UHPC Spray Projects in a Northern European Ore Mine

An ore mine operator in Northern Europe has commissioned one of our customers to install a UHPC wear lining on several cyclones. 

The installation was to take place on site at the ore mine. A UHPC wear protection layer of 25 mm was to be installed. The time frame for the installation was very tight due to the mine. For this reason, a UHPC spray installation was chosen. UHPC spray wear protection is sprayed on using a wet process. This has the very great advantage of a controlled and uniform material quality. Since UHPC spray only produces a maximum rebound of less than 2%, there was also no material loss during the spray installation.

Our customer first sprayed half the circumference of the cyclone parts on site and then the other circumference of the cyclone parts. Due to the ambient temperatures, the lined parts could be transported and installed without any problems after 48 hours. directly after installation, this part of the plant could go into operation.

 

 

WPE DK International

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

UHPC Liquid-tight constructions

Liquid-tight constructions are becoming increasingly important for the economy and insurance companies worldwide. 

In the past, industries such as refineries, seawater desalination plants, sewage treatment plants,
hydroelectric power plants, offshore industries, etc. were particularly interested. There is a huge range of sealing systems for concrete structures. Most systems are expensive, complex to install and do not have the same life expectancy as you would expect from the structure. So the sealants have to be applied several times, which in turn leads to problems and enormous
costs. For a few years now, there has been an increasing demand for coastal protection and especially flood protection structures that have to withstand the constant attack of moving seawater caused by high and low tides, but also by enormous wave movements.

Another growing problem is the rapid change in the climate and the ever-increasing amounts of rainfall that lead to inland flooding and, among other things, also flood residential buildings worldwide, which then have to be repaired in a time-consuming and costly manner. Concrete sealants are of limited or no help here.

One solution is concrete structures made of HPC or UHPC concrete. Here, waterproofing can already be achieved with a wall thickness of 10 - 15 mm. This concrete layer can be subsequently applied to any substrate in industry as well as in residential buildings. This is also possible in countries with predominantly natural material constructions.  
If the ground floor is completely built of HPC or UHPC or provided with a protective layer, no flood water, which is usually also dirty water, can penetrate into the building structure. 

After the floodwater has disappeared, the walls and floor can be cleaned with locally available cleaning machines such as high-pressure water jets, after which this area is immediately habitable again.

In industry, a UHPC layer can completely prevent or hold back breakthroughs for a very long time in the event of liquid attack from the outside, i.e. from floodwater masses, or from the inside in the event of ruptures or leaks in liquid tanks.

Sewage treatment plants can be constructed directly from HPC or UHPC, or they can be retrofitted after prior inspection of the building structure. The same applies to biotank systems for the production of biogas.

WPE DK International

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

UHPC Wear Protection lined pipe components produced in Vietnam

 Peter Severin, our UHPC partner for Vietnam, in cooperation with a Vietnamese steel construction
company, will offer UHPC wear protection lined pipeline segments in all sizes and geometries. Peter and the steel construction company have many years of experience in the production of piping elements for hydraulic and pneumatic conveying. These pipeline components have been used in power plants, steel mills, cement works and mines for decades. 

WPE DK International

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

UHPC silicon carbide custom-made burner elements for an ALSTOM coal-fired power plant project

The company ALSTOM wanted us to place an order for the supply and lining of very special burner parts
for a coal-fired power station. Due to the coal composition, the specially required flow conveyance and the very high temperatures, our customer had specified silicon carbide as the wear protection material. After we had calculated the costs of the material and the production, the responsible project managers at ALSTOM almost had a heart attack. The costs were very far over the planned budget and the delivery time for the custom-made silicon carbide elements was almost three times as long as ALSTOM had planned. 

We then offered ALSTOM a lining with a silicon carbide UHPC wear-resistant concrete as an alternative. The material costs were reduced by more than 50% and the delivery time of the elements manufactured by us was reduced by more than 70% compared to the elements made of silicon carbide ceramics. As we had already supplied many UHPC linings for ALSTOM over the past decades, the project managers had complete confidence in our proposed solution.

The production of the burner elements was carried out according to our time schedule and the elements
have fulfilled their purpose until today. 

In the meantime, other burner suppliers for coal-fired power plants have also successfully used this solution worldwide.

 

 

WPE DK International

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

 

Our UHPC laboratory is visited by an old friend, who will take over the representation for Sweden, Norway, Denmark and Vietnam in the future.

We had a visit from long-time friends in our UHPC lab. We have known each other for more than 25 years
father and son, Finn Severin Jensen and Peter Severin Jensen. We all worked for the same company years ago. Finn and Peter were the best supervisors we had. They have worked as supervisors for UHPC installation in almost every country in the world. There is hardly anyone who knows the practice of UHPC installation in different conditions as well as these two. 

Peter will be our representative for all our HPC and UHPC products for Sweden, Norway, Denmark and Vietnam.
Peter is also planning to start a pipe section production including a wear lining in Vietnam in the next few months.

We are looking forward to a successful future together.

 

 

WPE DK International

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

UHPC flooring for the most extreme loads

UHPC Phalt and UHPC TopLayer are floor coverings for the toughest environmental, temperature, corrosion, load, wear and tear, extreme loads from special vehicles and their movements and the combination of all these loads.

UHPC Phalt is a semi-flexible overlay, a combination of UHPC mortar and asphalt.
The pavement is laid without joints, similar to an asphalt pavement, using the same machines.

 

 

 UHPC TopLayer systems are UHPC grout concrete floor coverings for extreme loads, wear and corrosion. As a special UHPC TopLayer system, we produce high-temperature resistant floor coverings for industry. Which can be subjected to continuous temperatures far above 800°C.

WPE DK International

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

What is hard concrete - and what is UHPC hard concrete flooring systems

Flooring systems

Hard concrete

Hard concrete is generally described by its manufacturers as a cementitious, highly durable and wear-resistant floor covering. It is laid in a bond to the substructure. An average layer thickness of 25 mm can be given.
The wear resistance has its limits where the floor is no longer grindable. In many countries, grinding of floor coverings is standard practice.

The characteristics of hard concrete are
- Highly resilient
- Scratch and wear resistant
- Liquid-tight
- Indestructible floor covering
- Design and showroom flooring

Areas of application
- Warehouses used by vehicles with rubber tyres
- Access ramps used by rubber-tyred vehicles
- Exhibition and show room flooring

 

 

UHPC hard concrete

UHPC high performance concrete or as we call it UHPC TopLayer is a mixture of special UHPC binder systems and ceramic aggregates. The average layer thickness can be specified as 15 - 50 mm. As UHPC TopLayer is designed to withstand the highest loads, it is almost impossible to grind the surface. UHPC TopLayer can be processed in the same way as hard concrete.

The characteristics of hard concrete are
- Extremely resilient
- Very high wear resistance
- Water and frost resistant
- Very high corrosion resistance
- Very high compressive and flexural strength
- Extremely temperature resistant

Areas of application
- Warehouses used by heavy vehicles and tracked vehicles
- Roads and storage yards for heavy load storage
- Flooring for ore mines, steelworks, foundries, cold stores, military areas and parking areas for heavy vehicles

 

 

WPE DK International

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

 

Comparison Sand for the construction industry - Alternatives to Sand for the construction industry

 The global construction boom is continuing and will not decrease significantly in the future. climate change is forcing new constructions. Old constructions have to be replaced. Most of the world's major sites are on the coasts, and constructive coastal protection will buy these sites some more time, but the major sites will also have to change in terms of construction technology. Concrete as a building material is needed for this transformation.
Sand as part of this needed concrete has become a big problem. The gigantic demand leads to a lucrative trade business worldwide, which permanently destroys the nature of the coasts and rivers.
Several years ago we pointed out that with the UHPC technology it is easily possible to replace a very large proportion with recycled sand. Only these recycling plants for construction waste are rarer to find worldwide than diamonds. And yet, the expansion would be an extremely lucrative business, also for investors.
The fastest way to drastically reduce the current demand for sand is to use desert sand. For several years now, it has been possible to easily produce concrete from desert sand that is much stronger and easier to handle than standard concrete. If one were to calculate the current worldwide sand consumption as a standard, the desert sand of the Sahara would last about 100,000 years.
Even if the entire global construction industry still finds it extremely difficult to use desert sand, which there is actually no reason to do, development will force them to do so. For investors who become active now, this will be a gigantic business in a few years.

WPE DK International

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

CNN Article - It´s so hot, roads are buckling, they are putting foil on a bridge and roof....

 The climate has changed and even if all countries of the world would reach their climate goals, it would still take decades positively estimated until the climate change would move again in another direction. So we and the next generation of us have to live with the changes like heat. Now the architects are asked not to build beautiful glass palaces but buildings that resist heat. Take a look at the traditional building constructions in Africa and the Arabic countries and learn quickly. Our learning about building materials started years ago. We have a strong base in southern Africa. We learn and develop HPC and UHPC based on local raw materials and we combined our HPC and UHPC systems with local construction materials.
Many of our HPC and UHPC binder systems are high temperature resistant and may be easy to work with under higher ambient temperatures in the future.

 

WPE DK International

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

UHPC Aggregate - Mining of Nature Corundum in Zimbabwe

After a hard day in the corundum mine, blasting, grinding and transporting, we earned a cold beer by the river. 

 

 

 

 

 

Of course, with a proper distance from the shore. Some river dwellers can really be very unpleasant. On
the way to the river we found some interesting minerals here and there.

 

 

 

 

 

 WPE DK International

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

                                                                                         

Comparison Nature Corundum - Industrial Corundum

 

Natural corundum is an important aggregate for many of our UHPC material qualities. It is a natural material that is mined without much effort. Quite the opposite of the industrial production of corundum. There, very large areas of land are destroyed for the production and an enormous amount of energy is required for the production.

 

WPE DK International

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

 

UHPC Wear Protection installation for a Austrian mining company

For an Austrian mining company, we are to supply raw parts lined with UHPC wear protection and special ceramics. The pipe parts and their wear protection lining were not standard. The delivery was under extreme delivery pressure. Most of the conveyor system was already fully assembled and the customer was only waiting for our special parts to be able to put the conveyor system into operation. WPE DK fitters lined part of the system with UHPC wear protection on site in Austria. An assembly hall was built especially for this purpose. The other pipe parts were lined in the WPE DK workshop. The entire order was delivered on schedule. 

More than 40 tonnes of UHPC wear protection were installed.The average layer thickness was 25 mm.

 

 WPE DK International

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

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