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.

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

Figure 3: Explosion protection by DUCON and reinforced concrete

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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)

Close range
Rest bearing capacity [%]

Contact

RFConcrete DUCON DUCON DUCON

Confinement1 Confinement2

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
DUCON
Reinforced Concrete (RFC)

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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