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Introduction The DUCON®-Technology combines a self-compacting and high-strength concrete with a spatial micro-reinforcement (MicroMat®) into an innovative high-performance concrete with outstanding properties. DUCON®-Concrete is characterized by extreme strength and loading capacity simultaneous with a very high ductility. In combination with a very good durability and resistance to different impacts exceptionally thin and free-form building components are possible. The material properties can be adjusted by different variations of the material set-up to a requirements specification. Due to the excellent material properties DUCON® is used as security-concrete against dynamic impacts such as explosions, direct fire, brunt or earthquake. In addition, DUCON® has a general building inspectorate approval as WHG (Water Resources Act)-impervious overlay and can be installed jointless over large areas, e.g. industrial floors. Last but not least the thin building components and the formability enable particular architectural and technical design components such as concrete facades, staircases and furniture. DucoGlass® and DucoStone® combine the loading capacity and protective effect of DUCON®-Concrete with the look of glass and natural stone. Due to the simple material structure and low production costs DUCON® is a significantly more economical solution than other high-performance building materials. The production is handled by laying out the micro-reinforcement (MicroMat®) followed by mortar infiltration. DUCON® is both horizontally and vertically processible and can be produced as an in-situ or precast concrete. The high flowability and a modern formwork technology make a shaking of the concrete and a surface treatment afterwards obsolete. Executed areas can be loaded quickly again due to a high initial strength. The patented DUCON®-Technology is unique and contributes now for more than ten years to the success of new construction and renovation projects and meets special challenges in the areas of security, industrial overlay/coating, architecture and design.

Figure 1: DUCON Fields of application

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DUCON® Security The networking of flexibility and stability in the material properties of DUCON®-Concrete are crucial for the use of DUCON® as security concrete. DUCON® Security enables to increase the protection of buildings against violent events effectively with low component thicknesses. Unlike conventional reinforced concrete, which shows itself as little tight and brittle to dynamic effects, DUCON®-concrete behaves extremely strong and ductile. At that point it almost does not matter in what form forces act upon the building material. Explosions, direct fire, breakthrough, earthquakes, and combinations thereof withstands DUCON® already from a component thickness of only 4 cm. The resilience and subsequent functionality has been proven in numerous experiments and research activities of renowned universities and institutions. At the same time DUCON® can be aligned due to the formability to the overall architectural picture. The DUCON®-Technology protects in the form of DUCON® Security already several critical infrastructures, embassies, high-rise buildings, community centers, high-security data centers and nuclear power plants. The DUCON® technology with their exceptional material properties has already caused a sensation across borders. The performance was illustrated among others in formats like the Discovery Channel, RTL Aktuell and the Great Show of natural wonders.

Figure 2: DUCON Security

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Anti-Terror-Concrete The innovative DUCON®-Technology suits for the protection against terroristic attacks of all sorts. There is nearly no limit in the range of applications and constructions. The material properties, such as a high load bearing capacity simultaneous with an extreme ductility enables a high resistance against dynamic loading. Additionally, DUCON® warrants a high energy absorption. Among other things walls and facades made of thin DUCON®-slabs can be applied for the protection against explosions, direct fire, impact and forced entry. Simultaneously the constructions stay architecturally shapeable. DUCON®-slabs can be installed as a type of a protection skin, for example as a back-ventilated facade to existing buildings. In comparison to conventional concrete DUCON® can be implemented with half component thickness and thus half component weight due to the higher resistance and is moreover shatterproof.

Figure 3: Explosion protection by DUCON and reinforced concrete

Explosion protection of a DUCON building component with half component thickness and weight in comparison to conventional reinforced concrete. Additionally: No debris throw.

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Bullet- and forced entry-resistance The close-meshed, 3D micro-reinforcement of the DUCON®-Technology provides a high bullet protection. A component thickness of only 10 cm is needed to fulfill the highest class of ballistic codes PM7. Moreover, DUCON® ensures protection against multihit-fire with only local damage. Class of ballistic codes: PM7 armor piercing bullets d = 10 cm (wolfram carbide penetrator) The forced entry resistance is a key value of a material like DUCON® to resist against tools and machines according the code requirements. Just a thin panel of 7,5 cm fulfills the highest resistance class RC6. Resistance classes according DIN EN 1627: RC6: d = 7,5 cm RC5: d = 5 cm For higher protection levels of critical infrastructures and nuclear power plants the resistance of a 10 cm DUCON®-panel against core driller, jackhammer, oxygen lance and a diamond blade saw has been determined. The 10 cm DUCON®-panel with the standard set-up meets all criteria of the adapted devices catalog and of the correspondingly guideline. The internal set-up of DUCON® can be improved in a way that a breakthrough with core driller, diamond saw, jackhammers etc. is impossible. Regarding the dimensioning pertains the same formula: DUCON® fulfills the same protection at half of the thickness and weight of conventional reinforced concrete.

Figure 4: Component thickness: 10 cm: Breakthrough attempt with jackhammer (left); Multihit direct fire (middle); Breakthrough attempt with oxygen lance (right)

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Explosion protection DUCON®-concrete already meets the highest security requirements at very low component thickness. The explosion protection of DUCON® was demonstrated in experiments with detonation contact. While in reinforced concrete – despite higher strength – smooth passing shots were observed with debris throwing, originated in DUCON® only an explosive impression without debris throwing. Thus, after blasting continues a complete protection by DUCON®. The DUCON®-Technology is significantly used in walls of existing and new buildings. Due to the thinness of the components, facade constructions are also possible. The building material successfully protected several vulnerable infrastructures such as public buildings, embassies, data centers and nuclear power plants.

Figure 5: Explosion experiments with contact detonation: Reinforced concrete C50/60: Blast hole (left); DUCON: Blast impression, 90 % cross section preservation (right)

Figure 6: Application of DUCON Security as protection walls

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Earthquake protection DUCON®-concrete increases in the form of a shell, not only the resistance of reinforced concrete columns against explosion and impact but also from the effects of earthquakes. The thin shell with DUCON® prevents breakage of the reinforced concrete as a result of explosion and earthquake and thereby ensures the stability of the building structure. Therefore, the protection of high-rise buildings in front of a "Progressive Collapse" is possible. Shell and column-strengthening are available as precast or in-situ concrete in new and existing buildings. Column-strengthening with DUCON® are due to the short installation periods also very economical.

Figure 7: Column strengthening: concept (left), application (middle), final condition (right)

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Figure 8: Investigation oft he loading capacity after contact detonation: Reinforced concrete: 4-15 % (left), DUCON: 50-100 % (middle), graphical overview (right)

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Fragmentation protection Large rooms and halls with cantilevered ceiling areas such as gymnasiums, public buildings, production facilities or buildings with high security requirements such as data centers make high demands on the structural safety. Ceiling structures of conventional reinforced concrete exhibit in the case of component failure (e.g. through explosions) a for humans and the establishment dangerous debris throw. The strengthening of reinforced concrete ceilings with a layer of debris protecting DUCON®-concrete can here lead to a significant improvement in safety. Experiments have shown that debris protective layers of DUCON®-concrete can absorb the local failure of reinforced concrete components from a component thickness of 1.5 cm. The debris protective layer of DUCON®-concrete acts as a safety net, which prevents the precipitation of debris. Persons or highly sensitive facilities can be successfully protected.

Figure 9: DUCON as integrated debris protection layer (Simulation test, scale 1:2, Fraunhofer EMI)

Figure 10: Application of a debris protection layer

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Technical Data Description: Self-compacting micro-reinforced high performance concrete Technical Data: Compressive strength: 100 – 200 N/mm2 Flexural strength: 20 – 75 N/mm2 Centr. tensile strength: 9 – 20 N/mm2 Shear carrying capacity: 3 – 16 N/mm2 Tensile modulus: > 40.000 N/mm2 Bulk density: 25 KN/m3 Elem. thicknesses: > 10 mm Abrasion: Standard mortar: 10 cm3/50cm2 (< 15 cm3/50cm2, class 1)

2,8 cm3/50cm2 (< 15 cm3/50cm2 = Class 1) < 3 cm3/50cm2 = Class A3 (DIN EN 13813 concr. surf.) < 4 cm3/50cm2 = Class F11M (DIN EN 18560 hard material)

Slump factor: > 35 cm (EN 196, Haegermann, extreme fluid) Shrinkage: 0,5 – 0,6 ‰ (without micro-reinforcement: 0,9‰) Fracture energy: Gf = 50 – 80 kN/m (unreinf. concrete 0,1 – 0,15 kN/m) Bullet resistance: FB7: FMJ PB HC with t = 8 cm (DIN EN 1522) Forced entry resistance: RC6 at t = 7,5 cm (DIN EN 1627) Explosion protection: > 1,0 bar at t = 6 cm (endangered facility)

> 10 bar msec impulse at t = 6 cm Further properties: Extreme ductile, i.e. high formability High loading capacity, high impact strength, high energy intake High durability, Crack width restriction High abrasion strength, high frost and de-icing salt resistance

Imperviousness against substances hazardous to water Good heat transfer and –storage capacity, electric conductivity Spatial stiffness regulation Multifunctional, adjustable material properties Components: Random cross sections (e.g. circle-, box-, wave-, t-profiles) Impervious overlays, surfaces, container/cases, pipes, beams Wrapping of weak components (subsequent strengthening) Jointless, pre-cast components, prestress feasible Manufacturing: Placement of micro-reinforcement followed by mortar infiltration Modular design ensures simple, quick and economical application

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Figure 11: Comparison specific values of DUCON, reinf. concrete & fiber concrete (left); concept column strengthening (middle); bending test DUCON (right)

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Research institutions / Consultants Experiments, calculations and surveys were conducted i.a. at following institutes:

Germany / Switzerland

USA

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Investigations of the Fraunhofer Institute for Speed Dynamics (Ernst-Mach-Institute) with DUCON® Security revealed:

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