Modern infrastructure is changing faster than ever

Hydrogen plants, battery storage systems, data centers, and high-density industrial facilities are introducing new risk profiles—particularly in terms of fire, thermal exposure, and explosive events.

Yet, the materials we rely on for protection have largely remained the same.

Steel, conventional concrete, refractory linings, and coatings are still treated as separate systems—each solving only part of the problem.

This fragmented approach is becoming a critical weakness.

The Problem with Conventional Protection Systems

Traditional materials behave predictably under normal conditions—but not under extreme ones:

• Steel rapidly loses structural integrity above ~500 – 600 °C
• Standard concrete suffers from spalling and cracking under thermal shock
• Refractory materials handle heat but lack structural performance
• Coatings and fireproofing layers degrade over time and require maintenance

As a result, protection systems often become:

• layered
• complex
• expensive to maintain
• and vulnerable at their interfaces

In critical infrastructure, these weaknesses are unacceptable.

A Shift Toward Integrated Protection

What if protection was not an added layer—but part of the structure itself?

This is the concept behind WPE-DK ThermoShield®.

Rather than combining multiple materials, ThermoShield® is engineered as a single, mineral-based high-performance system that integrates:

• Structural capacity
• Fire resistance
• Thermal shock stability
• Blast and impact resilience 

 

Material Engineering Approach

ThermoShield is based on an advanced UHPC (Ultra High Performance Concrete) formulation, enhanced with:

• Ceramic microfillers (e.g., Al₂O₃, SiC) for high-temperature resistance
• Fiber reinforcement to prevent brittle failure and reduce spalling
• Dense microstructure to minimize permeability and thermal damage
• Optional energy-absorbing layers for blast mitigation

The result is a material capable of operating across a wide range of extreme conditions.

Performance Profile

• Temperature resistance: up to ~1200 °C (peak exposure)
• Thermal shock resistance: stable under rapid temperature changes
• Compressive strength: 130 - 200 MPa
• Fire classification: non-combustible (A1)
• Failure behavior: ductile rather than brittle
• Durability: long-term resistance to chemical and environmental exposure

Unlike conventional systems, ThermoShield® maintains structural integrity under thermal stress, rather than merely delaying failure.

Application Areas

The need for integrated protection is growing across multiple sectors:

Energy Infrastructure

• Hydrogen production and storage
• Battery energy storage systems (BESS)
• Substations and transformers

Industrial Facilities

• Refineries and chemical plants
• Pyrolysis and high-temperature processes
• Manufacturing zones with fire risk

Defense & Security

• Protective walls and shelters
• Ammunition storage
• Critical asset protection

Infrastructure

• Tunnels and transport systems
• Data centers
• High-risk logistics hubs

From Passive Construction to Active Protection

The key shift is conceptual:

From building structures that need protection → to structures that provide protection.

By integrating thermal and mechanical resistance directly into the material, ThermoShield® reduces:

• system complexity
• maintenance requirements
• and failure risk at interfaces

Why This Matters Now

The transition toward renewable energy, electrification, and decentralized infrastructure is increasing both risk density and consequence of failure.

In this context, materials are no longer just structural components—they are risk mitigation systems.

As infrastructure evolves, so must the materials that protect it. 

 

www.wpe-dk.com

ber@wpe-dk.dk