UHPC® Ultra High Performance Concrete production in Texas

Together with our longtime partner ASANTE and
Investors, we plan a production for high-quality
UHPC® materials in the United States.

We plan to produce all UHPC® material qualities for

With the UHPC® production of all our UHPC® Grouting,
UHPC® Mortar, UHPC® Cast, UHPC® Shotcrete and
UHPC High Temperature Resistant material, a
common wish of Douglas from ASANTE and myself
comes true.

ASANTE will extend its existing consulting services
for
  • UHPC® Material
  • UHPC® Installation
  • UHPC® Customer Training
  • Repair
  • UHPC® Engineering
Also here the products are exactly adapted to the
requirements of the customers.

For technical information or ordering of UHPC® material
please contact Douglas Miller. 

Douglas M Miller 
 3434 Dawnwood Dr, The Woodlands, TX 77380
Cell -    774-208-1766
Email -   doug@asante.design




Concrete breakwater as a coastal defense

In recent weeks, I have met people from the Coast Guard in
some European countries. I wanted to learn more about the
current protection of coastal areas, because I think we can
work together with our experience in the application of
UHPC® (Ultra High Performance Concrete) in the offshore
industry to develop some new solutions to make our shores
safer against soil erosion, beach erosion, eroding cliffs and
shoreline erosion.
 
Hard costal protection structures are
  • Sea dykes
  • Sea walls
  • Revetments
  • Groynes
  • Offshore breakwater
For all these structures, UHPC® can be used, directly casted or sprayed, as precast concrete elements or as a combination with asphalt as UHPC®Phalt.
Many of these solutions come from the experience and applications
of our mining, road construction and offshore operations.

We use UHPC® in port areas, jetty constructions, underwater 
foundations for wind turbines, tide power plants, canal locks,
sheet piling and hydroelectric power plants.
    UHPC® is beneficial for these applications because
    UHPC® is absolutely seawater resistant, lifetimes of 100
       years are quite possible
    UHPC® is already watertight compared to standard concrete
       in low layer thicknesses
    UHPC® achieves extreme strength
    UHPC® is extremely corrosion resistant
    UHPC® is extrem wear resistant
    UHPC® can be shaped in any geometry and any natural
       stone surface can be replicated
    UHPC® does not require a repair service
    UHPC® including reinforcement can withstand enormous
       loads.
    What I particularly noticed here are these particularly
    ugly breakwaters, that make the whole coastal area safe
    but also make the nature of the coast less attractive.
    Some of these constructions give me the impression
    that coast is protected for the next war.

    Dear architects and designers, it must be possible to
    develop according to the nature of the coast correspond
    to breakwaters and tsunami fuses.
    Already for years we supply UHPC® material for
    artificial rock landscapes. They are so integrated in
    nature that they can hardly be distinguished from the
    real rocks.


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


    Renovation of buildings and monuments whether new or antique with UHPC®

    UHPC® materials have many advantages over
    other materials in the rehabilitation of buildings
    whether new or antique, historic or monuments.
    The biggest advantage is probably its enormous
    adaptability to the existing building fabric.
    - UHPC® materials can improve the load
       bearing capacity or decide on a structural
       design that is under attack.

    - UHPC® material can be applied thinly to
       protect the existing construction against all
       kinds of environmental influences over a
       very long period of time.

    - Since UHPC® materials can be mixed very well
       with a variety of materials, whether new or
       antique, replicas can be created which have a
       higher resistance and bearing capacity than the
       original ones.

    - Most natural stones and their structure could be
       copied with UHPC®. The copies can be given the
       structure by the casting mold or subsequently
       processed or polished like a natural stone.

    - UHPC® materials that can achieve
       extremely fine and accurate structures can
       achieve absolutely identical replicas with a
       correspondingly high mold quality.

    - Similarly, old facades can be repaired and
       completely replaced as a copy of the original 
       catch, but in a much thinner plate thickness
       than the originals so that there is still enough
       space for modern insulation in the most cases.

    - Due to the very good flow properties, joints
       and cracks can be filled without extensive
       preparatory work.

    - There is no need for special tools to use UHPC®
       material.

    - UHPC® can use as mortar, cast or spray
       material.

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

    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