UHPC Navy Concrete - Ferrocement

The technique of using fine wire mesh as a 
reinforcement for concrete (ferroconcrete) 
structures is already very old. This 
technique has been used above all in the 
manufacture of boat and ship hulls, simple 
construction elements and in the design 
sector.

Today, less so-called chicken wire mesh is 
used and more plastic and ceramic mesh is 
used, which exceeds the tensile strengths 
of steel several times over.

With UHPC (Ultra High Performance 
Concrete) Navy binder it is also possible to 
use very fine aggregates, which in turn make 
it possible to use very fine meshes. Modern 
high quality UHPC Navy materials are a 
multiple times superior to standard concrete 
in all technical values.


UHPC has been used in the offshore industry 
for more than 25 years as a construction 
material and as a corrosion protection material 
under the harshest environmental conditions. 
In many areas, UHPC is superior to steel and 
replaces it there.

UHPC Navy offers the professional navy 
architect, boatbuilder and shipyard a more 
than interesting alternative to steel, plastic 
and wooden constructions.
Production methods such as casting and 
spraying and the rapid development of 
strength can save enormous costs.


This new development also makes it possible 
to manufacture boats or ships in series. 
Special hulls are possible. UHPC designs for 
floating windmill systems are in production today.

 

Statement on Ferrocement	Statement on UHPC Navy
Ferrocement = Steel reinforcement plus   mortar concrete   Small dia high tensil steel rods sandwiched   between layers of wire mesh (chicken mesh)	UHPC Navy = Steel, cermic fiber or plastic fiber   reinforcement plus   Ultra High Performance Concrete   Extreme high tensil strength ceramic or glasfibre   mesh and ceramic rods
The shell structure of mortar and steel would   be sufficiently impermeable, strong and   impact resistant and with the right degree of   flexibility	The shell structure of UHPC Navy and   reinforcement would be high sufficiently   impermeable, extreme strong, very high impact   resistant and with a extreme high flexibility.
Ferrocement boats are produced in Britain,   Canada, South Africa, Hong Kong and USA	Hong Kong, Singapore, United Arabs Emirates
Ferrocement hulls do not rot, nor do such   marine animals as bores and tered worm   have any effect on the mortar	UHPC Navy hulls are absolutly sea water resistant, absolutly restinstant      against marine animals high dense structure and extreme high corrosions resistant
Ferrocement hulls are stronger than hull    build in wood or glassfibre	UHPC Navy hulls are much stronger than hulls in wood or glassfibre
A partical characteristic of ferrocement,   unlike others, is that if gains strength with   age rather than loose it.	UHPC Navy already reaches more than 70% of final strength after 48 hours and gain strength with age.
Ferrocement   Tensil strength 37 MPa   Compressive Strength 83 MPa	UHPC Navy Tensil strength 52 MPa+ or 755 psi (depends on reinforcement system)   Compressive strength 140 MPa+ or 2300 psi   (depends on reinforcement)
Ferrocement is high temperature resistant	UHPC Navy is very high temperature resistant. In a special high temperature resistant version UHPC Navy it temperature resistant up to 1200°C or 2192°F
Ferrocement has a very low thermal  conductivity	UHPC Navy has a low thermal conductivity in   combination. With special insulation aggregates   UHPC will have a extreme low thermal conductivity
Absence of maintenance cost for the hull	UHPC Navy hulls are maintenace free
A problem would be the difficulty of   achieving complete penetration of mortar   through the mesh matrix	UHPC Navy mortar, spray and castable products are selfcompacting. The penedration through the mesh is nearly to 100%
Portland cement, Slag cement	UHPC Navy Binder
Water/cement ratio 0,35	Water/ cement below 0,25
Aggregate: Sand which pass 3/16 in sive	Aggregate: 0 – 3 mm Quarzsand or insulation   material in the same grain size or desert sand
Mixing ratio cement : aggregates 1:2	Mixing ration UHPC Navy binder : aggregates 1:1
Density 2400	Density 2400
Admixtures: for improve workability,   durability, acclerate or retard setting and   hardening   Such admixtures are only introduced in   minute qualities to produce the desired   effect, therefor the degree of control must be   very high.	Admixtures are not necessary for UHPC Navy
Recommended mixer is that which has a   paddle attached to the inside of the drum to   keep the mortar mixing evenly.   The mixer is often referred to as a plaster´s   mixer	Pan pot mixer or shaft mixer
Min. boat size approx. 18 ft	Not known
Hull skin thickness 3/4 in	Hull skin thickness max. 3/4 in
Salary rates for mortar work very high	Labor costs much lower, installation as shotcrete, casting and mortar possible. UHPC Navy material is self-compacting.
No serial production possible	Series production easily possible

 

 

 

 

 

 

WPE DK International

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

Unusual material with unusual residental solutions for unusual residential areas

Unusual material

With our UHPC binder + desert sand + very little water we can produce a concrete with a compressive strength of up to 100 MPa. So better than many standard concrete qualities. UHPC desert sand concrete is completely waterproof, corrosion-resistant and rot-proof. Desert sand concrete can be easily made with most desert sands. Desert sand is currently free.

Unusual living solution

The stone system is a building system for small children. With this fantastic system, you can intuitively build without having special knowledge, that is already shown by our children.
If you enlarge this system and the stones made of UHPC desert sand concrete, you can easily build simple and, if necessary, complicated constructions quickly without blueprint and remove again. With standard concrete such stone systems are not possible because they are not sustainable enough. With the high strength UHPC desert sand concrete, even very thin-walled load-bearing stones are possible. For the production of the stones only a few different cast forms are necessary.

Unusual residential areas
UHPC building block systems can be used without any problem in all areas of the world. Due to the

large cavity volume of the stones they are extremely well insulated against cold as well as against heat. They can be used in the desert, in the damp jungle and in extremely cold environments.

UHPC Binder systems development for customer

Experience and Know how - Everything from one source
We develop new innovative UHPC binder systems for a wide range of requirements for our customers. These materials developments incorporate more than twenty years of worldwide experience in the development, production and application of UHPC materials.
We have developed, produced and applied UHPC products for architecture, design, facades, offshore, anti-corrosion, wear protection, flooring, power plants, steel mills, mining, shipping, military, engineering, airports, port facilities, etc.

You would like to have your own UHPC binder production?
We advise and assist you

• In the design of the production plant
• Raw material evaluation of local raw materials
• Research and selection of alternative raw materials
• Assistance with the procurement of production facilities
• Production preparation and production start
• Accompaniment of local production by our specialists
• Training of local staff through workshops
• Introduction of a material and quality inspection

We develop according to your requirement specification for you

• UHPC binder systems for use as mortar, casting compound, shotcrete products
• UHPC binder systems for continuous temperatures up to 1200°C
• UHPC binder systems with fast-curing properties
• UHPC binding systems as lightweight concrete
• UHPC binder systems, impermeable to water and underwater applications

We produce for you according to your recipe your UHPC quality as ready mix in standard paper bags, plastic containers, bigbags or silo trucks in any quantity you want.

We can be your development partner
You have innovative, extraordinary UHPC material, product or application ideas and are looking for a development partner. Please contact us at any time. With your ideas and our experience, interesting future-oriented products should be created for you.

UHPC Construction test for the deep sea use

Research in deep sea construction

For more than a year, we participated in a research project of a German university. It was about the exploration of future concrete constructions for the deep sea.

For a few weeks, the result is available. The UHPC Binder material manufactured by us passed the tests by far from other binder materials.
The reasearch team of the university did models made of different concrete materials The models have been tested for corrosion, leaks and pressure resistance. The compressive strength should be so high that the concrete construction can withstand a sea pressure of 3500 m /2.17 mi permanently.

 

At the end of the long-term test, there were no cracks or other damage to the UHPC concrete construction.

 

Research in deep-sea energy storage
Another interesting research project is the construction of compressed air storage balls for the deep sea. The first concrete ball was manufactured in Germany by the Hochtief company and successfully tested as part of a research program. A very good standard concrete quality was used, but it reaches its material limits with a diameter of over 3 m.

One problem that still needs to be solved is the limited transportability of such hollow spheres due to their diameter.
For commercial use, the diameter must be larger. This means that the hollow spheres have to be manufactured on site, which is very costly, or the hollow sphere is manufactured from several prefabricated UHPC concrete elements, similar to the tower elements in wind power plants.

UHPC Offshore grouting could be an interesting alternative solution to this standard concrete here.

Why?

UHPC has a very high compressive strengt of over 200 MPa / 29000 psi
UHPC has been used in the offshore sector for more than 30 years.
UHPC is absolutely resistant to salt water
UHPC is easy to pump and is self-compacting
UHPC constructions can withstand much greate external and internal pressure loads than standard concrete. Due to the enormous compressive strength, the necessary wall thicknesses can be reduce  depending on type of construction
UHPC is waterproof from 10 mm thickness. Steel reinforcement is much more corrosion-proof in UHPC than in concrete
UHPC has an extremely low to no pore volume.
As far as the heat development during pressure build-up is concerned, the standard version of UHPC is temperature resistant up to 450°C. In the high temperature version, UHPC is permanent temperature resistant up to over 1000°C / 1832°F.

Sound barrier systems with UHPC and recycling aggregates

Highway noise barrier

There are a variety of sound barrier systems.
Soundproofing systems made of precast concrete
parts is one possibility.

Precast concrete walls are used especially as a
noise barrier on highways and railway tracks.
They can be made in any size and geometry,
adapting perfectly to noise protection and local
conditions.

UHPC Ultra High Performance Concrete
UHPC fiber reinforced concrete has a lot of
advantages compared to standard concretes
that already start with the production.

Recycled asphalt

Due to the extremely high strength values, the
elements can be designed leaner, resulting in
lower material consumption and final price.

Furthermore, UHPC materials reach their strength
in less than 24 hours, enabling them to be removed
from the molds. After less than 48 hours, already
70% of the maximum final strength is achieved.
UHPC is a concrete material with almost no pores.
This makes UHPC extremely corrosion resistant
and resistant to all environmental influences.

Of course, due to its extreme corrosion resistance,
UHPC concrete is ideally suited as a construction
material for soundproof walls that are to be planted.
The root system or frost cannot harm UHPC

Recycled rubber

constructions.
We also have experience of producing of UHPC
lightweight concrete for facade andwall construction.

A regular inspection of UHPC walls is not required.
The expected service life is approx. 100 years.

The future 
Use of all kind of recycling material as an aggregate 
to UHPC Binder
Our goal is to provide our customers with a material
that is not only recyclable but also largely made from
recycled materials such as plastic, rubber, asphalt,
concrete, glas, wall stones, all kind of bricks and
other mixed products. Through this use, the material
costs per ton concrete are drastically reduced. UHPC
is the perfect binder for these aggregates.

UHPC Bridge Deck Joint Filler BF

In many prefabricated concrete bridge constructions, the joints between the individual elements are filled
on site with a UHPC joint filler after the concrete elements have been installed. This creates a continuous concrete bridge deck.
Our BF joint filler systems have compressive strengths of 150 MPa - 220 MPa and flexural strengths of 14 MPa - 21 MPa.
The water to cementitious ratio is less than 0,22
Our BF System joint fillers can be processed on site with pan pot mixer, shaft mixer and horizontal mixer.
For very large sites with very large UHPC binder requirements we have mobile production plants for the binder and mobile mixing plants for the UHPC concrete. All plants are housed in containers and are therefore independent of weather conditions. With our mobile production plant for our UHPC joint filler systems, we are able to use local raw materials if suitable.

 

The joint filler BF systems can be used for all connections between adjacent box beams, next D beams, precast deck panels and beam haunch connections.
There is a wide range of concrete element connections. Each state in the USA and therefore DOT has its own specifications for these.

WPE DK International

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

UHPC Desert sand binder - Local Concrete for Africa

Almost four years ago we developed a UHPC Desert cement binder to process desert sand into a concrete with very high strength values. Only cement binders, water and desert sand are necessary for this. For mixing a standard concrete mixer is needed. The focus of binder development two years ago was on the professional construction industry.

In discussions with architects and organizations operating in Africa we were asked, if we could develop a simple, not so high-quality version of this binder that can support the traditional simple
constructions of the rural population. After some
discussion, a list of requirements for this new
binder was created with which we now work in
our lab. UHPC binders were originally developed
with the aim of achieving an extremely high level
of strength. Then we discovered with our UHPC
binder the incredible combination possibilities
with a variety of natural materials.


Our UHPC binders can perfectly support or
replace wood, straw, loam and clay constructions in terms of their strength and resistance to high
UHPC can also be easily combined with recycled material. It can be made of furniture and sanitary equipment. UHPC concrete is not flammable, which contributes to the safety of the accommodation.

The aim of our current binder development is to
drastically reduce binder costs, to keep the
mixing procedure as simple as possible, to
drastically reduce the proportion of binder in the
overall mix, to reduce possible material transports,
to enable new material combinations with local
raw materials and to preserve as many
properties of UHPC as possible, temperatures and high solar radiation. UHPC binders are completely waterproof, even in very thin layers, do not rot and provide safe protection against termites.

There is also the possibility to use local cement for the production of UHPC Desert Sand Binder in addition to the local desert sand. For this we would have to test local cements for their suitability for our UHPC binder.

A difference in the definition of UHPC is always a difference in quality

The American Federal Highway Administration (FHWA) defines UHPC as follows:

UHPC is a fiber reinforced, portland cement based product. Through the appropriate combination of advantagements in superplasticizers, dry constituent gradiation, fibre reinforcments and supplemental cementitious materials.

UHPC is a cementitious composite material composed of an optimized gradation of granular constituents, a water-to-cementitious materials 
ratio less than 0,20 and a high percentage of discontinuous internal fiber reinforcement.

The mechanical properties of UHPC include  compressive strength greater than 150 MPa and a flexural strength geater than 15 MPa.

We define our UHPC grades as Ultra High Performance Concrete but without steel fiber reinforcement.
For all our UHPC grades, whether cast, mortar or spray, we achieve the technical values without the addition of any fibers.

UHPC is a cementitious composite material composed of an optimized gradation of granular constituents, a water-to-cementitious materials ratio less than 0,20 and no procentage of internal fiber reinforcement.

 

The mechanical properties (without fiber reinforcement) of UHPC include minimum compressive strength of 150 MPa (up to 260 MPa and more) and a minimum tensile strength 15 MPa (up to 30 MPa and more). We achieve 70% of the maximum nominal strengths less than48 hours and not 28 days.

Of course, fibers of all possible qualities and geometries, steel reinforcements and a wide
variety of aggregates can be added to the UHPC concrete. On our website you will find a long list of
these materials that we have been using for over 20 years. But if we want to compare material with
material fairly, we have to compare the base with each other and that means the pure UHPC binder without fibers and reinforcements.

A difference in the definition of UHPC is always a difference in quality.

                     Our HPC and UHPC compressive strength standard

Fast - Faster - UHPC Rapid for new installation and repair

For very fast assembly in the taxiway of an airport
we have delivered a special UHPC (Ultra high
Performance Concrete) Cast.

Last Airport project:
There had to be laid cable protection pipes in the
area of ​​the taxiway. For this purpose, a slot of
20cm / 7,87in wide, 100cm / 39,37in deep and
100meters /109yd long in the existing concrete
floor had to be milled. For the filling of the slot
after the cable protection pipes had been laid,
we delivered a quick-hardening UHPC Rapid
Cast. The setting time of this special UHPC
is 2-3 hours, depending on the environmental
conditions. After this time it reaches a strength
above 20 MPa / 2900 psi. The final strength
after 48 hours is about 80 - 100 MPa /
1160 - 14500 psi.


Originally the UHPC Rapid product series
was developed about 20 years ago for wear
protection repairs in steel plants, power plants,
mining plants and cement plants.
Later, the UHPC Rapid was used not only as
a mortar but also as a cast and shotcrete. The
UHPC Rapid shotcrete was particularly used
in mining tunnels and the UHPC Rapid Cast
was used in the new lining and repair of
roadways, roads, storage areas and industrial
floors.

Meanwhile, it is also used as repair material
in airports, on highways and bridges.

hhbc-consulting and WPE DK service for HPC and UHPC material handling

We would like to share our more than 25 years of experience

in development, production and application in more than one

hundred industries worldwide. We would like to accompany

our customers in our journey in the future development of

HPC and UHPC binder and concrete.
That's why we've developed this customer service organization with our most experienced staff and international partners.

 

We offer the full range of services to all interested parties. Country of event: Germany
The majority of our service offer can also take place on the premises of the respective interested parties by prior arrangement, provided that they have the appropriate premises.

 

We offer this service for our following HPC and UHPC
HPC      - C80 - C140                                       Mortar, Castable, Shotcrete
UHPC   - C150 - C240                                     Mortar, Castable, Shotcrete
UHPC   - Phalt                                                 Semi rigid overlay system
UHPC   - TopLayer                                          Concrete industrial floorings
UHPC   - Security                                             Military and Security
UHPC   - Offshore                                            Offshore Grouting
UHPC   - Wear Protection                                Mortar, Castable, Shotcrete
UHPC   - Leight Weight, insulation                 Mortar, Castable, Shotcrete
UHPC   - HT Hight Temperature resistant       Mortar, Castable, Shotcrete

• HPC and UHPC Material Laboratory Service
  Reseach and Development
  Research of new raw material
  Documentation of the raw material
  Purchasing of raw materials


• HPC and UHPC Installations Service
  Supervisor
  Installation documentation
  Testing the customer processing machines for suitability for UHPC material

• HPC and UHPC Workshop Training Service
  Practical training of a castomer installation team
  Training of a Supervisor
  Training of the inhouse technican
  Training of the sales teams


• 

  Training of Instructors Service
  Practical and theoretical training of the customer instructor


• Workshop Repair Service
  Documentation of repair methodes


• Engineering Service
  Construction of a mixing plant
  Construction of a UHPC production
  Project consulting
  Technical documentation incl. drawings
  Quality control
   
  Appointments in our workshop or at interested parties as well as the scheduling are coordinated by us after a discussion with the interested parties according to their needs.
  If you are interested, please contact us via: service@hhbc-consulting.de
  

UHPC - Asphalt Combination for high speed race circuits

Many friends and customers of our UHPC
Ultra High Performance Concrete material have repeatedly asked us in the past why there are streets, lanes, squares, etc. with UHPC Phalt (UHPC Phalt semi-flexible wearing course consist of an open-graded asphalt filled with high strength UHPC mortar) content that are exposed to extreme traffic and environmental conditions but are not race tracks. 

We are big fans of automobile or motorcycle

racing. We are also very confident that we can

develop and deliver extremely good pavement 

systems for high speed racetracks or city courses.

Unfortunately, we have no contact with the

operators, organizers or architects. 

If you think about it, UHPC Phalt is a very

good solution for the strain of the racetracks.

With a standard road asphalt surface, the quality

can only be changed via the quality of the

asphalt. The new thing is that at UHPC Phalt

the quality of the surface can be changed via

the quality of the asphalt and the UHPC. So

there are combinations that standard asphalt

cannot offer. In addition, the expected lifetime without loss of quality of the combination 

covering is several times longer.

The original idea for developing this material

combination was to line roads, runways and

industrial roads with extreme traffic loads and

extreme environmental conditions with an

extremely hard and heavy-duty UHPC-Asphalt

combination. The implementation of this idea

was very successful, as the experiences of the

last 25 years show.

The UHPC Phalt material combination can

be set so that it is extremely abrasion-resistant /

wear-resistant or extremely load-bearing or

extremely resistant to temperature changes. In

city streets, the UHPC Phalt surface does not

lose its properties even after years of continuous traffic.

So there should be enough reasons to use this
surface on high-speed racetracks and street
circuit racetracks.

Technical advantages of UHPC Phalt

- Very high wear resistant
- Very high pressure resistant
- Extreme low material deformation
- Constant temperature resistance
   from - 60°C/-76°F - +90°C/+194°F
- Very simple and fast installation
- Very short curing times
- Can be laid on asphalt concrete or
   similar substrates
- Installation with standard laying
   machines
- Cheap material costs
- Extremely long durability
- Very high corrosion resistant
- Variable surface design
- Variable layer thicknesses

UHPC flooring system for residential housing, parking decks and concrete repair

The UHPC is known in the industry as extreme

wear-resistant flooring for more than 25 years.

Recently, UHPC floor coverings are increasingly

being used in residential housing projects. One

of the many advantages over traditional floor

coverings is that the UHPC floor covering is

absolutely watertight from a layer thickness of

8 mm. UHPC floor coverings can be processed

just like normal cement screed. In  addition to

the above-mentioned waterproofness, UHPC

flooring coverings also have a very high

compressive strength.

UHPC floor coverings are ideal partners for all

kind underfloor heating systems.

The fast strength development, with more than

70% of the nominal strength achieved after 48

hours in the normal quality, makes it an

interesting floor covering for a variety of

applications.

If repairs are carried out in damp basements or

damp existing floors, UHPC flooring can be

installed directly on the damp surface.

UHPC flooring is also an outstandingly extremely

durable corrosion protection for everything that

is cast in this material, such as reinforcements

and for that already a few millimeters cover is

sufficient.

If UHPC concrete is used, expensive electrical

corrosion protection systems or corrosion

protection coatings are unnecessary.

UHPC machine beds, frames and foundation for a high-tech machines

Various UHPC binder systems have been used by us for more than 25 years worldwide for different
industries such as cement plants, power plants, iron, steel and mining industries. Developed and produced as wear protection and industrial flooring or as foundations and anchoring systems for the offshore and engineering industries.

UHPC concretes are very suitable for machine beds and frames of any kind of high-precision drilling machines, grinding and milling machines.

The advantages
A very high surface quality. Due to the accuracy of the moulds, subsequent machining can often be dispensed with. With UHPC, an accuracy of 0.1 mm/0.004 in from the mould can be achieved when using suitable moulds. The accuracy can be increased to 0.005 mm/0.0002 in by grinding.
Very high pressure resistance
Very good stiffness and dimensional stability

Very good damping properties compared to cast steel constructions and same vibration damping as natural stone. The vibration damping of UHPC concretes is approx. 70 - 80% faster than standard cast steel constructions. Higher precision with faster processing speed.

Thermal properties:
Applicable up to 450°C/840°F without loss of engineering properties and dimensional stability.
High thermal shock resistance
Inertia during heat transfer
Low thermal expansion
Non-flammable

Very good flowability.
High integration capability. All types and sizes of anchors, pins, threaded sleeves, structural steel elements
and pipes can be cast without problems.
Extreme adhesion to cast-in fasteners and anchor elements.
Very high corrosion resistance
Due to the high strength development, material thicknesses and material weights can be calculated significantly lower.
UHPC castings can be removed from the mould within 24 hours and reach more than 70% of their final strength after 48 hours.
Faster delivery times
Drastically reduced costs
Elements made of UHPC can be recycled and reused like normal construction waste.
Due to the low energy consumption and low CO2 impact, the production is much more environmentally friendly than cast, steel and reactive resin concrete.


Technical data for UHPC Cast products

Density 2400 - 2900 kg/m3 / 168 - 181 lb/ft3
Compressive strength after 2 days 100 - 120 MPa / 14500 - 17500 psi
Compressive strength after 28 days 140 - 250 MPa / 20300 - 36200 psi
Flexural strength 17 - 29 MPa / 2755 - 4200 psi
Max. Process temperature 450°C / 840°F


Applications
UHPC is suitable
for foundations, beds and frame parts of highly dynamic machine tools
for foundations of highly loaded machines, e.g. engines, generators, turbines, etc.
for foundations in the paper, wood, printing and textile industries

WPE DK International

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