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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 was carried out in 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.
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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.

PROJEKTREFERENZ INGENIEURDIENSTLEISTUNG
Machbarkeitsprüfung von Fertigteilstürzen aus Carbonbeton
Zur Reduktion des Bauteileigengewichts und zur Verbesserung des Handlings auf der Baustelle wurde eine Machbarkeitsstudie zur Optimierung von Fertigteilstürzen durchgeführt. Durch die Optimierung des Bauteilquerschnitts und den Einsatz von Carbonbeton können zukünftig bis zu 45 % Beton eingespart werden. Die Elemente können in unterschiedlichen Längen eingesetzt werden und haben einen Dämmstoffkern, welcher von einer dünnen Carbonbetonschicht umgeben ist. Die Tragfähigkeit der optimierten Bauteile wird in einer Prototypenprüfung untersucht und anschließend wird eine abZ für die Fertigteile erwirkt.
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PROJEKTREFERENZ INGENIEURDIENSTLEISTUNG
Ultraschlanke vorgespannte Carbonbetonbinder
In diesem Dresdner Pilotprojekt entstand erstmals ein Dachtragwerk aus vorgespanntem Carbonbeton unter realen Bau- und Nutzungsbedingungen. Die neue 1-Feld-Sporthalle der 49. Grundschule erhielt dafür vorgefertigte, vorgespannte Binder und dünne Platten aus Carbonbeton.
Ziel war ein ressourcenschonendes, langlebiges und zugleich filigranes Tragwerk als übertragbares Praxisbeispiel. Trotz fehlender Regelwerke für vorgespannten Carbonbeton gelang die Umsetzung durch umfassende Voruntersuchungen, detaillierte Bemessung, gezielte Prüfungen sowie die erforderliche Zustimmung im Einzelfall bzw. Bauartgenehmigung.
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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