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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 Architectural & Design

In addition to the use as security concrete, for what DUCON was originally developed, this innovative
high-performance building material allows a new style of the design for buildings and components
due to its high ductility and low component thickness. Form and function unified in the building
material DUCON.

DUCON-Concrete is an enrichment for architects worldwide. Not least because of its high flowability
the building material covers the demands of planners to perfect and flawless components in various
forms and colors.

DUCON complements the formal language of architecture in concrete engineering impressively by

filigree and extreme plasticity: roof structures, pillars, cantilevered beams, such as canopies or
balconies, can be created in new shapes and dimensions. Step elements, such as stairs or precast
tribune components can be created with extremely thin cross sections at the highest strength. Here
DUCON will also meet the high demands on surface optics of visible concrete parts. These can be
customized in different colors and textures such as marble structures. Mat, rough, shiny to reflecting
surfaces top the variety of surface optics off. Another benefit is the reduced building volume
compared to other building materials, which leads to a reduction in construction costs, including in
the topics formation and transport.

Figure 2: Textured table (left); Sun protection blade (right)

The increased demands in safety, not only since September 11, 2001, can be harmonized with
fashionable architecture by the patented DUCON-Technology. Modern skyscrapers with DUCON
building cores will have a much higher stability and resistance to external impacts than before.
Facade cladding as protection for vulnerable buildings can be executed subsequently. The DUCON-
Technology in this case ensures that items with large component thicknesses have become obsolete.
Thin, curtain and customizable facade panels are completely feasible.

DUCON-concrete, a feat in form and function for Architecture & Design in present and future.

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Energy facades

By the thermal activation of DUCON-panels through incorporating capillary tubes into the micro-
reinforcement the DUCON-Technology gets another interdisciplinary property. Thereby DUCON-
plates become an active part of a production system in the field of energy management.

This innovative feature uses already the unique research project ETA-Factory (Energy-Efficiency-,
Technology- and Application-Center) of TU Darmstadt. The research project examines representative
production plants of metalworking under energy efficiency aspects. In addition to the energy
improvement of individual production plants, the primary aim is to network the periphery of the
production plants, the building services and the building envelope to enable further energy-savings
and -efficiencies.

Figure 3: The ETA-Factory of the Technical University Darmstadt at the location Lichtwiese Eibe Soennecken

The outer shell of the ETA-Factory is made out of 11 m long and 5.5 cm thin DUCON-panels with
thermal activation. Due to the good heat conductivity and high heat storage capacity of concrete the
DUCON-panels are suited as an effective cooling surface in winter and summer (by wetting with
collected rain water and the following evaporation effect).

The evaporation effect causes on summer days with a daily maximum temperature of 33 C and a
temperature level of the supplied heat transfer medium of 40 C a cooling capacity of 386.4 kWh (at
280 m2 activated surface; 6:00 to 18:00 pm). At night, the cooling capacity was 537.6 kWh. Thus the

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daily cooling demand of the production of about 100 kWh is covered by a multiple. In the transitional
periods the DUCON-panels support heating as a massive absorber.

In this form DUCON-panels contribute actively in an interdisciplinary energy management.

Figure 4: Manufacturing with capillary tubes (left); Dimension of an activated DUCON-Panels (right)

Figure 5: Ceiling of the ETA-Factory (left); Thermal image of an activated DUCON-Panel (right)

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Figure 6: Entrance of the ETA-factory (left) and close shot of one facade element (right) Eibe Soennecken

Figure 7: Side view of the ETA-factory, slenderness of one element = 200 (left), entrance (right) Eibe Soennecken

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Panels, Stairs & Free Forms

DUCON enriches the design language of architecture impressively by unique delicacy and extreme
formability in the segment of concrete construction.

Roof constructions, pillars, cantilevered components such as porches or balconies can be developed
in new forms and dimensions. Step elements for stairs or precast stands can be created with
extremely thin cross sections with highest strength at the same time. Facade elements can be
handled with component thicknesses of 4.5 7 cm. Folded plate staircases have a component
thickness of 9 - 13 cm and 3D Bench systems of 1 5 cm.

Simultaneously, the high demands on surface appearance for visible concrete parts are met. The
surface appearance is individually adjustable. The range covers from different colors to the most
varied patterns such as marble structures. Mat, rough, shiny or reflective surfaces top the variety of
the range off.

The planning department of DUCON processes requests from clients regarding the technological
feasibility of precast concrete elements or complete construction performances and creates
appropriate offers. Using the latest CAD technology sophisticated building plans are carried out to
realization. The final design involves the DUCON-Technology technically and creatively perfectly into
future buildings.

Figure 8: DUCON staircase t = 8 cm, l = 4.3 m, cantilevered (left); Comparison DUCON vs. reinf. concr.
staircase (right)

Figure 9: Free forms (left); Various colours and structures (middle); Smooth surface (right)

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Figure 10: Concrete-facade at Liberty Park, WTC NYC (left); Installed planter at Liberty Park (right)

Figure 11: View of Liberty Park, 9/11 Memorial and the St. Nicholas Shrine (under construction))

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Figure 12: DUCON Planter in front of the 1WTC (left), DUCON concrete seats (middle), close shot (right)

Figure 13: Topview and disposal of the four big DUCON Planters in the park

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 Figure 14:Architecture: White-concrete free-form DUCON-panels, t = 7 cm, panel shape: 7.5 m x
2.8 m

Figure 15: After completion: Concrete with marble-aggregate, grounded and polished

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 Figure 16: Black staircase (left); DUCON arch t = 1.5 cm (right)

Figure 17: Filigree and monolithic entrance portal, t = 7-10 cm, h = 4 m, l = 4.3 m

Figure 18: Various surfaces (left); Curved facade elements (middle); Chimney (right)

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 Figure 19: Ceiling membrane as Smoking mushroom, = 2 m, t = 3 cm

Figure 20: Vineyard house, wall- and ceiling thickness = 3 cm, building components stucked and
cemented; TU Kaiserslautern, Innovation price Rheinland-Pfalz 2011

Figure 21: Ceiling membrane Parapluie: Thin panel, t = 2,5 cm, l = 3 m, b = 2 m

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Furniture & Surfaces

The unique properties of the DUCON-Technology creates completely new application fields for
designers. The manufacturing of products, which are normally realized from other materials becomes
possible by DUCON-Concrete. Furniture such as tables, chairs, washroom- and kitchen-panels,
stairs, etc. are executable through DUCON-Concrete. There are no limits to shape, color and surface.

Smooth, reflective surfaces can be adjusted by the combination of self-compacting DUCON-Mortar

and a specific formwork. The combination oft he specific formwork and DUCON-Mortar makes even a
post-treatment of the concrete surface obsolete. Of course, other surface structures are conceivable.

Figure 22: DUCON table in restaurant (left); DUCON vanity (right)

Figure 23: DUCON chair (left); DUCON kitchen counter (right)

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DucoGlass & DucoStone

With DucoGlass & DucoStone arises the combination of concrete with glass or natural stone. Glass
and / or natural stone can form the design elements, for example of a facade while DUCON-panels
take the load-bearing- and protective-function (see DUCON Security).

The application areas of DucoGlass reaches from buildings with glass facades to pipes with glass
lining against chemical attack up to design elements, such as table- or facade-panels.

DucoStone is similar compound component as DucoGlass. The natural stone can be installed in
large formats and thin-walled. Application areas are buildings with natural stone facades and design
elements in the construction industry.

Figure 24: DucoGlass

Figure 25: DucoStone

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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 pprotection: > 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

Figure 26: DUCON: Material properties new defined: Thin, flexible & high loading capacity
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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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