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 technology 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 technology 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.

Latest news

 

Impulse seminars at the 11th Carbon and Textile Reinforced Concrete Days 2019 in Dresden

On 24 and 25 September 2019, the annual user conference takes place in Dresden. CARBOCON once again has its own stand at the accompanying trade exhibition and is available with its team for questions and answers. A presentation on current projects is also planned. For the first time, the conference…

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Project progress - reconstruction of the Thainburg pedestrian bridge

As a leading supplier in the field of carbon reinforced concrete technology, CARBOCON is currently entrusted with various monument reconstruction projects. One of the oldest reinforced concrete bridges is located in Naumburg in Saxony-Anhalt and was built using the Monier construction method which…

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First carbon reinforced concrete road bridge

Carbon reinforced concrete technology continues to attract attention in the industry: planning for the first road bridge for heavy-duty traffic made of carbon reinforced concrete is underway in Saxony. An existing bridge on the S111, east of Bautzen, about 7 meters long, is to be restored using…

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Reinforcement of the hypar shell in Magdeburg

The hypar shell 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 hypar shell, a listed building, already showed structural damage years ago. In recent years these have become more prominent, so that a reconstruction concept has been sought. Based on an inventory analysis, it was decided to strengthen the shell construction with carbon concrete technology. The structure will be saved from demolition by applying a protective 10mm thin carbon reinforced concrete layer on the top and bottom of the concrete shell.

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Strengthening of a bridge in Naumburg/Saale

p>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. The CARBOCON project team developed a strengthening concept and integrated this into the plans for approval. The innovative strengthening with carbon reinforced concrete was chosen for reasons of material efficiency and design.

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Carbon reinforced concrete bridge for the Free State of Saxony

The first carbon reinforced concrete road bridge in eastern Saxony is being planned as part of the '100-Bauwerke-Programm' of the Free State of Saxony. This bridge is located in the area of a state road and is therefore used by conventional road traffic. For the first time, carbon reinforcement bars and mats are being used in the design of the engineering structure. The carbon rods are developed and produced in the Free State of Saxony. The project is therefore regarded as an important milestone in bridge construction and application of the innovative composite material, carbon reinforced concrete, and is intended to demonstrate the durability of the material under real conditions.

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Large structural component tests for the University of Innsbruck

The Leopold Franzens University of Innsbruck is one of the leading universities in Austria. This is particularly true in the field of research and development. And this also applies to carbon reinforced concrete. The field of solid construction and bridge construction, headed by Prof. Dr Eng. Jürgen Feix, has been researching the practical application of carbon reinforced concrete for many years. In close cooperation with the Otto Mohr Labor in Dresden as a partner of CARBOCON, steel reinforced concrete girders were produced for Innsbruck, reinforced with carbon reinforced concrete and subsequently tested.

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Reinforcement of slabs and beams in Beyer Bau Dresden

As part of the reconstruction of the Beyer Bau building complex on the TU Dresden campus, load-bearing deficits in beams and ceilings are to be eliminated by strengthening with carbon reinforced concrete technology. The deficits mostly result from increased usage requirements and the very slim design of the existing building. In a feasibility study, the use of carbon reinforced concrete was proven to be a good alternative to the demolition and new construction of the existing historic structure, and was favoured not only in terms of the protection of the existing structure but also from an economic point of view.

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Reinforcement of the ceilings during conversion of an above-ground bunker

Within the scope of the conversion of an existing bunker in Bremen, the private client asked CARBOCON for support. Carbon reinforced concrete technology is to be used in order to increase the required load-bearing capacity of the ceilings with a small reduction of the room height in the areas of use of the bunker. The client also had special requirements with regard to the application temperature in the bunker system. Under normal operation, temperatures of up to 40°C are to be expected. Since the possibility of cooling failure cannot be ruled out, temperatures of up to 80°C are possible for short periods. Accordingly, a project-related approval must be provided.

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Feasibility study for the reinforcement of a bridge underpass in NRW

As part of the total overhaul of the A3, the 'Landesbetrieb Straßen.NRW' is also involved in work on the Rottbach underpass. Based on an analysis of the existing structure, a new replacement structure was recommended, but this proposal was rejected. A preliminary design for a strengthening option was then suggested, with a 20 cm thick shotcrete shell of steel reinforced concrete as a replacement structure. However, this would cause a considerable narrowing of the cross-section of the structure and high costs for the construction logistics. Within the scope of a feasibility study, different options were examined. These resulted in several carbon reinforced concrete options which could be used as an alternative to the classic strengthening with steel reinforced concrete.

Foto: © Roads.NRW

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Transfer of ideas and knowledge into the economy

In this project, carbon reinforced concrete technology is to be applied profitably within the construction industry. Based on the existing state of knowledge from research into carbon reinforced concrete, application-oriented potentials should be used to make this technology accessible to a broad specialist audience. The focus here is on being able to react quickly and flexibly to the needs and requirements of industry. In addition, "bridges should be built" in the interests of the construction industry, in order to compensate for the lack of certain expertise there and to be able to adequately answer the open questions and challenges in connection with new technologies.

Foto: © Ulrich van Stripriaan

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

The Augsburg State Building Authority plans to strengthen and repair an existing bridge over the Danube in Donauwörth (Bavaria). The aim is to achieve a remaining service life of at least 20 years. Due to various technical challenges, the planning team turned their focus to carbon reinforced concrete. It turned out that with carbon reinforced concrete strengthening the currently identified deficits of the bridge could be remedied within the scope of the reconstruction process. Furthermore, it was determined that a project-related approval was required for the innovative materials to be used and for the character of the pilot project in the federal state of Bavaria.

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

Hessen Mobil plans to renovate and repair a multi-span bridge in Hesse. The target is a remaining service life of at least 15 years. In the course of a recalculation of the existing structure, various deficits were identified which call for precautionary remediation with regard to future requirements and traffic loads. In this context, the strengthening of individual elements was envisaged. A feasibility study in cooperation with a planning project partner illustrated that strengthening with carbon reinforced concrete would be the only sensible approach.

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Strengthening of sugar silos in Lower Saxony

Carbon reinforced concrete technology 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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Reinforcement of electricity poles in Romania

Romania has a large number of steel reinforced concrete poles which have been severely damaged by corrosion over time. With the help of repairs using carbon reinforced concrete, the load-bearing capacity and serviceability were to be restored. A significant increase in load capacity could be proven in the tests due to the textile reinforcement made of carbon. A careful condition analysis and conceptual design by CARBOCON showed that this would be a cost-effective reconstruction solution for the long-term preservation of the existing structure.

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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 concrete technology.

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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 technology 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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Development services and consulting for industrial partners in fabric development

Material tests and trials were to be carried out to qualify and develop a fabric. These were then to be used to apply for inclusion of a process of strengthening steel reinforced concrete with TUDALIT (textile reinforced concrete) in the existing national technical approval. A three-stage test programme was set up for this purpose. The required material tests were carried out in the partner laboratories.

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Development services and consulting for industrial partners with regard to material qualifications

The industry partner Koch developed a strengthening layer of carbon reinforced concrete for multi-storey car parks, which, in addition to a structural bending strengthening also functions as active cathodic corrosion protection by means of a direct current. The carbon fabrics form the anode and conduct a current. In addition to preliminary trials, as part of this collaboration, CARBOCON is developing a test concept in order to investigate the durability of the carbon reinforced concrete in the present combination, taking into account the influence of the electric current applied to the carbon fabric.

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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 technology.

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Feasibility study and planning for the use of carbon reinforced concrete in a mill channel

The building complex of the Klostermühlen Museum in Thierhaupten is about 500 years old. The venerable Benedictine monastery was once the dominant centre of the village for centuries. Over the years, the Benedictines built four mills for self-supply: a sawmill, an oil mill, a paper mill and a grain mill. After its closure, the listed building became increasingly dilapidated and seemed doomed. After extensive reconstruction, the monastery mill museum was opened in 1997. Within the scope of an upcoming reconstruction of the channel in front of the museum, various reconstruction technologies were tested in 2019.

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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 technology to 'classic' planning for the strengthening of bridges and other structures with carbon concrete.

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