Further development of HPC and UHPC binder systems for the African continent with African raw materials

Today we are starting a new UHPC development project that is unusual for us. With our friend and business partner Gordon Viol we are going to Africa, more precisely to Zimbabwe.
Gordon Viol has a mine where he mines natural corundum. Natural corundum is a very interesting material and important aggregate for some of our UHPC concrete systems. We want to have a look at the mining of natural corundum. 

But we also want to learn about local building materials and traditional building methods. How can we integrate these local materials in our HPC and UHPC concrete systems?

What are the requirements for building materials in Africa? What cement qualities are available here? How are these materials processed? It is exciting to learn about all this. Sustainable building materials, nature building materials and the processing of these building materials are at the top of our priority list for development projects. We already have many ideas. As always, we are ready to go unconventional ways. For example, we want to combine clay and earth with our UHPC binder systems. We already know very well from desert sand that it is possible to produce high-quality concrete with it. We are looking for new materials that can be combined with our existing binder systems or with binder systems yet to be developed. These binding systems should be processable under the local environmental conditions. 

For this project we want to take three weeks on site. Afterwards, we will evaluate all findings and materials in our development laboratory near Flensburg. We will report on this development project in loose order.

 

WPE DK International

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

UHPC Special Binder System for a Flood Gate

For our customer FDN we have developed a special high performance UHPC binder. With this binder, FDN has developed the first flood gates made entirely of UHPC concrete. These flood gates will replace many old flood gates in the future. Floodgates made of UHPC are absolutely corrosion resistant and have an enormous strength. To prove this strength, the local authorities required a load test in addition to many material tests. In the attached video you can see the UHPC slab which has a similar wall thickness as the future gate constructions. 

 

 

Both load tests with a cast iron ball from different heights were passed without any damage.
We assume a life expectancy of at least 100 years for the UHPC concrete without the need for regular maintenance work.

 

WPE DK International

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

UHPC OilWell Binder for local production

Offshore and onshore oil drilling projects and active oil production platforms number in the thousands worldwide. OilWell cement binder is required for all these objects and in large quantities. Until now, these extreme quantities were shipped worldwide to the places of need, transported by truck or by a combination of both, regardless of which transport route was chosen, it was time-consuming and expensive.
Today and in the future, these transport routes will become more complicated, unreliable and much more expensive.

We would like to offer an alternative to the standards used so far. We have been developing and producing UHPC binder systems for more than 25 years. Among other things, we also produce UHPC binders for the offshore industry.

Our alternative to the current transport routes is the production of UHPC OilWell binder on site with local raw materials. After testing the local raw materials, it is possible to quickly determine which OilWell qualities can be produced locally and replace standard OilWell binder from overseas.
For the production, a mobile production unit consisting of three to four containers is used, depending on the desired production quantity, which can load the produced binder into BigBags or silos.

WPE-DK

E-mail: ber@wpe-dk.dk
Homepage: www.wpe-dk.com

 

UHPC concrete meets aesthetics

UHPC Ultra High Performance Concrete offers designers and artists completely new design possibilities. Whether as a binder system or in combination with metal, fibre or textile reinforcement, there are no limits to the creative and constructive imagination.

In addition, it is very easy to process, whether as mortar, casting compound or shotcrete. Anyone can process our HPC and UHPC material. We can also modify the HPC and UHPC mortar material structure according to the customer's wishes, whether as a fine clay structure or a coarse clay structure or plaster structure.
Sculptures or constructions made of HPC or UHPC are also long-term resistant to even the most extraordinary environmental conditions. HPC and UHPC concretes can also be used under water. They are absolutely waterproof from a layer thickness of 10 mm.

The advantage for designers
    - Thin, filigree structures of very high strength
    - Large-scale elements in a cast thin-layer structure.
    - HPC and UHPC can be combined with almost all materials in a new way.
    - Very smooth or extremely fine surface structures can be achieved with HPC and UHPC
    - UHPC is several times more resistant to chemical attack than any standard concrete.

We produce all HPC and UHPC material qualities as mortar, casting and injection moulding compounds.

UHPC concrete meets aesthetics
In the living area as well as outdoors

    Concrete bowls
    Lamps made of concrete
    Outdoor furniture
    All kinds of pool or whirlpool designs
    Garden design elements such as stones, tiles, etc.

Standard concretes have a natural surface with an open-pored structure. In contrast, UHPC concretes also have a natural surface but without a porous structure.
Due to the very high material quality, our HPC and UHPC products require very little or no maintenance. The life expectancy of design objects made from our products can be
can easily be assumed to be +100 years.


UHPC concrete meets modern extraordinary lifestyle

Here we develop and produce special and extraordinary binder systems for the design of unique pieces on customer request.

Here, special HPC and UHPC binder systems are produced from sustainable raw materials from all over the world, which are then combined with exceptionally rare or expensive materials at the designer's and customer's request. The end product is then unique and cannot be copied and is very, very expensive.
 



 
WPE DK International

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

UHPC Phalt Truck transport to Spain for a semi-rigid surface course installation

Seven truck loads of UHPC Phalt binder go to Spain for a distribution center.

The customer was quickly convinced of the advantages and benefits of a semi-rigid surface course solution for their distribution center. The hall area is 6400 square meters. The installation of the semi-rigid surface course is carried out by a local road construction company, which also supplies the asphalt. At the customer's request, we also provide the necessary pot mixers for the duration of the installation.

WPE DK International

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

UHPC Transport with mixer truck

Over 60 tons of UHPC concrete were mixed by our customer in a mixing plant last month and transported
to the construction site by 9 cubic meters truck mixer. The driving time took 35 - 45 minutes and the pouring of the forms another 10 - 15 minutes. According to our customer, the flow properties of the UHPC concrete were very good during casting. It required very good flow properties because the casting mold was very complex in geometry and bubbles should not form in any case. The compressive strength achieved was 190 MPa. The customer's requirement was 175 MPa.

WPE DK International

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

Brazil UHPC Wear protection lining of a BF Top Gas Cleaning system

 BF Top Gas Cleaning

The Paul Wurth gas cleaning system for the Thyssen Steel Brazil furnace was one of several Paul Wurth gas cleaning systems we supplied with UHPC wear protection complete the wear protection. The installation was carried out by a local installation company.

We installed the anchors directly at the steel construction company. The UHPC wear protection lining was then lined on site at the steel mill in the installed condition. The total lining area was approximately 1200 sqm. The layer thickness was specified by the plant builder from 25 mm to 40 mm depending on the area in the cyclone. 

    

UHPC Mortar 2000 HT was specified by our customer as the wear protection material. UHPC Mortar 2000 HT is enormously wear resistant even at continuous temperatures up to 1200°C. The cyclone should have a normal average operating temperature of 400 - 500°C. However, it is possible that hot gases up to 1000°C may enter the cyclone uncontrolled from blast furnace.

 

The planned service life is at least 10 years. During these 10 years the blast furnace will not be stopped and therefore repair of the cyclone will be possible only under very difficult conditions.

WPE DK International

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

 

SouthAfrica UHPC Wear protection lining of a BF Top Gas Cleaning system

BF Top Gas Cleaning

The Paul Wurth gas cleaning system for the Newcastle Steel plant blast furnace was one of several Paul Wurth gas cleaning systems we supplied with UHPC wear protection complete the wear protection. The installation was carried out by a local installation company.

We installed the anchors directly at the steel construction company. The UHPC wear protection lining was then lined on site at the steel mill in the installed condition. The total lining area was approximately 400 sqm. The layer thickness was specified by the plant builder from 25 mm to 40 mm

depending on the area in the cyclone.

UHPC Mortar 2000 HT was specified by our customer as the wear protection material. UHPC Mortar 2000 HT is enormously wear resistant even at continuous temperatures up to 1200°C. The cyclone should have a normal average operating temperature of 400 - 500°C. 

However, it is possible that hot gases up to 1000°C may enter the cyclone uncontrolled from blast furnace.

 

The planned service life is at least 10 years. During these 10 years the blast furnace will not be stopped

and therefore repair of the cyclone will be possible only under very difficult conditions.

WPE DK International

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

South Korea UHPC Wear protection lining of a BF Top Gas Cleaning system

BF Top Gas Cleaning

The Paul Wurth gas cleaning system for the Hyundai blast furnace was one of several Paul Wurth gas
cleaning systems we supplied with UHPC wear protection complete the wear protection. The installation was carried out by a local installation company.

We installed the anchors directly at the steel construction company. The UHPC wear protection lining was then lined on site at the steel mill in the installed condition. The total lining area was approximately 1000 sqm. The layer thickness was specified by the plant builder from 25 mm to 40 mm depending on the area in the cyclone. 

          

UHPC Mortar 2000 HT was specified by our customer as the wear protection material. UHPC Mortar 2000 HT is enormously wear resistant even at continuous temperatures up to 1200°C. The cyclone should have a normal average operating temperature of 400 - 500°C. However,

it is possible that hot gases up to 1000°C may enter the cyclone uncontrolled from blast furnace.

 

The planned service life is at least 10 years. During these 10 years the blast furnace will not be stopped and therefore repair of the cyclone will be possible only under very difficult conditions.

WPE DK International

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

UHPC HT lined Blades /guide vanes for a Paul Wurth cyclone in a steel plant

Once again we supplied blades / vanes for a Paul Wurth dedusting cyclone. Over the last years we have manufactured and delivered more than 210 blades / vanes of different sizes. We delivered for new projects or for spare parts supply.
The blades are lined on both sides with 25 mm thick UHPC HT (high temperature resistant UHPC). 

Each delivery is extensively tested by us. 

It has been proven over the years that the blades manufactured by us can withstand the maximum loads in a blast furnace dedusting for years.

WPE DK International

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

UHPC Ultra High Performance Concrete in local Asian architecture

UHPC Ultra High Performance Concrete is barely considered in modern Asian architecture, although this material is over 25 years old. 

HPC and UHPC concrete is not just a concrete, it is something special. In the beginning, 25 years ago, we broke one strength record after another. We have done extreme constructions and linings and cold and heat.
For the last 15 years, we have been focusing on sustainability in the Asian market with our HPC and UHPC materials, using local materials. We can perfectly combine our materials with local construction materials such as bamboo. The result is a unique, sustainable, cost effective material or construction. With our HPC and UHPC binder systems, we can incorporate almost any local material. We can work with local architects and contractors to create buildings and structures that can withstand floods, fires, storms, earthquakes and insect attacks. We also want to learn with local

builders how we can work together to create permanent floating platforms for living on the water or on the coast.

 

Yet this extraordinary material offers a large number of answers to the requirements of modern Asian architecture.

Corrosion
HPC/UHPC materials are very good corrosion resistant. Old concrete, wood or steel structures can be easily and inexpensively repaired and made usable for many decades.

Waterproof
HPC/UHPC materials are waterproof from a layer thickness of 10 mm. Houses can be made resistant to

flooding so that they can be quickly cleaned and used again after a flood.

Seawater
UHPC materials are absolutely seawater resistant. HPC/UHPC can be processed underwater. This means that jetties can be repaired easily and quickly. they can then be used again for the next 50 years.

Rotting
UHPC do not rot. Wooden structures that are already starting to rot or are damaged can be quickly and permanently repaired with HPC/UHPC.

Material Strength

HPC/UHPC materials reach strengths from 20 MPa to 240 MPa

Steel structures
HPC/UHPC materials can permanently replace steel structures and require no maintenance

Earthquake
HPC/UHPC materials offer solutions to increase the seismic safety of existing buildings

Temperatures
HPC/UHPC materials are extremely temperature resistant from -90° to +1200°C. An ideal material for facades

Design
With HPC/UHPC materials it is possible to achieve extremely fine surface structures

Processing
HPC/UHPC can usually be processed like standard concrete. We produce HPC and UHPC castable,

mortar and shotcrete versions.
HPC and UHPC materials help to drastically reduce the concrete requirement / weight.
HPC and UHPC sheathing of steel or wooden structures standing on or in the water, will permanently protect the construction against rotting.
Of course, UHPC can also be used to repair buildings and floors easily, quickly and effectively.

There are many other arguments for the use of UHPC in Asian architecture.
We are happy to be of service to every designer, architectand contractor with our decades of experience.

At the moment we are producing our HPC and UHPC materials in Europe. However, we plan to build one or two production locations in Asia in the near future.

 

WPE DK International

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

 

High temperature resistant UHPC pavement

Constant very high temperatures and high
loads cause high damage to stone or concrete
floors.
Last year we re-lined a floor in the steel collis
warehouse with UHPC HT. The freshly rolled
steel collis have an average weight of 20 tons
and are still more than 280°C / 536°F warm
for a few days when they are stored. The
radiant heat has caused massive damage to
the floor area in most areas of the hall. In
addition, the hot collis are driven from the
rolling mill into the warehouse with special
forklifts and placed correctly.

The routes in the warehouse had to be
completely renovated for safety reasons.
Since the ground was so bumpy, there was
a risk that a forklift with the hot colli might
fall over.

For this reason, the old floor was completely
removed. The subbase floor was rebuilt and
carefully compacted. Subsequently, at least
50 mm /2 inch thick UHPC HT high temperature
resistant flooring, which also has a very high
compressive strength and wear resistance, was laid.
In the UHPC HT floor covering, two-layer
reinforcement was introduced in order to absorb
the shear stresses that are generated by the heavy
forklift movements.
We relined approx. 1000 sqm hall floor. 

WPE DK International

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

 

 

Companies which used UHPC Wear Protection in the last 25 years

 

We are always asked who has been used UHPC
Wear protection for the past 25 years. WPE DK our UHPC wear protection specialist, took the task to compile a list of companies who used UHPC as wear protection during these years.

The list includes plant system supplier and plant operators in
worldwide. The list should give an impression of where
UHPC is already standard as wear protection everywhere. In
In many cases, plant operators have the UHPC material
installed by own fitters.

Here is the list:
The company names can change over the years and some
companies probably have merged with other companies.

A Tech Anlagentechnik GmbH &Co KG, Austria        LOESCHE GmbH 

Aalborg Portland Cement A/S        TASEK Cement, Malaysia       Al Bijjar, UAE

Nigeria Cement        Allgaier Process Technology GmbH        Thung Song, South Korea

Mikropul GmbH        California Cement, USA        Moxba NL                                  

 

Aumund Fördertechnik GmbH            OMYA, Austria

                                         

MULTOTEC, South Africa        Aurubis AG        Nohma, Italy    Engineering Dobersek GmbH   

BES Brandenburger Elektrostahlwerke GmbH        Oschatz GmbH        Babcock Borsig Service GmbH

ÖMAG  GmbH, Austria               Babcock Borsig Steinmüller GmbH       

Phoenix, Australia       

 

Balke Dürr  GmbH        Pilkington GmbH        Bartin Cimento, Turkey        Pioneer Cement, UAE

BASF Antwerpen N.V. , Belgium       Vattenfall Europe Generation AG        Austria Tec S.A., Mexiko

Polysius AG            Bayer Leverkusen        RWE        British Steel   

 

                                  JSW Steel Limited India

       

Binder + Co AG, Austria        Salzgitter Flachstahl GmbH                       Bio Bio Cimento 

 

   Scheuch GmbH                   Paul Wurth, Luxembourg

Italcimenti, Italy      Burmeister Wain Energy a/s, Denmark       Votorantim, Brazil            Schott AG

Cemtec Cement & Mining Technology GmbH        Blue Circle, GB        Siam Cement            

 

Asia Cement

      

CEMEX Cement plants        SMS GmbH        Christian Pfeiffer GmbH 

 

          Titan Cement, Greek            Huyndai Steel, SouthKorea

                           

STAG Austria        Claudius Peters Project GmbH                Colacem, Italy  

 

      SSAB, Sweden

 

Cima Perlis, Malaysia        Cementos Portland Valderrivas    Coperion GmbH

ThyssenKrupp India        KHD GmbH        Shree Cement, India                    NUH Cimento Turkey

Cementir Holding, Italy        TPI Polene, Thailand        DESI Process    voestalpine Steel, Austria

ThyssenKrupp Steel AG        Wacker Chemie AG         

 

E.S.C.H. GmbH                E. Schwenk Ciment

Rautaruuki, Finland        Emscher Aufbereitung GmbH                        EON Power plants        LKAB, Sweden 

 Posco Steel SouthKorea

Eternit GmbH        Lucky Cement, Taiwan        FISIA Babcock GmbH  

  

                                                 FLS Möller GmbH

FLS Pfister GmbH        FLSmidth, Denmark        ALSTOM Power                 Gebr. Pfeiffer SA      

Heidelberger Cement Cement plants         

 

HITACHI Power Europe GmbH

Hoffmeier Industrieanlagen GmbH        HOLCIM Cement Plants                         IBAU Hamburg mbH

IKN GmbH        Intensiv Filter GmbH & Co KG        Kali+Salz AG Werke

Krupp Fördertechnik GmbH        Küttner GmbH & Co KG                           Lafarge Cement plants

WPE DK International

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