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Materials

We are material scientists and chemical engineers. We chemically fine-tune every formulation for every individual product. With chemistry, curing conditions and finishing processes we tune concrete products` surface look, touch feeling, color etc ...

We can manipulate almost every physical and chemical characteristic of concrete: density, porosity, air content, temperature stability, shrinkage, strength, ductility, chemical stability, durability.

White and grey Ultra High Performance Concrete (UHPC) with or without pigmentation
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Superfluid UHPC formulation allows filling of thinnest sections in a mold. Extremely high tensile and flexural properties with combination of AR and carbon fibers and mesh reinforcement offer production of thinnest concrete elements.

ECOncrete
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ECOncrete is the most sustainable, greenest binder in the world. This High performance Geopolymer with scientific reference (referenca) is composed of industrial waste materials (95%), giving the ECOncrete almost zero CO2 fingerprint and thus making this outstanding environmental material revolutionary. ECOncrete gains up to 100 MPa of compressive strength and 15 MPa of flexural strength.

High-performance lightweight aggregate concrete (HPLAC)
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High-performance lightweight aggregate concrete (HPLAC) is a lightweight version of UHPC. The UHPC matrix in lightweight aggregates makes this material especially useful in structural elements with visible surface. It offers the same quality of surface finish like UHPC at densities between 1.2 - 2.2 kg/L. This type of concrete is not aerated and there gives us a perfect surface appearance.

Super lightweight cellular concrete is air-entrained concrete with lightweight aggregates. We could get densities down to 500 kg/m3.

High performance heavyweight concrete HPHVC
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High performance heavyweight concrete HPHVC (density up to 4 kg/l) with mineral (Iron free) materials. This material exhibits similar mechanical performance compared to UHPC.

Heavyweight eco concrete with density up to 6 kg/l. This material is based on waste materials from steel production. The binder matrix is very strong and therefore makes this material durable also in outdoor application.

Polymer modified UHPC (PM-UHPC)
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Polymer modified UHPC (PM-UHPC) is a type of UHPC, modified by latex polymer. This type of concrete exhibits improved ductility and therefore a possibility of even tinier structures compared to UHPC. Latex polymer additionally makes concrete more prone to abrasion and environmental degradation.

High temperature resistant sustainable concrete
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This refractory is based on modified calcium aluminate (CA) chemistry. We could reduce the CA cement need (and therefore a CO2 fingerprint of the material) up to 80%. Class I Up to 800°C, Class II up to 1100°C, Class III up to 1400°C.

High performance gypsum
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High performance gypsum is an outstanding material, usually used in dental practice. Our special chemical formulation achieves abnormal 20 MPa of flexural strength. Together with ability of non-shrinkage, this material offers production of super thin products bellow 1mm.

Technologies

We have developed our own technologies for mixing, casting, reinforcing, finishing and production. With these state-of-the-art technologies, we could produce outstanding products with superior quality, cutting edge design and production capabilities.

High-shear vaccum mixing of fine granulated concrete
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Mixing of concrete with very small size of aggregates (< 1 mm) usually results in small clumps of unmixed powder materials. These clumps make defects on concrete product surface. Using adequate mixing technology for very fine concrete is thus essential for high-quality esthetic products. Moreover mixing of concrete inevitably entraps air into the concrete mix. Most of the air in naturally deaerated from liquid concrete mix, but small air bubbles up to 10vol% remain in the mix. This air makes not only esthetic problems in a concrete product but also substantially reduces mechanical strength. Therefore we have developed our own, innovative vacuum planetary mixing technology, allowing us to mix concrete in compete deaerated vacuum.

Vacuum mixing of concrete formulation prevents air to be entrained in the mix during the mixing process. This technology gives us a perfect concrete surface even with thixotropic mixes with fiber reinforcement. With absence of air bubble we achieve homogeneous surface, much greater concrete quality and bleeding free formulation.

Besides vacuum mixing we also vacuum cast the concrete. This procedure is used when we would like to get a product with negative angles completely without bubble at any of product's surfaces.

Robotized production of concrete products
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We have set up the world’s first robotized unit for producing concrete products. We have used a Fanuc robot, known especially in automotive industry. With our robotized cell we cast the molds, cure, demold, brush, polish and collect the products. Robot also automatically clean and oil the molds. Production capacity of the robot depends on the product sizes and material used (curing time). With some of our products we have a capacity over 1.000.000 p/y, and realization of 800.000 p/y.

A crucial part of the robot unit is a dosing device. With this, in-lab developed machine we could dose four channels almost every consistency of the concrete with the speed of up to 200 g/s of the concrete for all 4 channels at once.

Molding: 3D printing of molds 3D cutting in PU or MDF
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For almost every mold we start from the positive (prototype, original…), which is 3D printed, CNC or made by artist. We could print in several 3d techniques, like FDM, SLA, SLS ... The maximum 3d printed part is cca 500x500x500mm, depends on the 3d printed technology.

Depend on the shape of the product and production quantities we choose the mold material. Usually the silicon or PU is used, for larger series we use sprayed plastic molds.

Colors/Pigmentation
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Natural color of the concrete depends on the natural color of the binder and in minor extent also on the color of fine aggregate. Natural color of the binders are usually from brown (CA 40), grey brown (like CEM I), grey (CA 50 cement), white (like CEM I white cement, CA 70) yellowish or white bluefish. The color of concrete is furthermore a consequence of hydration reaction and curing conditions and concrete rheology.

For colored concrete we add pigments and supplementary materials (like wetting agents). We use special inorganic pigments, which are stable in outside environment (the color does not change over time). We have developed a palette of very special pigments which are (unlike the FexOy pigments) very vivid. Our specialty are the brightest and the most vivid colors in concrete technology like yellow, red, green, blue, violet and the blackest possible concrete color.

Reinforcement
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Fiber reinforcement

We could reinforce all the materials described above with several different fibers. The choice which type of fibers we use depends on the final characteristics of the product. We use steel, stainless steel, flexible alloys, basalt fibers, AR fibers, carbon fibers in different lengths and thickness.



Mesh reinforcement

We use steel, stainless steel, AR mesh and carbon-fiber mesh in different dimensions and qualities.



Geotextile fabrics

We use several formulations in combination with textiles, like alkali resistant fabric, non woven PP or carbon-fiber geotextiles, to produce very thin structures (1-5 mm). Final products are strong, stable and prone to freezing.

Finishing
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Finish of the final product depends on the several parameters:

  • finish of the original positive from which the mold is done
  • material (concrete type) used
  • curing temperature of the product and shrinkage
  • finishing process, like polishing with pads
  • coatings and densifiers

Shiny surface

  • mirror like
  • polished

Matt surface

  • well defined laser engraved
  • sandblasted
  • etched

Coatings

We use several different coatings to meet the desired surface quality, like edible surface, hydrophobic surface, oleophobic surface, decreased porosity of the surface, touch feeling.