UHPC

With our high-performance UHPC products, we started

using sustainable products years ago. We are also

increasingly focusing on sustainability when it comes

to units for our UHPC binders.

One example is corundum, which we use as an aggregate,

among other things. Corundum can be produced as

synthetic corundum with very high energy consumption

or can be mined as natural corundum in open-cast mining.

We have chosen natural corundum for more than 15 years.

Together with our partner in Africa, we pay attention to a

nature-friendly mining and an equally nature-friendly

restoration of the surface areas. The natural corundum

mined by our partner has proven to be an almost perfect

unit for our UHPC over many hundreds of applications

in the offshore industry, architecture, wear protection

and security industry.

Another problematic aggregate of quartz sand, we can

completely replace today with desert sand, including

from Africa. The technical values ​​of desert sand

concrete are far above the best standard concrete.

In our opinion, it is not necessary to destroy beaches

and rivers by sand mining. The cost of desert sand

mining is many times less than the predatory mining

of river sand or beach sand.

As far as the reinforcement systems or fiber systems

are concerned, nature offers us very sustainable

products that can be used in combination with

high-quality UHPC binder systems to create a perfect

sustainable product.

Our goal is always to produce UHPC binder systems

so flexibly that we can always use a high proportion

of local raw materials.

WPE DK International

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

 

UHPC Wear protection lining in a titan ore grinding system

After more than 15 years of grinding operations,

the first repair on the UHPC wear protection lining

are now necessary.

More than 15 years ago, the classifier housing and

the fine material discharge of the vertical roller

grinding system were lined with a UHPC wear

protection lining. The grinding system grinds a

special titanium ore for prigment production.

Originally, very little wear was expected and no

wear protection system was planned. However,

the regrind was extremely wear-resistant and after

a very short time after the vertical roller grinding

system was put into operation, the sheet metal 

construction showed considerable wear.

For fluidic reasons, only a layer thickness of 15 mm

for wear protection could be permitted.  The

UHPC wear protection work was started quickly

and was completed within a few days. The

grinding plant was put back into operation after

six days of inactivity.

WPE DK International

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

UHPC Wear protection lining in a granulated slag grinding plant

For a granulated slag grinding plant in Germany, 

the channel between the mill and filter was lined 

with UHPC wear protection. The layer thickness 

of 25 mm / 1 inch has so far been standard in all 

of our granulated slag grinding plants lining 

projects.

For around 20 years, areas of cement-, clinker-,

coal- and slag grinding systems have been lined 

with UHPC wear protection material. 

A particular important advantage alongside many 

other UHPC wear protection devices for slag 

grinding plants is the jointless lining.

The assembly effort compared to the assembly of

ceramic plates or special welded metal sheets is the

simple and quick assembly.

WPE DK International

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

UHPC Wear protection for a KHD Sepmaster cement separator system

Today we lined our 60th KHD SEPMASTER

cement separator with UHPC wear protection. 

For a long time UHPC castable wear protection

concrete was specified and standard for all KHD

SEPMASTER separators.

The first KHD SEPMASTER separators were

lined with UHPC wear protection concrete more 

than 25 years ago. In the current project, the 

associated classifiers and chutes were also lined 

with UHPC wear protection mortar. 

The classifier was cast with UHPC castable wear 

protection concrete. The cyclones and

chutes were lined with a 25 mm / 1 inch UHPC

wear protection mortar layer.

Based on the very long experience we now have,

we expect the lifetime of the UHPC lining is15 years.

WPE DK International

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

Repair of dams and hydroelectric power plant constructions with UHPC concrete

Hydroelectric power plant

UHPC Concrete has been used as a construction or

repair material in offshore, port construction and

coastal protection worldwide for more than 25

years. UHPC concretes are far superior to standard

concretes in their application and service life

expectations.

Typical areas for UHPC concrete repairs

 - Core walls
 - Deflection tunnel
 - Spillways
 - Stilling basins
 - Slope protection

Advantages of UHPC compared to standard concrete

 - Extremely high compressive strength
 - Very good adhesion
 - Waterproof from a layer thickness of 15 mm
 - Very high wear resistance
 - Very high corrosion resistance
 - Very high resistance to frost and ice
 - Very good impact resistance
 - Quick and easy installation, even of large areas
 - Thanks to the extremely fine UHPC binder, even the

   smallest joints and cracks can be closed well and permanently
 - UHPC can be processed as shotcrete, castable or as mortar.
 - UHPC reaches more than 70% of its maximum nominal

   strength after 48 hours.

Dams
Especially the slides of a dam are subjected to high amount

of wear as a very high volume of water is running over

these. UHPC can easily withstand this water. UHPC is the

ideal material for dam reinforcement and repair/maintenance.

UHPC materials can be quickly and extensively processed

as mortar, cast or shotcrete.

The rapid and high strength development favors a quick

restart of the system.
In the lake in front of the dam, the dam will be subjected

to impact by debris, which can deteriorate concrete. Placing

a layer of UHPC will end the deterioration.

New build and repair of sewage treatment plants and sewers with UHPC concrete

Sewage treatment plants and sewers are exposed
to a permanent chemical and mechanical attack
by sewage from households and industry. Due
to the changing climate conditions and the resulting
extreme rain or flood masses, the systems and
channels are extremely stressed and damage that
their function is no longer guaranteed.

A material with high resistance to chemical and
mechanical attacks is necessary for the maintenance
of these systems.
This material should also be able to be processed

flexibly on site and should not require any complex
machinery.

Damage causes in a sewage treatment plant
- due to mechanical wear
- through frost and de-icing salt
- due to chemical attacks or solvents
- due to concrete corrosion in closed systems

UHPC Ultra High Performance Concrete
UHPC are special concrete products with a minimum
compressive strength of 130 MPa and a water/cement
ratio of less than 0.2.UHPC products can be used very
well for the rehabilitation of concrete - and steel structures.
UHPC products can increase to be rehabilitated
construction next to the corrosion protection even
with admixture of ceramic aggregates the static
bearing capacity.

Benefits of UHPC
- Easy installation as spray, mortar, cast
- Very high corrosion resistance
- Extremely wear-resistant
- Extreme low to no carbonation
- Usable at very high humidity
- Very high impact strength
- Extreme low chloride permeabilit
- Very high resistance to mechanical loads
- No pore formation
- Maritime and port water resistant    
- Installation in the water possible
- Duration resistant
- The standard drying time is under 48 hours
- Penetrates into the smallest joints and cracks,
   and closes them permanently
- Joint less installation
- Very good thermal shock resistance
- Absolutely frost and de-icing salt resistant

Machining UHPC concrete like metals

UHPC is a very unusual material that is still

far too little considered by architects and
designers. It is still viewed and processed
like a normal concrete.
Our view is more that we design and
manufacture UHPC to treat it more and more
like metal. UHPC in the right quality can
already be machined with tools from the metal
industry. Very high accuracies can be achieved
here whether in surface processing or in shape
processing.
The surface treatment can either be carried out
using special UHPC casting molds or by
identical processing steps as for metals, or
combined casting and subsequent processing.
There are no limits to the design options here.
In terms of shape, metalworking tools or machines
can be used with the same objective as metals.

Architects, designers and artists have not even
used a fraction of the technical possibilities.

One example is the use of computer-controlled
water jet cutting machines. For a customer, we
should test the possibilities of making special
bevel cuts as plate slots that cannot be cast in
this way. Additional cutting tests were carried
out to check which geometries can be cut and
what minimum wall thicknesses can be achieved
between the individual cuts. With the right
combination of UHPC binder, unit quality and
setting of the cutting machine, amazing results
can be achieved. The tested UHPC plates had a
plate thickness of 15 - 25 mm, no metallic
reinforcement and were dried for 48 hours in
normal ambient temperature before they were
processed.

With the UHPC binder-aggregate combination
used in the test, cutting distances of 5 mm could
be achieved.
As soon as possible, further cutting tests will be
carried out with UHPC desert sand binders.
Water jet cutting enables complete "images" to be cut in UHPC panels or special construction elements.
With this type of material / machine technology, it is possible to produce a large number of facade panels with an elaborate cut design at low cost in a short time.

WPE DK International

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

HPC Leight weigth and standard products systems for architecture, civil construction and design

In addition to our UHPC offshore, industrial
flooring, wear protection, security product
systems, we will produce HPC product
systems for architecture, civil construction.

These products will not have the extreme strength
values ​​like the UHPC industrial qualities but have
all the characteristic properties of a high quality
UHPC, such as verygood corrosion resistance,
high early strength development, very good flowability etc.

The new HPC product qualities are:
HPC Leicht 25   Compressive strength 20 - 25 MPa (Lightweight)
HPC Leicht 35   Compressive strength 20 - 35 MPa (Lightweight)
HPC 45              Compressive strength 45 - 50 MPa
HPC 85              Compressive strength 80 - 85 MPa
HPC 135            Compressive strength 130 - 135 MPa

We will offer these HPC qualities in various
packaging sizes, most likely from 25 kg paperbag
to 1 to big bags. We will produce these HPC
products as mortar, castable and shotcrete or as
interieur or exterior plaster.

We can offer private customers as well as
industrial customers all UHPC qualities as
pure binder material or as a mixed material
binder + aggregate.

 

WPE DK International

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

How we handle the virus situation in hhbc-consulting

Since we are a small team of experts, there is always
one of us traveling around the world, we set ourselves
up long ago to work together from different places in
the world.
For this reason, we are now only very slightly hampered
by the current virus situation in our work.
All of our employees returned from their trips abroad in
good time, and what is very important is that everyone
is healthy.


We are in close contact with all of our global partners to
help and support where necessary. All of our contacts are
still available to our customers under the usual contact
channels. We hope that we can have personal meetings
with our customers again as soon as possible.

The material production continues to work normally, as
we improved the automation of the production system
years ago so that in an emergency a maximum of 2 people
can maintain production. The raw material supply is also
sufficient for a long time.

The whole hhbc-consulting team wishes everyone health,
energy and the necessary serenity to survive this
extraordinary situation.


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

Yearly training semiars for handling of UHPC material

At the customer's request, WPE DK and

hhbc-consultingtrained customer supervisors in

handling of UHPC materials in a two-day seminar

in our workshop or in customers workshop.

Supervisor and Fitter
The theoretical lessons taught the knowledge of the

what is Ultra High Performance Concrete,

manufacture of UHPC and processing of UHPC

materials under the most varied conditions on site.

The supervisor and fitters were then trained in the

practical handling of all of our UHPC materials

such as UHPC Cast, UHPC Mortar and UHPC

Shotcrete.

Special training for different industrial areas

At the customer's request, the practical processing

of UHPC wear protection material, offshore material

and UHPC industrial floor material should be

concentrated, as orders have been placed for this.

Various situations were also worked through on the
construction site and repair methods with UHPC
materials were also trained.

At a later point in time, training in the processing

of UHPC Phalt (combination of asphalt and UHPC
binder) should be carried out.

It was the first of several seminars and training

courses every year. From this year on, WPE DK

and hhbc-consulting will not only train supervisor

and fitters in our workshop.

Architects and Engineers

Seminars for architects, designers and civil

engineers are also held. Such seminars are also

offered by our local partners in the USA and Asia.

Students and Universities

For universities and students we have a special
program where we provide different UHPC
material qualities for projects free of charge and
also accompany the projects free of charge on
request.
We can also offer seminars for students, which
can then be held at the university or near to the
university.
Universities and students are welcome to contact

us at any time for detailed information.

Anja Wolfmann will be happy to answer any
questions and information you may have. You can
always reach Anja at a.w@hhbc-consulting.de.

Test your UHPC Know How - Learning Module

This is one of our learning modules for UHPC Concrete. A new version will be released this year. We use such modules for training purposes. New ones are added every year. This year there will be four new modules. 

You want to check your answers for correctness? Send us an email service@hhbc-consulting.de with the password "LMS 1/6" and we will send you an answer sheet.

Module no. 1/6

What are the main components in UHPC?

1. Cement, microsilica, superplastisizer
2. Cement, flyash, superplastisizer
3. Epoxy, microsilica, dispersant
4. Cement, sand, epoxy
5. Cement, sand, microsilica

Acid will deteriorate UHPC

1. True
2. False
3. Only if pH is below 5
4. Only if pH is above 5
5. Only if pH is below 3

Alkali will deteriorate UHPC

1. True
2. False
3. Only if pH is above 12
4. Only if pH is below 12
5. Only if pH is above 13

The following aggregates are used in UHPC Standard wear protection?

1. Quarz
2. Bauxite
3. Corundum
4. Silicium carbide
5. Titanium carbide

The wear resistanse of UHPC increases with these aggregates?

1. Quarz, bauxite, corundum, silicium carbide
2. Bauxite, quarz, corundum, silicium carbide
3. Silicium carbide, bauxite, quarz, corundum
4. Bauxite, corundum, quarz, silicium carbide
5. Silicium carbide, corundum, bauxite, quarz

What is the lowest temperature at which it is ok to install UHPC?

1. 20°C / 68°F
2. 10°C / 50°F
3.   5°C / 41°F
4.   0°C / 32°F
5. - 5°C / 23°F

What do you need to protect UHPC against when installing it?

1. Drying out
2. Freezing
3. Wind
4. Direct sun
5. Rain

What should you focus on when mixing UHPC in regards to water?

1. The product cannot seggregate
2. The product must remain dry
3. There must be free water on top of the product in the mixer
4. You cannot add too much water to UHPC
5. Any mixing problem can be solved by adding more water

You notice lumps in a bag of UHPC Binder, what do you do?

1. No problem, I just add more water when mixing
2. I contact hhbc-consulting or to have a new bag
3. I control the storage environment
4. I discard the bag
5. I check the date on the bag to see age of product

When mixing UHPC lumps are formed shortly after adding of water?

1. No problem, I just add more water
2. I wait a while to see if they mix out, if not I will add a little more water
3. I throw away the mix
4. I check if the mixer is proper prepared for mixing UHPC
5. I increase the speed of the mixer

When mixing UHPC I notice free water on the surface of the mix?

1. No problem, Just need to use the product fast
2. I allow the mixer to run for longer time, untill the free water is no longer there
3. I will try to scoop out the free water
4. I throw away the mix
5. I add more powder untill the free water disappeares

What is the purpose of Microsilica in UHPC?

1. It is packing between cement particles, increasing density and displacing water
2. It is like little ball bearings making the mortar more flowable
3. It reacts with Ca(OH)2 from the cement hydration and create a denser material
4. It has no significant effect, just a filler to make the product cheaper
5. There is no microsilica in UHPC

What is the purpose of superplasticizer in UHPC?

1. It makes the product more flexible
2. It charges all particles so that they repell each other. At the same time it makes stearic hinderence so that particles cannot bridge build on each other, and in this way it displaces water.
3. There is no superplasticizer in UHPC
4. It is a polymer, added to make the product easier to mix
5. It is lubricating the particles so that they can react better

UHPC Binder can be installed over head?

1. True
2. False
3. Sometimes if you are lucky
4. Only during the weekend
5. Only if you use a special throwel

HT products can be used in temperature areas of

1. Up to 1200°C / 2192°F
2. Not above 1000°C / 1832°F
3. Not above 600°C / 1112°F
4. Not above 400°C / 752°F
5. Not above 200°C / 392°F

UHPC (not HT) can be used in temperature areas of

1. Up to 1200°C / 2192°F
2. Not above 1000°C / 1832°F
3. Not above 600°C / 1112°F
4. Not above 400°C / 752°F
5. Not above 200°C / 392°F

It is important to know what chemicals UHPC will be subjected to

1. True
2. False
3. Only acid or alkalies
4. Especially if there are salts present
5. Only if temperature is above 100 deg C

When mixing you notice the wetting time is increased. What do you do?

1. No problem, I just add more water
2. I wait it out for a while to see if it wets through, and I adjust the water accordingly
3. I throw away the mix
4. I ignore it
5. Cross my fingers and hope everything will be ok

What happens to UHPC if too much water is added?

1. Nothing, you can add as much water as you like
2. The product will most likely seggregate, but properties will in general be reduced in direct correlation with the amount of water added.
3. Especially if we are working with a UHPC Cast product, installation will be a lot easier
4. Strength will increase as we will hydrate more cement
5. The stickyness of the product will increase a lot

How does UHPC differ from cement/concrete?

1. It is the same, no difference
2. UHPC is stronger in terms of compressive strength
3. UHPC is more dense
4. Concrete is more flexible
5. UHPC can be installed under water

How does UHPC differ from refractory?

1. It i the same, no difference
2. Refractory needs heat to finalize its reactions, UHPC does not
3. UHPC is more wear resistant
4. The insulation properties of UHPC is better than that of refractory
5. UHPC can withstand higher temperatures compared to refractories
    
    
   WPE DK International
   
   Phone: 0049 176 601 73146
   E-mail: ber@wpe-dk.dk
   Homepage: www.wpe-dk.com