SERVICES

CARBOCON is the leading service provider when it comes to carbon reinforced concrete technology. We take care of project management, planning and consulting for construction projects, knowledge transfer to the economy or special questions concerning the development and approval of innovative and technical solutions as well as patent­ applications. As a member of the TUDAG Group, we provide knowledge transfer and R&D services. With our network, we can integrate the right partners into the entire value creation process in a targeted manner to reach the best solution.

CARBOCON transfers knowledge and technology quickly and professionally to partners in business and industry and acts as a service provider or partner in construction, funding and cooperative projects. Consulting and planning services can be provided quickly and flexibly on behalf of customers. CARBOCON is at your disposal with its expertise in working out the best solution together with customers and partners.

Our customers

Prefabricated component manufacturers

Manufacturers of precast concrete products are faced with the challenge of mastering the logistics costs involved in lifting and transporting the finished products. But the production of finished parts is also characterised by consistent quality in high quantities. CARBOCON can help you, for example, to reduce logistics costs, expand product portfolios and generate competitive advantages.

Fabric/concrete manufacturers

The basic components of carbon reinforced concrete are supplied by manufacturers of concretes and their components as well as manufacturers of fabrics and rebars. CARBOCON links the manufacturers and their products with the most diverse construction projects and continuously refines the products together with the manufacturers. The transfer of the latest knowledge is of crucial importance.

Component manufacturers

In addition to the classic "ingredients" of concretes and reinforcements, the components used to join carbon reinforced concrete structures in hybrid applications form an important basis for the composite construction material. CARBOCON offers manufacturers solutions and ideas for portfolio expansion. Moreover, existing products can be qualified for use with carbon reinforced concrete in approval procedures.
 

Planners and users

In the building planning process, engineers and architects contribute different competencies and solutions at different stages of the project's development. With its expertise in carbon reinforced concrete technology, CARBOCON helps engineers and architects by offering a solutions-oriented approach and participating in the project by providing advice and comprehensive planning support.

Private clients

Apart from design aspects, private clients primarily evaluate development projects from an economic point of view. The advantages and feasibility, the competitive environment and the image of the project play an important role in decision-making processes. CARBOCON's projects using carbon reinforced concrete technology offer a highly innovative and sustainable building material and an improved image.
 

Public clients

For the public sector, criteria such as sustainability and innovative strength are becoming increasingly important in planning and construction. For existing structures in the infrastructure and building construction sectors, CARBOCON offers excellent solutions to meet these criteria. Carbon reinforced concrete can be included in the planning process at a very early stage when restoring, strengthening and maintaining bridges and other structures.

our network partners

Structural engineers | Manufacturers | Construction companies | Expert consultants/researchers | Laboratories | Approval authorities


CARBOCON acts as a central interface bringing customers and network partners together. In special construction projects involving carbon concrete, CARBOCON assumes the role of project manager in order to advance complicated issues and processes between the parties involved. We build 'bridges' to the authorities involved in the approval process, and expert reports are prepared to guarantee success. In addition, a wide variety of experts from our industry network are involved in complex development and planning processes. This ensures a decisive advantage for the customer when it comes to efficiency.

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 reinforced concrete.

Service packages in the value creation process

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

Portfolio, feasibility analyses, dimensioning

Taking customer and project requirements into account from an early stage within the scope of feasibility and portfolio analyses creates an excellent basis for securing the subsequent success of the project. Be it design calculations or economic considerations for the engineers, a holistic view is important.

Prototype construction and test programmes

CARBOCON has extensive experience in the development, planning and construction of prototypes, demonstration models and the associated test programmes for simulation and verification. Be it the selection of the right materials, partners or design models, CARBOCON always has the right solution.

Expert support for national technical approval / project-related approval

For the application of carbon reinforced concrete technology a national technical approval for the strengthening of steel reinforced concrete components is available. CARBOCON can obtain a project-related approval or a national technical approval for special applications and help the customer in interacting with the authorities and other parties involved. We will also map out the complete planning process, the execution of tests and expert reports.

Distribution Products and Licences

In addition to the approval of products, their integration into practical projects is of utmost importance. Here CARBOCON combines product variety with application. Partners in our network and from the construction industry benefit from the best solutions through licensing models, among other things.

QM self monitoring / third-party monitoring

CARBOCON ensures consistently high quality in the application of this innovative technology, not only during the planning stage of the construction project, but also in the later execution phase. This means that customers and project participants can be sure to benefit from CARBOCON's expertise in providing a comprehensive solution throughout the entire value creation process.

 

REFERENCE PROJECT ENGINEERING SERVICES

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.

Foto: © CARBOCON

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REFERENCE PROJECT ENGINEERING SERVICES

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.

Foto: © CARBOCON

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REFERENCE PROJECT ENGINEERING SERVICES

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.

Foto: © CARBOCON

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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.

Foto: © CARBOCON

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REFERENCE PROJECT ENGINEERING SERVICES

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.

Foto: © CARBOCON

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REFERENCE PROJECT ENGINEERING SERVICES

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.

Foto: © CARBOCON

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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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Reference Cooperation Project/Research Project

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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Reference Project Engineering Services

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.

Foto: © CARBOCON

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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.

Foto: © CARBOCON

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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.

Foto: © CARBOCON

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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.

Foto: © CARBOCON

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Reference Project Engineering Services

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.

Foto: © CARBOCON

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Reference Project Engineering Services

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 %).

Foto: © CARBOCON

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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.

Foto: © CARBOCON

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Reference Project Engineering Services

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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Reference Project Engineering Services

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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Reference Project Engineering Services

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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Reference Project Engineering Services

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.

What can we do for you?
Give us a call. +49 351 82120420