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BIA-Brukerstyrt innovasjonsarena

Materials and manufacturing methods for large UHPC marine structures

Alternative title: Materials and manufacturing methods for large UHPC marine structures

Awarded: NOK 2.2 mill.

Project Manager:

Project Number:

245657

Project Period:

2015 - 2017

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Ultra High Performance Concrtete (UHPC) is a new concrete material with superior mechanical strength and durability. This makes it an interesting material for the construction of large marine concrete structures. Globally the use of UHPC as a new construction material is growing. However the material's high cost, and its often challenging workability, are limiting its use, typically to smaller or high-value structures for special purposes. Only a few specialized construction companies can currently handle UHPC in their working processes. This project developed new lower-cost UHPC materials and associated manufacturing/construction methods. The solutions are aimed to allow the economical use of UHPC as primary construction material in large marine concrete structures. A comprehensive set of UHPC mixes with dedicated properties has been developed by the project. Material processing and performance testing has been performed and the applicability of UHPC for casting large-scale structures for marine applications has been demonstrated. Cost performance of the UHPC has been optimized with a range of options according to design strength requirements.

Large concrete structures are placed in the ocean both offshore and near-shore - for example immersed tunnels, pipes and offshore O&G platforms/subsea tanks. The demands for placing these structures in greater water depths are growing. But to go deeper the structures must be strengthened by increasing the wall thickness to the point where they are too heavy to float and be transported. Ultra High Performance Concrete (UHPC) can be used to produce stronger structures at a lower weight. UHPC exists, but its use in large marine structures is limited because of a high amount of costly ingredients and challenging workability properties to cast the structures. No economical solution exists that enables industry to cast large marine structures with thick walls from UHPC. The project will develop a combination of new UHPC materials and associated manufacturing methods that allow the broad-scale use of UHPC in very large marine offshore structures. This will be achieved through the combined development of new UHPC materials and manufacturing methods that will be lab tested and analysed. From this, a concept for the large scale manufacturing of these structures will be developed. The Consortium partners combine complementary skills in the value chain of concrete manufacturing, construction and user applications. The project results can put Norway in the lead for UHPC for marine applications. Low-cost UHPC solutions can also have a high impact on other construction sectors, like civil infrastructures.

Funding scheme:

BIA-Brukerstyrt innovasjonsarena