UHPC® Architecture on the sea coast

The big cities on the coasts and rivers have

big problems for the future. A problem is the 
lack of natural space for the permanent 
expansion of cities. Building ever higher 
skyscrapers is not a solution in the long run. 
One solution is to expand the construction 
site by adding fillings in the coastal area, 
as we see in Dubai and Singapore, among 
others. Another solution to the problem is 
the very old traditional construction of pile 
dwellings and houseboats, as they have 
always done in Asia.

Modern architecture has been thinking 
about its designs for a long time with interesting 
designs and projects about future life in coastal 
and river areas. Here, the old living concepts 
are reinterpreted. New materials such as 
UHPC® concretes can easily incorporate 
existing local living concepts and constructions 
and implement them in permanent concepts. 
UHPC® offers absolute seawater resistance with 
extremely high strength. Light, thin but 
high-strength constructions can be combined 
with local traditional materials such as bamboo.

Floating residential and industrial concepts can 
also be realized with UHPC®, and not just above 
water. The first underwater concepts have 
already been implemented worldwide with new 
hotel concepts. Recent plans also include 
entire artificial islands on which hospitals, 
workshops, hotels, kindergartens, residential 
complexes including leisure facilities are built.
Some international architecture firms are 
interested in using UHPC® Ultra High 
Performance Concrete in their living concepts, 
because the advantages of this material are 
unique in their variety and quality.

UHPC® offshore constructions are already in 
use in areas with extreme environmental 
conditions. UHPC® is very wear-resistant, 
among other things, moving ice masses is 
not a real problem for a UHPC® construction. 
UHPC® materials have no pores, are therefore 
extremely corrosion-resistant and offer an 
extremely long repair-free service life.


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Design with UHPC Ultra High Performance Concrete

UHPC is a very flexible and extremely easy
to combine material. It can be easily molded
as a mortar and very easy to pour as a casting
compound.
Processing times can be set during material
production. Depending on which aggregate
has been mixed in, UHPC can be very well
retrofitted or polished.
UHPC can also be very hard and machining
would only be possible with diamond tools.
With UHPC it is possible to cast extremely
fine structures. The reason for this is the
processing of nanomaterials in the binder
system. Thus copies of historical originals
can be cast, which are almost 99.9%
identical to the original, all cracks, pores,
cracks, etc. of the original are shown in
the copy.
UHPC with very high compressive strengths
of more than 240 MPa enable design designs
that are exceptionally large but are light in
weight.
UHPC materials are resistant to almost all
environmental impacts.

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.


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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.

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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.

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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



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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

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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 

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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

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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

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