CARBOCON is a leading independent service provider in the field of carbon reinforced concrete. We are your contact for any questions related to development and approval of innovative and technical solutions or patent applications. If you are looking for a partner to be at your side and support your projects from the first feasibility study, through the development and monitoring of test programmes, to the safe approval and later monitoring of the product application, then we are the right choice for you.

Comprehensive services for clients, architects, planners and manufacturers

CARBOCON transfers knowledge and technology quickly and professionally to partners in business and industry and acts as a partner in construction, funding and collaborative projects.

Consulting and planning services can be provided quickly and flexibly on behalf of customers. CARBOCON is always available with its extensive expertise to work out the best solution together with customers and partners.

Special products related to carbon reinforced concrete

Many planning services and subsequent carbon concrete applications require special solutions and approaches. The knowledge of services and the existing and approved products of conventional technologies only allow the use of carbon reinforced concrete up to certain limits. Building with carbon reinforced concrete therefore requires its own variety of unique products. At CARBOCON we determine this at an early stage and act as a developer and licensor for our partners.

durable, load-bearing, sustainable

The carbon reinforced concrete principle briefly explained

Carbon reinforced concrete is a composite material consisting of two high-performance materials. The innovative combination of carbon fibre fabrics or bars with fine-grained concrete simultaneously enables significantly more varied designs and a high load-bearing capacity. Due to the corrosion resistance of the fabrics and rebars, the concrete cover and thus the use of resources can be reduced to a minimum. Carbon reinforced concrete can be used for sustainable, resource-saving, less material-intensive and lighter construction.

Load-bearing, durable, sustainable

Light as a feather and powerful – The reinforcement

Anyone who speaks of carbon reinforced concrete inevitably thinks of concrete. The core element, however, is the feather-light reinforcement. But carbon is by far not the only material. CARBOCON determines which reinforcement is the most suitable for a specific project on a case-by-case basis. Basalt, aramid and glass fibre reinforcements can also be used here. The form in which these high performance materials are used as reinforcement highly depends on the intended use and technical requirements.

Photo © Ansgar Pudenz, DZP 2016

Load-bearing, durable, sustainable

Proven for decades and yet innovative - Concrete

Concrete has been the most widely used building material in the last 120 years. Concrete contributed significantly to the expansion of infrastructure, urban and industrial development and thus formed the basis for a diverse and modern society. Structural engineering developed an architectural language of its own. The innovative carbon reinforced concrete builds on this development. Carbon reinforced concrete can be used on the one hand to make slimmer structures, and on the other to strengthen and maintain existing steel reinforced concrete structures.

Load-bearing, durable, sustainable

Steel reinforced concrete vs. carbon reinforced concrete – a sustainable alternative

Since its introduction as a load-bearing building material, steel reinforced concrete has enabled very important and at the same time extremely robust structures to be built. The use of concrete as the world's most frequently used building material after water has always led to a high consumption of raw materials and energy. This is exactly where the new carbon reinforced concrete comes in. It reduces the total consumption of materials and replaces the steel with carbon. Since carbon does not rust, less concrete is required to protect the steel from corrosion.

Photo © filmaton.tv

Load-bearing, durable, sustainable

Both flexible and sustainable – The technology behind it

The advantage lies in the approx. 50,000 individual fibres, which are much thinner than a human hair. These fibres are combined into a yarn, processed into a grid structure and coated. Compared to steel, carbon is four times lighter with up to six times more load-bearing capacity. Architecturally, versatile building geometries can be realised that are difficult to achieve with steel reinforced concrete. 'Lightweight construction' and 'concrete' are no longer a contradiction in terms, but a concept for the future.

Photo © TU Dresden, Jörg Singer

Excellent prerequisites for your success

The keys to success are innovative ideas, motivated employees and a high-performance environment. The high level of innovation at the TU Dresden forms the basis for flourishing economic development in the Free State of Saxony. TUDAG creates an excellent infrastructure so that knowledge and technology can be put into practice. Both institutions are important network partners for CARBOCON to actively promote the introduction of carbon reinforced concrete technology into the economy and industrial landscape.

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Reinforcement of the Hyparschale in Magdeburg

The Hyparschale in Magdeburg, built according to the plans of civil engineer Ulrich Müther, is one of the largest concrete shell constructions of its kind. The roof construction consists of four hyperbolic paraboloid shells. The Hyparschale, a listed building, already showed structural damage years ago. Carbon reinforced concrete was implemented as the reconstruction solution. The structure was reinforced with a carbon reinforced concrete layer of 10 mm on the top and the bottom of the concrete shell, thus protecting Magdeburg's landmark from demolition.

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Strengthening of a bridge in Naumburg/Saale

Naumburg is home to one of the oldest preserved steel reinforced concrete bridges in Germany – the Thainburg pedestrian bridge. The bridge, which is now under a preservation order, was built in 1892 and made of steel reinforced concrete, a new material at that time. In recent decades, the structure has suffered corrosion damage due to lack of maintenance and constructional sealing defects. For reasons of material efficiency and design, a strenghtening with carbon reinforced concrete was chosen. The strenghtening works were carried out in summer 2021. The finishing renovational works are being carried out until autumn 2021.

 

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Carbon reinforced concrete bridge for the Free State of Saxony

The first carbon reinforced concrete road bridge is being built as part of the 100-Bauwerke-Programm of the Free State of Saxony. The previously conventionally reinforced concrete structure from 1934 is located in the area of a state road and is heavily used by conventional road traffic. The bridge is now being constructed as a replacement building made of carbon reinforced concrete (carbon rods and grids). The bridge's substructures and foundations are conventionally constructed using reinforced concrete. At the beginning of April 2021, work began on the construction of the so far unique carbon reinforced bridge over the Kuppritzer Wasser near Wurschen on the S111. After the completion of the works on the superstructure, intended for autumn 2021, long-term monitoring is planned.

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Reinforcement of slabs and beams in Beyer-Bau Dresden

The striking Beyer-Bau complex on the TU Dresden campus needs to be renovated. Due to increased usage requirements, static structural deficits in beams and ceiling planes have to be eliminated, as the existing construction was very slim compared to today's normative specifications. The chosen solution for the strenghthening is a reinforcement of the joists and ceiling planes with carbon reinforced concrete. This solution prevents a demolition and rebuilding of the historic structure. By using carbon reinforced concrete, the existing structures can be reinforced in a minimally invasive and economical manner while complying with preservation orders. The Beyer-Bau project is a very impressive example for a sustainable preservation of a historical building.

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Reinforcement of the ceilings of an above-ground bunker

The existing  bunker in Bremen shall to be converted. As part of these considerations, the client asked CARBOCON for support. The client plans to slightly reduce the height of the used rooms of the bunker system. Thus an increase of the load-bearing capacity is necessary for which the client wants to use carbon reinforced concrete. The client also put down special requirements with regard to the application temperature in the bunker system. Furthermore, a project-related approval must be obtained because a reinforcement grid is to be used that is not yet covered by the general building authority approval.

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Consulting services and implementation of project-related approval for federal road bridge in Bavaria

The Augsburg State Building Authority plans to strengthen and repair a prestressed concrete box girder bridge over the Danube in Donauwörth (Bavaria) that was built around 1968. The structure consists of two superstructures, each spanning two fields. The aim is to achieve a remaining service life of at least 20 years. Due to its technical requirements carbon reinforced concrete is recommended, with which the identified deficits of the bridge can be remedied as part of the renovation process. Since carbon reinforced concrete is an innovative material and is therefore used for the first time in Bavaria, a project-related approval is required first. Works are planned for 2023.

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Feasibility study and implementation of project-related approval for federal road bridge in Hesse

In Hesse, a multi-span bridge, built in 1971, was renovated and repaired. In this project, carbon reinforced concrete was used for the first time to reinforce a motorway bridge. The approximately 70 m long structure in Frankfurt transfers the A648 motorway in three parts over two cycle paths and the  the Nidda river. As part of the renovation, the bridge's deficit in load-bearing capacity was compensated for by targeted reinforcement with just a few centimeters of carbon reinforced concrete. At the top, the reinforcement layer was completely integrated into the road structure without having to raise the gradient. The restrictions for the underpassing cycle paths in the peripheral areas are minimal with only 3.5 cm reinforcement layer thickness. The sensitive nature around the river Nidda under the main field remained completely untouched by the construction work.

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Strengthening of sugar silos in Lower Saxony

Carbon reinforced concrete was used in the reconstruction of several sugar silos. Before the start of the project, during inspection and sampling, the silo walls showed severe damage in the form of deep cracks, spalling and reduced tensile strength. The aim was to permanently restore a uniform cross-section with a smooth and hygienic surface. The approximately 5,000 m² interior wall of the silo received a strengthening layer of textile reinforced concrete, which ensured both better load-bearing capacity and sustainable serviceability. In this situation the SiloSolution product was used.

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Repair of a historic arched bridge in Naila/Bavaria

The historical arched bridge in the city of Naila, which is more than one hundred years old, showed extensive crack formation and cavities almost over the entire surface. Since the listed building has a sentimental value for the region, a reconstruction method had to be found that preserves the old appearance and geometry and at the same time ensures compliance with current requirements for structural integrity, road safety and durability. Strengthening with carbon reinforced concrete was not only an economically attractive solution, but was also convincing in terms of durability, fine crack distribution and the simple practical application of carbon reinforced concrete.

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Reinforcement of steel reinforced concrete columns in Berlin

The aim of the construction project was the structural strengthening of steel reinforced concrete columns in an office building. The carbon reinforced concrete was introduced as part of the conceptual design and planning. The existing national technical approval provided the perfect conditions for this. First, the old concrete surface was prepared using a high-pressure water jet. The strengthening work was then carried out. Fine-grained concrete and carbon reinforcement were alternately applied to the surface. A few centimetres of cross-sectional expansion with carbon reinforced concrete were sufficient to significantly increase the load-bearing capacity of the columns (load increase of about 40 %).

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Strengthening of a high-rise building in Munich

The 40-year-old Arabella skyscraper in Munich was damaged by cracks, spalling and frost damage on some balconies and balustrade panels. These affected the durability and safety of the balconies and the building's surroundings. During the repair work, the complex geometry of the facade was to be maintained without scaffolding where possible while the building continued to be used. The ideal solution here was a covering of carbon reinforced concrete. The low material requirement allowed outdoor work by industrial climbers. A textile concrete layer of only 6 mm ensured both the preservation of the old appearance and long-term load-bearing capacity.

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Construction supervision and quality management during facade reconstruction with carbon concrete slabs

The building on the Dresden University of Technology campus has a facade made of betoShell® panels. The panels are double-layered and reinforced with fibreglass. As part of the installation work, anchor systems were dismantled and replaced by new anchor systems. As part of his quality management concept, the principal requested comprehensive documentation and supervision of the installation work. The monitoring of contractors should incorporate experience with carbon reinforced concrete.

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The CARBOCON team is also at your disposal as a central contact partner with interdisciplinary expertise. In connection with our range of services, this enables us to take care of various customers with different requirement profiles.

CARBOCON supports the projects from the first analysis to the subsequent application. The spectrum of projects ranges from comprehensive consulting on strategic, operational and technical issues in the use of carbon reinforced concrete to 'classic' planning for the strengthening of bridges and other structures with carbon concrete.

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