HYPERCON technology: redefining UHPC production

What makes HYPERCON technology unique

HYPERCON ensures efficient UHPC production through a streamlined three-step process. First, an AI-driven software designs the UHPC mix, optimizing the packing density of particles for superior performance. Next, raw materials are precisely milled and sorted to meet the designed specifications. Finally, the UHPC mix is produced, delivering high-performance concrete consistently and with minimal waste.

HYPERCON utilizes AI to develop customized UHPC mixes tailored to specific project needs, optimizing UHPC performance, profitability, and sustainability. By continously monitoring and maximizing the packing density of all mineral components, including cement and fines, the technology ensures the ideal balance of strength, workability, and resource efficiency while reducing costs and environmental impact.

HYPERCON enables the production of UHPC directly at the construction site or at the precast elements manufacturing plant, reducing transportation costs, minimizing emissions, and ensuring fresh, high-quality material. This flexible approach supports both large-scale infrastructure and customized architectural projects, while enhancing cost-efficiency and sustainability.

Customized and convenient UHPC production

HYPERCON technology processes raw materials based on the client’s available resources, ensuring a customized UHPC mix. It also enables UHPC production at the clients' site, giving clients full control over manufacturing and allowing them to produce UHPC on demand, not limited to a single application. This flexibility supports a diverse range of projects and products, adapting to specific design and performance requirements.

Substantially more cost-effective UHPC mixes

UHPC mixes produced with HYPERCON technology are up to 70% cheaper than traditional UHPC ready-mixes. Cost savings come from upcycling byproduct materials, reducing cement content, and enabling on-site production, which minimizes transport and logistics expenses. By optimizing mix design, production, and supply chains, HYPERCON makes UHPC both accessible and cost-effective, even compared to standard concrete.

Sustainable concrete and circular economy

HYPERCON technology not only enables on-site production and the upcycling of byproduct materials into UHPC aggregates but also significantly enhances sustainability. By reducing transportation needs, it lowers the environmental footprint of UHPC production. Additionally, UHPC structures require up to 75% less material than traditional ones, improving resource efficiency, while maintaing superior performance. 

Step 1: AI-driven mix design

HYPERCON designs UHPC mixes tailored to customer needs, optimizing for highest product quality and performance, maximum cost-efficiency, and minimum environmental impact. To achieve that, in a first step, the packing density of all mineral components is maximized. 

Step 2: Raw materials preparation

HYPERCON uses the mix specifications designed in Step 1 to prepare the raw materials, using milling and sorting equipment from partners. During the milling process, the target material fractions are continuously separated, while the coarse are returned to the mill.

Step 3: UHPC mixing

Lastly, the raw materials are mixed in a high-performance mixer from our partners, Eirich, and controlled by the HYPERCON software. This advanced mixing process ensures optimal particle dispersion, achieving a homogeneous and highly workable UHPC mix with superior strength and durability.

Step 4: Pressure casting of UHPC

HYPERCON pressure casting optimally balances flow properties and ultra-high strength by precisely controlling the water-cement ratio. Initially, the UHPC mix contains enough water to ensure smooth and even filling of the most complex molds. Then, immediately after filling, the mold is pressurized, forcing excess water through a fine filter until the ideal water-cement ratio is achieved, ensuring the desired compressive strength.

Step 5: Curing of pre-cast UHPC elements

Curing plays a key role in achieving full strength and durability of precast UHPC elements made with HYPERCON-produced UHPC. It supports proper hydration, reduces shrinkage and cracking, and enhances strength parameters and resistance to environmental stresses. Humidity and temperature are controlled and optimized to support the curing process. Steps 4 and 5 are seamlessly integrated into the HYPERCON production process, beginning with the optimal mix design to ensure every UHPC element achieves maximum performance and longevity.

Minerali Industriali Engineering (MIE) specializes in designing and building plants for processing of industrial minerals and recycling of non-hazardous waste. With 100 years of experience, MIE offers turnkey solutions, from geological surveys to plant construction and customer support, promoting sustainability in industries like glass, ceramics, and chemicals.

Eirich is a global leader in mixing and processing technology, specializing in industrial mixers, granulators, and material preparation systems. With over 150 years of experience, Eirich serves industries like cocnrete, ceramics, metallurgy, and batter production, offering innovative solutions for efficient and high-quality material processing.