ULTRA-PANELSInnovative Technology for High Trafficable Concrete Surfaces

ULTRA-PANELS

Introducing Ultra-Panels from Mainmark - Innovative Concrete Technology for High Abrasion EnvironmentsMainmark is the exclusive manufacturer and distributor of Ultra-Panels, an innovative alternative to cast-in-place concrete surfaces and hard stand areas in high abrasion environments. This revolutionary product can be used in various applications and is ideal for rehabilitation and replacement of high traffic and chemically affected concrete surfaces.

Ultra-Panels utilise revolutionary technology that is exceptionally abrasion-resistant and durable, resulting in the ability to withstand extremely abrasive conditions. The Ultra-Panels, which can incorporate steel fibres into the concrete, are also highly impact-resistant and provide excellent

fatigue performance under repetitive loading.

When Mainmark’s Ultra-Panels are installed, high abrasion environments experience a significant decrease in rates of surface loss. This reduces the frequent need for repair and replacement of worn or damaged concrete.

Install Ultra-Panels and take advantage of an innovative product that ultimately will save time and money.

The Ultra-Panels production and installation process is proprietary. They are environmentally inert.

Below: Ultra-Panels being installed at 1400m deep production level in Cadia East gold mine, Orange NSW.

ULTRA-PANELS

ULTRA-PANELS EXPLAINEDPre-fabricated panels are made with Ultra High Performance Concrete (UHPC). This special category of concrete has a minimum compressive strength of 120MPa.

The pre-fabricated Ultra-Panels come in a standard size, though they can be customised to suit specific requirements and conditions, and have an average compressive strength of 140MPa. Ultra-Panels are produced with lifting eyes pre-installed, so they are ready for transportation to the site.

The Ultra-Panels essentially act as wear plates over a cast-in-place concrete base slab, which provides

the necessary structural support to ensure correct distribution of point loads and prevents further cracking.

The extreme strength of the Ultra-Panels, combined with the exceptionally high level of abrasion resistance, results in a product that will last significantly longer than cast-in-place products. Cost efficiency is further enhanced by the quick installation process and the fact that the panels are at full strength when they are installed, so will tolerate traffic in a matter of hours.

Above: Pre-fabricated Ultra-Panels.

ULTRA-PANELS

APPLICATIONS

Mainmark’s Ultra-Panels can be utilised in various industries, across a diverse range of situations and circumstances. Typical applications include concrete roads, driveways, pads, floors etc in:

• Mines

• Wharves, sea bridges

• Scrap yards

• Military facilities

• Tracked vehicle yards

• Blast walls

• Chemicals loading yards

• Refill stations

• Garbage disposal centres

• Dairy facilities or abattoirs

ULTRA-PANELS

Pre-cast panels made with Ultra High Performance Concrete

• Extreme abrasion-resistance of upper surface, for maximum performance

• Extremely wear resistant to high traffic

• Resistant to chemical abrasion

• At full strength when installed, and once grouted, can be used almost immediately (2 to 12 hours)

• Rapid installation process

• Shrinkage cracking will not occur as there is zero heat out-put and drying shrinkage

High level of performance: average compressive strength of 140MPa

• Substantially improved strength of the trafficable surface

Engineered to last longer

• Substantial increase in product life

• Cost effective

• Time efficient

• Reduced downtime

• Increased productivity

• Improved safety

High fatigue resistance • Great increased life under bending loads

Impact resistance• Long lasting in high impact environments

such as scrap metal yards, chemical loading yards and mines

High content of steel fibres(non standard - project specific)

• Resistance to impact and crack propagation

FEATURES BENEFITS

Above: Ultra-Panels being produced with steel fibres and steel mesh.

ULTRA-PANELS

40MPa concrete sample before and after acid

ACID RESISTANCE TEST RESULTS

60MPa concrete sample before and after acid

80MPa concrete sample before and after acid 140MPa concrete sample before and after acid

Above: 40MPa Concrete suffered 5mm loss of surface material with pits up to 10mm deep.

Above: 60MPa Concrete suffered material loss of about 3-5mm, some pits up to 6mm deep.

Above: 80MPa Concrete suffered general loss of surface paste to a depth of 1-2mm, with pitting up to 3-4mm deep.

Above: 140MPa Concrete suffered general loss of surface paste to a depth of 0.5mm, no pitting evident.

• UHPC has a water/binder ratio of 0.18 and very high pozzolan content

• Tests were performed to assess resistance to sulfuric acid

• S16 Molar (98%) H2SO4 was ponded on the surface of concrete samples for 30 hours (changed every 6 hours) and depth of material loss was compared

10 20 305 15 25

10 20 305 15 25 10 20 305 15 25

10 20 305 15 25 mm mm

mm mm

ULTRA-PANELS

SPECIFICATIONS

• Compressive strength: minimum 120MPa,average 140MPa, ultra-high performance

• Standard size: 3m x 4m x 250mm thick(tolerance of +/- 2mm width/depth, +/- 5mmthickness)

• Custom sizes: made to measure, to meetclient’s specific size requirements

Above: Addition of 120kg/m3 of steel fibres can increase resistance to cyclic loading by a factor of at least 100, as shown in the Whöler diagram for mixes produced and tested by Mainmark using flexural panel specimens. This will translate into a much longer service life in trafficable environments.

• Factory produced and cast concrete can includeup to 1800kg/m³ of high strength, abrasionresistant aggregate

• Steel fibre content of up to 160kg/m³ ispossible, to meet specific project requirements

ULTRA-PANELS

www.mainmark.com

AustraliaMainmark Ground Engineering Pty. Ltd.mge.au@mainmark.com1800 623 312

New ZealandMainmark Ground Engineering (NZ) LTDmge.nz@mainmark.com0800 873 835

Mainmark offers unique, innovative solutions for rectifying problems with foundation ground in residential, industrial, commercial and civil engineering situations. For over 20 years Mainmark has led the world in developing and offering the most advanced and accurate systems of geo-polymeric injection techniques for ground engineering. We have successfully treated over 11,000 sites in Australasia, varying from small domestic applications to large commercial, industrial, civil and mining projects. Worldwide, Mainmark has completed many tens of thousands of projects. Mainmark has also expanded capabilities to include other innovative ground engineering and asset preservation solutions. As part of post-earthquake remediation works in both Japan and Christchurch, we developed expertise in technologies such as JOG Computer-Controlled Grouting and Jet Grouting.

Oct16