Sika® Unitherm® Platinum – Sustainable and cost

INTERNATIONAL
Issue 1 | 15
SikaKorroNews
Magazine for Corrosion-, Tank- and Fire Protection
The new Sika Liquid Plastics R & D Centre in Preston
Sika® Unitherm® Platinum –
Sustainable and cost-effective for the future
The success story of an innovation
Steel structures can’t burn, but under the impact of fire they can lose their load-bearing capacity, and thus their static stability, within a few
minutes. The function, profile, thickness and material of the steel parts are decisive for the required structure and the application of the fire
protection coating. Sika® Unitherm® Platinum offers absolutely new solutions for steel fire resistant coatings, since in addition to its conventional function it has further outstanding properties that allow fire protection coating in the factory.
General function of fire protection
coatings:
In case of fire the original coating only
millimetres thin turns into a thick, micro
porous foam like layer that insulates
the steel surface against heat. The fire
resistance duration of beams, columns
and frame members in the interior and
the façade of buildings is thus increased.
Special features of Sika® Unitherm®
­Platinum:
Sika® Unitherm® Platinum is a solvent-­
free, epoxy-resin fire protection coating
R 30 – R 120 for steel components for
indoor and outdoor use. A film thickness
of up to 4 mm is possible per work step.
The wet film thickness corresponds to
the dry film thickness. Sika® Unitherm®
Platinum is classified according to ETAG
018-2:2006 type X and its fire protection behaviour according to B-s2, d0 ­(EN
13501-1). In addition, the steel fire pro-
SIKA® UNITHERM® PLATINUM AT A GLANCE
Uses
• S
olvent free, maximum build two pack modified epoxy fire protection ­coating
for steel components in interior and exterior areas
• increases the fire resistance rating of beams, columns and frameworks
for interior and exterior use
• In case of a fire Sika® Unitherm® Platinum forms an isolating layer which
­improves the fire resistance rating (R 30 – R 120) of steel components
• Advantageous for shop application
Advantages
• F ilm thickness up to 4 mm per application
• 1 00 % total solid state, wet film thickness = dry film thickness
• H
igh mechanical impact, shock and abrasion-resistant,
•
•
•
•
•
therefore no transport damages
S
hortest application and drying time
S
hop application under defined climatic conditions
A
pplicable with or without primer
A
pplicable without top coat in interior and exterior areas
C
leaning of the coated surface possible with a high-pressure water jet washer
tection system has been independently
tested in accordance with EN 13381-8.
A top coat is not necessary. Also, the
steel fire protection system can be applied both with and without a primer,
tailored precisely to the different requirements by adapting its thickness
and build-up.
In the Sika Liquid Plastics R & D ­Centre
in Preston, for example, no ­primer or top
coat was used; the 1,200 m2 three-storey building is protected by Sika® Uni­
therm® Platinum only. The new R & D
Centre is modern and equipped for the
needs of the employees and their research, and partly replaces a 100-yearold single-storey warehouse on the Sika
Liquid Plastics site.
One of the first and at the same time
one of the largest projects to be coated with Sika® Unitherm® Platinum was
the extension building of the wellcontinued page 2
2
KorroNews INTERNATIONAL 01 | 2015
JUST A WORD
Dear KorroNews readers,
‘The most strange thing with the future
is that one day it will be called the good
old days.’ Let me begin with this quote by
Ernest Hemingway to introduce you
to what we are currently dealing with
in this new edition of KorroNews – we
are intensively developing in the present,
using proven elements from the past,
in order to above all fulfil our respon­
sibilities for the future. There are, for
example, two brand-new products,
Sika® Uni­therm® Steel W-60 and
Sika® Unitherm® Steel W-120, innovations from the waterbased research line
of our developers. At the same time we
fall back on known elements, modifying
or expanding their efficiency: The characteristics of our reliable SikaCor® PUR
Color and SikaCor® PUR Color Thixo types
were bundled and developed ­further to
make our SikaCor® PUR Color NEW. The
extension of our approval portfolio by the
new Sikalastic®-827 HT in combination
with SikaCor® HM ­Primer and SikaCor®
HM Mastic shows how the strength of
traditional products is enhanced by new
developments. The other articles of this
current K
­ orroNews describe how our customers are writing their success stories
today with Sika products – whether proven or innovative. On this note I would like
to thank you for the excellent cooperation
in 2014 and wish you all the best for 2015.
Thomas Kerkmann, Head of Sales and
Marketing Industrial Coatings, Germany
CONTENT
Sika® Unitherm® Platinum
The success story of an innovation
News
Sika products – proven or innovative
SikaCor® Elastomastic® types
Renovation of the intersection at
Frankfurt-West railway station
Bridge construction in the Chiemgau
Germany’s first heatable steel bridge
The Pretziener Wehr
A technical masterpiece
Offshore Wind farm Butendiek
First park with solvent-free coating
News – New product development
SikaWindServiceTeam
Always there for you, even offshore
Sealing of the ‘Berliner Brückenzug’
by a new system on steel
without buffer layer
Sika’s New Website –
Simple, fast and practicable
The Industrial Coatings
export department
Your contact – all over the world
1 – 3
3
known Swiss freight forwarder Galliker
in Nebikon (Switzerland). The existing
vehicle depot in which cars and trucks
are prepared was to be extended into a
six-storey building within a very short
time. 32,000 m² of steel had to be coated
according to the requirement R 30 because of the long escape routes in case
of fire.
The 2-pack Epoxy formulation of Sika®
Unitherm® Platinum* is capable of bearing high mechanical loads as a workshop coating, withstands all weathering
when applied with primer and top coat*
and can be transported and assembled
after just 24 hours thanks to it's fastcure properties. This simplifies and accelerates the building process compared
to conventional 1-pack fire protection
coatings which need to be applied on
site due to their physical characteristics.
In this project, coating in the factory,
loading and assembly took place continuously, allowing completion of the project within 24 weeks. On average about
350 m² were installed each day.
Extended Car Logistics building of the Galliker freight forwarding company
Sika® Unitherm® Platinum is highly dura-
ble and resistant to impacts, shocks and
abrasion. This allows the coated steel
components to be taken to the desired
destination without transport damage
following coating in the factory. Storage
in the open air is also possible. This is
shown by the Bad Vilbel library project,
in which steel beams and columns coated with Sika® Unitherm® Platinum were
stored for some time on the river bank
where the library was to be built as a
bridge over the Nidda river. The patina
was removed simply and quickly using
water jet. The construction of the bridge
connects the newly created town square
and the spa gardens with each other in
order to create a new centre for public
life.
24 hours after coating the components are mounted
This interesting building is shaped by
distinctive, modern architecture and a
Sika® Unitherm® Platinum* offers fire circular geometry. With a diameter of
and corrosion protection in one and has almost 85 m and a height of 16.5 m, the
been tested according to DIN EN ISO arena seats up to 4,500 spectators. The
12944 for corrosivity class C5 M/I.
construction of the new ice rink was
Since ice rinks are exposed to special completed in late 2012 after only few
weather conditions, various ice rinks months. The hall support structure conhave been coated with our innovative sists of fish-belly-shaped frame girdproduct, for example 600 m² of steel ers spaced at distances of 5 m to each
at the Ilfis ice rink in Langenau (CH) other, resulting in a steel consumption
or 4,000 m² of steel at the EgeTrans-­ of around 65 to 70 kg per m². Sika®
Arena in Bietigheim-Bissingen (GER). Unitherm® Platinum received a top coat
of polyurethane based SikaCor® EG-5 in
RAL 5012. The visible construction thus
has a radiant blue appearance.
International demand has constantly increased since the introduction of the innovative product. Many different structures have already been coated with
the Sika® Unitherm® Platinum steel fire
protection system, so that many experiences have been amassed. Very recently
completed or current projects include,
4 – 5
5
6 – 7
8 – 9
Cleaning with high-pressure cleaner
9
10
11
12
12
Municipal library in Bad Vilbel
The exhibition hall 3A in Nuremberg
for example, an airport in Tanzania, a
clinical centre in Belgium (800 m²), a
port in Cuba (2,500 m²), the Tech-Center
in Hamburg-Finkenwerder (10,000 m²),
the AOK Stadium for the women’s football team in Wolfsburg (3,800 m²) or the
Nuremberg Exhibition Centre (600 m²).
(Further references can be found in the
overview table.)
Rebecca Blum, DHBW-Student
Sika® Unitherm® Platinum* offers costeffective and sustainable solutions for
the protection of steel against fire.
*Sika® Unitherm® Platinum
in the coating system:
ategories of corrosivity
C
according to DIN EN 12944:
• W
ithout primer and
without top coat: C3
• W
ith primer and with top coat
up to C5-M / C5-I
KorroNews INTERNATIONAL 01 | 2015
3
Further references for Sika® Unitherm® Platinum
• Audi AG, new multi-functional hall, Györ (H); 4,500 m²
• Hella Sonnen- und Wetterschutz GmbH, Abfalterbach (AUT); 600 m2
• Lely,new steel construction, Maassluis (NED); 6,000 m2
• NS Vastgoed retail trade, new building, Haarlem (NED); 250 m2
• Chemiepark Marl, CDT plant, Marl (GER); 6,000 m²
• Sika Liquid Plastic, new building, R&D Centre, P
­ reston (UK)
• RFC Dormo, new steel construction, Borculo (NED); 2,500 m2
• Nuremberg Exhibition Centre, new Hall 3A, Nuremberg (GER); 600
• Porsche AG, new multi-functional hall, ­Stuttgart (GER); 4,000 m²
• Z
entrum für Angewandte Luftfahrtforschung (ZAL) GmbH,
ZAL-TechCenter, Hamburg Finkenwerder; 10,000 m2
• etc.
KEY ACCOUNT MANAGEMENT FIRE PROTECTION
Sika fire protection experts have gained a wide
range of experience through many years of involvement in projects within Europe. These experts are
ready to assist you – whether you are an architect,
a planner, a fabricator or responsible for creating
tendering documents – when you need an individual
fire protection solution Sika can help:
Marius Gulyas-Carciu
KAM Corrosion and Fire Protection Intercompany
gulyas-carciu.marius@de.sika.com
+ 49 (0) 171 7640553
Ice rink EgeTrans-Arena
News
PRODUCT OPTIMISATION
SikaCor® PUR Color NEW
This coloured, robust and fast-hardening
corrosion protection for steel structures
is particularly suitable for stationary
working and for dry film thicknesses of
80 microns to 160 microns in a single
work step. The addition of 1 % by weight
SikaCor® PUR Accelerator will achieve
a very fast onset of hardening and
through-hardening.
Most recent reference:
• Porsche Leipzig, factory extension
Panamera G2, about 156,000 m²
Product features / Benefits
• 1-coat system directly on steel
• U V- and weather resistant
• Tough-elastic and solid,
non-brittling
• Shock and impact resistant
• Excellent chemical resistance
• Fast curing, even at low
­temperatures
• U
nger Stahlbau Ges.m.b.H.
A-7400 Oberwart, about 156,000 m²
• Stahlbau Brehna GmbH
D-06796 Brehna, about 25,000 m²
NEW PRODUCT DEVELOPMENT
Sika® Unitherm® Steel W-60 and
Sika® Unitherm® Steel W-120
– a brand-new generation of water
borne fire protection products
The water-based fire protection coatings from Sika Deutschland GmbH are
free of halogens and aromatic solvents
and are thus qualified for sustainable
construction.
These products are non-statically-­
loading and are very well suited to
strongly structured components and
design-oriented shapes.
Product features / Benefits
• N
ew binding agent technology
• Very fast drying (faster than
solvent-based systems)
• V
OC 0 g/l
• S
upports the highest DGNB stage
• S
imple application
• W
orkable down to +5 °C
• L ow film thicknesses, hence very
economical
4
KorroNews INTERNATIONAL 01 | 2015
SikaCor® Elastomastic® types
Renovation of the intersection at Frankfurt-West railway station
The renovation of the Deutsche Bahn track system is always associated with time pressure. It was no different when it came to renewing
the tracks at the Frankfurt-West railway station, where the corrosion protection of two single-track ballast-trough bridges was renewed.
The biggest challenges here were very short time frame for the renovation, the geometry of the structure, the time-consuming accessibility
and an extension of the order at short notice. The two carriageway slabs also had to be renovated during the same period due to massive
damage that only became apparent during the first building sequence.
On the basis of the project described, a
digression regarding the requirements
for possible protective systems should
be allowed at this point
Project description
Section 3611
Frankfurt main station (low) –
Friedberg
km 3.381 – km 3.679 (track 1 / 11)
km 3.381 – km 3.673 (track 2)
Steel-trough bridges are designed for a
service life of about 100 years. Once the
ballast is in place, the coating system
underneath is no longer accessible and a
possession means complex and expensive restrictions to the timetable. All the
more important, therefore, is a permanent functionality of the corrosion protection.
2-track intersection built in the
1960s, the overall length of the
2 throughs is approx. 550 m.
grade. Only special companies with a
great deal of know-how and equipment
are able to process the hot-spray grade
with its very short curing time of 6 hours
and a pot life of about 90 seconds.
Optionally, a priming coat can be applied
in order to quickly and promptly protect blast-cleaned steel surfaces from
weathering.
Both coating types have proven themselves over a period of many years and
have established themselves on the
market as German Sheet 84 Appendix
in TL/TP-KOR-Stahlbauten.
The Deutsche Bahn demands that the
respective coating systems exhibit very
high resistance to wear and at the same
time elasticity, because freight trains
exert a high pressure on the ballasted
track and thus a point-load on the coating system. Intensive vibrations with
different frequencies are generated by
high-speed trains. The structure and
thus the coating system must be able
to permanently withstand these loads
over the whole year – at very low temperatures in winter and very high temperatures in summer.
Planning
For this project it quickly became clear
that only the polyurethane hot-spray
grade could be used, as the possession of the structure was limited to 38
days. The epoxy-polyurethane variant,
­SikaCor® Elastomastic® TF, is very robust
and economical with its consumption
of around 4.0 kg/m² for a thickness of
4 mm when applied manually, however the material is mechanically loadable
only after 24 hrs. In the case of SikaCor®
Elastomastic® HS, considerably more
material is required – approx. 6 kg/m² –
and at least a plural airless equipment
for the application, but the ­significantly
shorter curing time of 6 hours enables
secure planning of the building sequence.
In addition, accessibility is greatly limited, so that repairs are only possible with
higher expenditure. The Deutsche Bahn
therefore demands a 50-year protection
period instead of the usual 25 years.
Present-day coating systems are able
to do that, as is also proven in practice
when professionally applied.
The requirements for wear-resistance
are simulated in the laboratory by
means of short-term tests. These include checking adhesion after alternating hot/cold loads and the fatigue limit
with ballast. These testing methods are
described in Sheet 84 and in future in
DBS 918084.
Sequence of work
In Germany the corrosion protection of
steel railway bridges has undergone an
intensive transformation in the past –
from 2 to 5 cm-thick bitumen layers
(mastic asphalt covering) and protective concrete to combinations of tar and
epoxy, although tar has been replaced
on account of its carcinogenic effect by
polyurethane as a co-binding agent for
the German Sheet 84 formulation according to TL / TP KOR-Stahlbauten.
The following demands were made in
the 1980s of a new present-day system,
Sheet 84 Appendix:
1. High fatigue limit under the ballast
load and at the same time higher
­elasticity, i.e. no perforation of the
coating system by the ballast
2. Fast-cure coating materials, hence
shorter construction sequence, i.e.
­reduced possessions.
3. Simpler application, i.e. spraying
method or manual application without
power float at low temperature.
Re-coated ballast-trough
Intensive development took place in the
1980s on the basis of these specifications, basically producing two different
coating systems:
1. Solvent-free epoxy resin with
­polyurethane as co-binder:
SikaCor® Elastomastic® TF
and
2. Pure, tough elastic, solvent-free
polyurethane:
SikaCor® Elastomastic® Airless and
SikaCor® Elastomastic® HS
While the epoxy-polyurethane variant
is still mixed and broadcasted with
quartz sand, or just broadcasted and
predominantly installed by hand, the
polyurethane coating is applied by airless spraying.
The epoxy-polyurethane mortar has a
significantly higher content of binder
than Sheet 84 asks for, it is robust and
flexible, so that the formation of cracks
is avoided.
The polyurethane coating system requires greater care with regard to surface cleanliness where moisture and
care of the spraying equipment are concerned. At the same time, one should
not disregard the high investment in the
equipment either.
The polyurethane system is available
as a slow type, which can be processed
using a powerful airless device with a
flow heater, and as a so-called hot-spray
Contrary to the original planning, the
work sequence had to be completely changed after the removal of the
ballast, since the base not only had
to be partially repaired, but an additional 1,490 m² had to be stripped and
4,000 μm² re-coated with SikaCor®
Elasto­mastic® HS – this with an UNCHANGED time period of 22 days for the
works. Due to weather conditions, the
contractor Mssrs. Litterer effectively
had only 19 days for surface preparation
and protection.
Execution of work
The existing, old protective system adhered better in some places than others. Sometimes it could only be removed
with an high pressure water blast robot
(approx. 1,600 bar) and at the corners
with hydraulic chisels.
Following stripping, the wall surfaces
were conventionally blast-cleaned with
abrasives (Asilikos). The bridge deck surfaces were treated using a shot-blasting device with the addition of grit in
KorroNews INTERNATIONAL 01 | 2015
5
order to achieve the required roughness.
The preparation degree Sa 2½ grit and
coarse was demanded according to EN
ISO 12944-4. On average, 14 employees
from the contractor Litterer worked in
two shifts, plus one or two setup teams.
notice. The total amount of material
consumed was around 15 tonnes. The
project was a challenge for everyone involved in terms of time!
In each of the two troughs there was a
mobile enclosure made of a scaffolding
structure with noise-insulation panels
and tarpaulin seal of about 33 m length.
In order to be able to strip and coat
continuously, the enclosure often had
to be moved and rebuilt, since the two
troughs were not straight, but curved.
Special constructions were used at the
station and over the points.
Despite regular maintenance, a second
plural spray equipment was kept on site
for security so as not to endanger the
schedule if the equipment should fail.
Since the coating area increased from
about 2,100 m² to roughly 3,600 m²,
Sika had to produce a further 9 tonnes
of ­SikaCor® Elastomastic® HS at short
The supervisors had to examine and
release each blast-cleaned surface area
before coating works could begin. High
flexibility was also called for here on the
part of the supervisors, which they also
demonstrated. After spray application,
the surface areas were visually inspected and the layer thickness was measured. Rework was carried out where the
layer thickness was insufficient.
Supervision
In principle, this building site proved the
following: In case of a necessary and
planned track renewal, even the renewal of the trough coating can be accomplished within a very short time frame
by a competent specialist company with
the right coating material.
The schedule for the renovation was
precisely adhered to and trains have
been rolling over the two bridges again
since late August 2014.
J. Pflugfelder, Sales Manager South
Scope:Welded and riveted steel bridges with and without ballast
Application: workshop and/or on site
Coating system
SikaCor®
Elastomastic®
TF
SikaCor®
Elastomastic®
Airless
SikaCor®
Elastomastic®
HS
Material no.:
684.33
684.32
684.30
Application
method
manual
Airless, manual
touch-up
Plural airless
spray equipment
Pot life at + 20° C
60 min
25 min
90 s
Surface ­temperature
+ 10° C bis + 40° C + 5° C bis + 50° C
+ 5° C bis + 50° C
Accessible
at + 20° C after
12 h
8h
45 min
Can be ballasted
at + 20° C after
3 days
24 h
6h
Slip resistance class
R13 / V10
Smooth,* 13 / V10 Smooth
* when broadcasted with quartz sand 0.7 – 1.2 mm
Spectacular bridge construction in the Chiemgau
Germany’s first heatable steel bridge
The picturesque town of Marquartstein is situated on the banks of the Tiroler Ache between Rosenheim and Traunstein. As part of a local
development measure, the town council decided to build a footbridge and cycling path that connects both parts of the town and is a major
component of a planned riverside circular path with an adventure character. What makes this project so unusual amongst other things is
that this is the first steel bridge to be built in Germany with a heatable bridge deck layer, thus initiating a trailblazing development in the
corrosion protection of steel.
The Traunstein architect‘s office Dietrich
planned the modern steel structure of
the cantilever bridge. Despite the overall
length of 73 metres, a single-sided arch
on the north side suffices for the support
structure; the view can open up freely to
the south. The prefabricated bridge elements were delivered in three sections by
heavy-duty transport and placed on the
prepared abutments on the river banks
with millimetre precision using a special
crane. Following completion of the assembly, the bridge was to be given a nonslip trafficable surfacing in October 2012.
dust primer (SikaCor® Zinc R), a double
intermediate coat of epoxy resin micaceous iron oxide (SikaCor® EG-1) and
a polyurethane top coat in the colour
RAL 9006 (SikaCor® EG-5).
Ice-free thanks to electrical radiant
heating
The planning provided for a synthetic
resin based thin-layer system on steel
(RHD coating). A special requirement
was also to keep the bridge free of snow
and ice in the winter months and thus
accessible on foot and cycle without a
slip hazard the whole year round.
The Dresden-based company STL Böden
+ Design GmbH has ­developed various
radiant heating systems under the brand
name STELOtherm. The STELOramp
system, for example, has been used for
several years with the proven Sika products for ramps in multi-storey car parks.
The SikaCor® Elastomastic TF product
also applied in steel construction is used
with this system. Following positive experiences in multi-storey car parks, the
idea arose to use the STELOramp system in modified form for the first time
on a steel bridge. STL Böden + Design
GmbH developed a radiant heating system on the basis of a thin film which was
tested in accordance with German ZTVING Part 7 Section 5 (ZTV-RHD-ST).
In order to meet the electrical safety
requirements, a double potential equalisation was integrated into the system,
once underneath and once above the
heating level. Twelve electrical heating
circuits, which can be activated modularly according to needs, were necessary
for the complete road surface. Numerous temperature and moisture sensors
are integrated in the system. They control the switching on and off of the surface heating system. If there is a danger
of frost and accompanying moisture,
the sensors react and start the heating process. As soon as the moisture
sensors signal dryness, however, even
at sub-zero temperatures, the heating is switched off. Therefore neither
black ice nor melting snow can form
on the bridge. This solution saves huge
amounts of energy, since the controller
reacts exclusively to the reference temperatures from the road surface and the
heating only switches on when moisture is additionally present. The use of
de-icing salt also becomes completely
unnecessary, so no aggressive corrosive medium gets into the bridge deck
layer. For this reason long maintenance
intervals are to be expected. Apart from
that, doing without de-icing salt in the
natural surroundings makes an impor-
tant contribution towards environmental protection.
Innovative bridge deck surfacing
The combination of RHD coating and
radiant heating system works in a similar way to the ramps in multi-storey
car parks. The heating level with the
STELOtherm KS heating fabric, which
is precisely made-to-measure in advance, and the insulating layers with
potential equalisation is laid on the substrate, which is prepared and provided
with a coat of system primer. Our robust
epoxy-polyurethane hybrid SikaCor®
Elastomastic TF forms the final wearing
layer with non-slip surface texture.
Proven corrosion protection system
The areas of the bridge construction
not used by pedestrians or cyclists were
protected with the SikaCor® ­EG-System,
a high-quality corrosion protection system according to German TL/TP-KORStahlbauten, Page 87.
This proven system is suitable for high
loads and consists of an epoxy-resin zinc
For the Marquartstein town council it
was a great advantage that the surface heating and coating could be implemented from a single source and in
a very short space of time. Only two
months were required for the total
package, from the energy calculation
and the electrical and structural planning through to the completion of the
surfacing, enabling the bridge to be
inaugurated on 15 October, before the
start of the cold season, by the Mayor
Andreas Dögerl in the presence of the
former Federal Minister of Transport Dr.
Peter Ramsauer and further representatives from politics and industry. For
our sales partnership with STL Böden
+ Design GmbH, this pilot project on the
steel bridge opens up completely new
perspectives for further applications of
the system with different steel structures.
Marcus Rybarski, Marketing Services
Flooring /Waterproofing
Facts and figures:
Construction period:
September/October 2012
Client:
Marquartstein Town Council
Area:
150 m2 bridge covering, heated
500 m2 corrosion protection system
General planning:
Dipl. Ing. Architekt
Richard J. Dietrich,Traunstein
Planning and implementation
of the heating system:
STL Böden + Design GmbH, Dresden
6
KorroNews INTERNATIONAL 01 | 2015
The Pretziener Wehr –
A technical masterpiece
Freshly renovated monument protects people in 2013 from a flood disaster
A vast and listed building made of sandstone and metal is placed in the south of the village Pretzien. It regulates the water supply to a 25 km
long divert canal. In case of a flood the Pretziener Wehr reroutes round about one-third of the Elbe water to the cities of Magdeburg and
­Schönebeck.
a four-coat system with a total thickness of 290 microns (SikaCor® EG-Sys­
tem). Apart from an additional edge
protection with epoxy zinc phosphate
(SikaCor® EG Phosphat), all rivet heads
(100,000 pieces) had to be brought forward before airless spraying with the
respective material. The actual protective system was applied on an epoxy
zinc rich primer (SikaCor® Zinc R) with
a heavy-duty corrosion protection system based on a total solid epoxy resin
­(SikaCor® SW-500) and a polyurethane
m.i.o. topcoat (SikaCor® EG-4).
The Pretziener Wehr, completed in 1875,
is the largest sluice weir in Europe and is
regarded as one of the most effective
flood protection installations in Central
Germany. During the flooding problems
in June 2013, the Pretziener Wehr was
opened for the 64th time and thus protected the surrounding towns from the
threatening masses of water.
The pictures of the flood disaster still
remain in our memories and many of
those affected will have to struggle
with the numerous long-term effects
for a long time to come.
Rust is the worst enemy of iron and
steel and affects the functional capacity
and statics of the entire weir. In the year
2010 the steel construction, which after
all is 135 years old, was renovated using
corrosion protection products from Sika
Industrial Coatings.
The assemblies of the weir that are less
subject to corrosion were protected by
© www.pretziener-wehr.de
Normal water-level (weir closed)
© www.pretziener-wehr.de
High tide (weir open)
Facts and figures:
Object: Pretziener Wehr / Location: Saxony-Anhalt, south of the small town
of Pretzien / Task: Renovation of weir bridges taking into consideration
­preservation regulations / Period: March to October 2010 / Area: 4,000 m²
It was thus possible to retain an engineering masterpiece from the 19th Century as an important component of the
flood protection concept of the state of
Saxony-Anhalt.
By the way, the Pretziener Wehr is situated on the international Elbe cycle path
and a visit is recommended to anyone
interested in technology.
Barbara Rößner, Henrik Timm
KorroNews INTERNATIONAL 01 | 2015
7
Coating systems for hydraulic steel structures of Pretziener Wehr – Total area approx. 4,000 m², thereof 1,600 m² locking device
1:50
Cross section
1:50
Partial view with
chack construction
Detail seal fence
1:5
Weir bridges assembly (incl. winch carriages and old small parts)
Load according to Tab. 1 of EN ISO 12944-2: Category of corrosivity C2 – low
Substrate: new steel construction
Preparation: Blast derusting Sa 2½ according to Appendix A, EN ISO 12944-4
Seal assembly – sluices
Load according to Tab. 2 of EN ISO 12944-2: lm 1 – fresh water
Substrate: new steel construction
Preparation: Blast derusting Sa 2½ according to Appendix A, EN ISO 12944-4
System 1:
System 4:
Film
Primer
Edge protection
1. intermediate coat
2. intermediate coat
Top coat
Material
EP-zinc dust
EP-zinc
phosphate
EP
EP
EP-micaceous
iron oxide
Total dry film thickness
NDFT
50 µm
–
80 µm
80 µm
80 µm
Product Sika
SikaCor® Zinc R
SikaCor® EG Phosphat
(CH)
SikaCor® EG-1
SikaCor® EG-1
SikaCor® EG-4
(C: DB 601)
Seal assembly (loose frames, small parts)
Load according to Tab. 2 of EN ISO 12944-2: lm 1 – fresh water
Substrate: new steel construction
Preparation: Blast derusting Sa 2½ according to Appendix A, EN ISO 12944-4
System 2:
Material
EP-zinc dust
EP high solid 1)
EP high solid
EP high solid
EP-micaceous
iron oxide
Total dry film thickness
1)
NDFT
50 µm
–
250 µm
250 µm
80 µm
Product Sika
SikaCor® Zinc R
SikaCor® SW-500
SikaCor® SW-500 (CH)
SikaCor® SW-500 (CH)
SikaCor® EG-4
(C: DB 601)
630 µm
1) manual pretreatment of the edges with the coating material of the subsequent coating in a different colour
System 3:
Film
Primer
Intermediate coat
Top coat
Total dry film thickness
Material
EP high solid1)
EP high solid
EP high solid
EP-micaceous
iron oxide
Total dry film thickness
1)
NDFT
–
250 µm
250 µm
80 µm
Product Sika
SikaCor® SW-500
SikaCor® SW-500
SikaCor® SW-500 (CH)
SikaCor® EG-4
(C: DB 601)
580 µm
manual pretreatment of the edges with the coating material of the subsequent coating in a different colour
290 µm
CH – Colour change; C – Colour
Film
Primer
Edge protection
1. intermediate coat
2. intermediate coat
Top coat
Film
Kantenschutz
1. intermediate coat
2. intermediate coat
Top coat
Material
EP-zinc dust
EP high solid
EP high solid
NDFT
50 µm
250 µm
250 µm
550 µm
Product Sika
SikaCor® Zinc R
SikaCor® SW-500 (red)
SikaCor® SW-500 (black)
Additional stainless steel parts (protective covers, intercom)
Load according to Tab. 1 of EN ISO 12944-2: Category of corrosivity C2 – low
Substrate: new steel construction
Preparation: Sweep-blast derusting according to Appendix C EN ISO 12944-4
System 5:
Film
Primer
Top coat
Material
EP
EP-micaceous
iron oxide
Total dry film thickness
NDFT
80 µm
80 µm
Product Sika
SikaCor® EG-1
SikaCor® EG-4
(C: DB 601)
160 µm
Additional galvanised steel parts
(Light masts, cable trays, holders, others)
Load according to Tab. 1 of EN ISO 12944-2: Category of corrosivity C2 – low
Substrate: Hot-dip galvanising according to EN ISO 1461, minimum coating 85 μm
Lightly blast surfaces
System 6:
Film
Primer
Intermediate coat
Top coat
Total dry film thickness
Material
EP
EP
EP-micaceous
iron oxide
NDFT
50 µm
80 µm
80 µm
Product Sika
SikaCor® EG-1
SikaCor® EG-1 (CH)
SikaCor® EG-4
(C: DB 601)
210 µm
Alternative: Powder coating according to DIN 55633 in system 2.5 of Tab. A.2,
Primer and top coat, NDFT 120 μm, EG colour DB 601 as above
8
KorroNews INTERNATIONAL 01 | 2015
Offshore Wind Farm Butendiek
First park with solvent-free coating
areas and a great deal of experience –
that a­ llows us to work in a goal-oriented
manner.”
The Butendiek project (Low German:
“outside the dyke”, on the sea side of the
dyke) is an offshore wind farm planned
by the OSB Offshore Bürger-Windpark
Butendiek GmbH & Co. KG in the German exclusive economic zone of the
North Sea, about 35 km off the west
coast of northern Schleswig-Holstein. In
2010 the windfarm was sold to WPD AG.
The construction of the wind farm with
80 wind turbines of the type Siemens
SWT-3.6-120, each with a rated output
of 3.6 MW, started in spring 2014 west
of the island of Sylt.
Last year Sika Industrial Coatings KAM
Wind succeeded in winning the contract for the corrosion-protection of
the Butendiek wind farm. The project
was successfully completed in close
co-operation with our long-standing
customer, the Krebs Group. During the
coating work the editorial staff of the
Sika Wind News took the opportunity
to get an impression of the scope and
dimensions of this contract and to speak
to Detlef Krebs, who is one of the two
CEOs alongside Manfred Krebs.
Asked how such a complex project can
be pictured, Detlef Krebs answered,
“Keeping to schedule, working at various
sites, one’s own requirements – such as
environment, quality, economic working,
service, being fair, following the principle ‘what we coat, we also move’ – and
all of that within a very tight timeframe
– we implement that as a family-run
company. With this individual strength,
skilled employees from various specialist
Numerous coating contracts in the offshore sector for transformer platforms
such as Baltic 1 and 2, Meerwind, Sylwin
and many more as well as over 500 transition pieces for Wolney 1 and 2, Gwynt y
Môr GlobalTec 1, etc. – a total of over 1.4
million coated square metres – testify
to a wealth of know-how and experience.
Sika has also handled extensive projects
with Krebs in the past years, so that the
“Butendiek challenge” became a professional partnership-like co-operation.
OFFSHORE WIND FARM BUTENDIEK
•Planned as a “Bürgerwindpark” in the year 2000
•2001 application to the BSH/2002 building permission
•Environmental compatibility study until 2004
• Sale to WPD 2010
• Award of the project October 2013
•80 monopiles / 80 transition pieces
Coating work of Sika
•Total application area 140,000 m²
•First park with solvent-free f­ oundation coating
The coating work for Butendiek was carried at four different “Krebs locations” Lubmin, Stralsund, 2 x Rostock. Detlef
Krebs: “We can manage that thanks
to a flat management structure with
dedicated long-standing managerial
staffs, short communication paths and
clear responsibilities. The possibility of
being able to fall back on some of Nordic
Yards’ manufacturing areas in Rostock
is a further factor for high flexibility.”
Continuous expert support by our SikaWindServiceTeam allowed all technical
questions to be taken up and solved
in advance. Our Frosio inspectors were
constantly available. Detlef Krebs: “We
felt that the Sika employees gave us optimal support at all times.”
•First park with interior monopile coating (2 × 300 µm)
Barbara Rößner, Marketing Services
KorroNews INTERNATIONAL 01 | 2015
9
The Krebs group
• Since more than 60 years the company is led by the Krebs family
•More than 400 employees guarantee a qualitative and ecological job
­performance, confirmed by external quality marks as well as third party
­approvals and certifications
•There are diverse, various sites of Krebs in the Northern Germany area,
which operate in corrosion protection, service and cleaning of constructions
for notable customers
•The Krebs experts can call on a privately owned motor and equipment fleet,
when working on stationary or mobile projects
Some examples for protection
Monopiles
Transition Pieces external
Sa 2 ½
Sa 2 ½
2 × SikaCor® SW-500
redbrown, grey
3 × 200 µm SikaCor® SW-500 redbrown, black, white
1 × 60 µm Sika® Permacor®-2230 (RAL 1012)
TP inside – below platform TP inside – above platform
Sa 2 ½
Sa 2 ½
2 × 250 µm SikaCor®
SW-500 (redbrown, grey)
1 ×250 µm Sika® Permacor®-2215 sand yellow
1 × 60 µm Sika® Permacor®-2230 RAL 7032
News
Due to our long-term experience in the
field of corrosion protection with solvent
free epoxy products for hydraulic engineering projects and offshore windfarms
two new products are introduced into
the market. They are consistent further
developments and modifications of our
well-established SikaCor® SW-500.
NEW PRODUCT DEVELOPMENT
SikaCor® SW-501
SikaCor® SW-501 is a new me­cha­ni­c­ally resistant epoxy-resin coating with
100 % volume solids for hydraulic steel
structures.
Product features / Benefits
Offshore References of Sika Deutsch­land GmbH Industrial Coatings:
The Industrial Coatings Division of Sika Deutschland GmbH has gained a great deal of experience in the wind industry
over the past years – first of all onshore, since 2002, and for about the last 4 years offshore as well, based on the
­synergies between our onshore expertise and our skills in hydraulic steel construction.
Object
Place
Ormonde
Northwest coast of England,
Irish Sea
Eastern North Sea
Period
Coating object
Area
2011
Steel tower coating
inside and outside
36,000 m²
Northeast of Helgoland
2011
Steel tower coating
inside and outside
115,000 m²
Eastern North Sea
Northeast of Helgoland
2011
Measuring mast
2,500 m2
Van Oort
Holland
2011
Measuring mast
2,500 m2
Thornton Bank 2
Off the coast of Zeebrügge,
Belgium
2012
Steel tower coating
inside and outside
69,000 m²
Thornton Bank 3
Off the coast of Zeebrügge, ­
Belgium North Sea
2013
Steel tower coating
inside and outside
41,500 m²
• A
pplicable in 1 layer up to
1000 microns (standard layer
thickness: 500 microns)
• T
ough hard, abrasion resistant
• S
olvent-free
• H
ighly dT-resistant
PRODUCT MODIFICATION
SikaCor® SW-500 GF
SikaCor® SW-500 GF is a glass flake reinforced epoxy-resin coating with 100 %
volume solids. It is a high build corrosion protection for areas, where resistance against heavy corrosive media is
also required as high resistance against
abrasion and mechanical wear, such as
splash zone areas for offshore structures, foundations, transition pieces.
Product features / Benefits
• T
ested and approved acc. to
­Norsok M-501 rev. 6, system
no. 7A and 7B at the Teknologisk
­Institutt as, Oslo
10
KorroNews INTERNATIONAL 01 | 2015
Always there for you, even offshore –
the SikaWindServiceTeam
All of those demands that exist with
wind turbines present themselves in
an increased or more difficult form offshore.
INDUSTRIAL COATINGS – OUR SPECIALISTS FOR WINDENERGY
Key Account Management Wind
Accessibility­of the objects, high wind
load, low temperatures, contact with
water, etc. place very high demands
both on the wind turbine itself and
on its maintenance – and thus on the
people.
High demands are also and above all
placed on the materials processed there
– they must be easy to transport, easy
to handle during the application and fast
drying.
The basic prerequisite for working on the
high seas is, however, the Sea­Survival
Certificate – nothing is possible without
that. Our SikaWindService­Team has it –
so that it can not only advise but also go
into action on site.
The certificate – for the oil, gas and
wind sectors – enables the employees
of our SikaWindService­Team to operate
in and on the water, both nationally and
internationally.
However, the SeaSur­
vival Certificate
is not so easy to obtain. Candidates
must attend a three-day course and
pass a test. On the course the participants learn, for example, their personal ‘breath-holding time’ as well as how
to handle the rescue equipment carried
according to the situation, such as the
methods of inflating life jackets.
The boarding and erecting of a capsized
life raft are also part of it. In particular
the simulation of the technique of the
emergency exit from a helicopter is not
simple: the required evacuations from
the air, on the water surface and under
water sound adventurous, but they also
make it very clear that we are concerned
with survival training here.
Even after obtaining the certificate the
test must be repeated every four years.
In addition there are requirements with
regard to physical fitness. Fitness has
to be confirmed by thorough medical
checks, which include a full blood count,
an exercise ECG and an examination of
the lungs.
KAM Onshore
Matthias Winkler
Head of KAM
KAM Offshore
Stefan Luipers
KAM Global Enercon Onshore
Achim Fries
KAM Offshore Maritime
Roland Jonas
Technical Support
Market Field Manager
Wind
Claus Ackfeld
Market Field Manager
Hydraulic Steel Structures
Axel Petrikat
Only specially certified doctors may
carry out these examinations – and they
have to be repeated every two years.
The members of our SikaWindService­
Team – Stefan Luipers and Thomas
Krug – are allowed to rush offshore to
give assistance.
Like all sales advisors and application
technicians from Sika they are naturally qualified as FROSIO inspectors in accordance with NS 476 FROSIO.
This certification is based on Norwegian
standards, is recognised worldwide and
conveys knowledge about corrosion protection and surface treatment. ­
Thomas Krug meanwhile trains prospective ­FROSIO inspectors and, in addition
to the Sea Survival Certificate, also has
a qualification as a professional and industrial climber.
Stefan Luipers – Key Account ­Manager
Offshore Wind Power – also brings
along a great deal of technical expertise
in addition to his 25 years of experience.
Application Specialist
Thomas Krug
Application Specialist and
Market Development Wind
Kay Fischer
This SikaWindServiceTeam accompanies you offshore to your objects,
­analyses problems and actively helps to
find individual solutions – worldwide!
Carina Jauch, c/o Marketing Services
KorroNews INTERNATIONAL 01 | 2015
11
Sealing of the ‘Berliner Brückenzug’ by a
new system on steel without buffer layer
Approval extension: SikaCor® HM Primer + SikaCor® HM Mastic + Sikalastic®-827 HT
The widening of the A59 motorway to
six lanes between the motorway junction Duisburg (A40) and the motorway
junction Duisburg North (A42) is casting a long shadow. Repair work on the
1.8 kilometre long section of BAB A59,
the ‘Berliner Brückenzug’, began in May
2014, during which considerably more
extensive damage to the steel superstructures and the concrete bridges was
found than the State Office of Road
Construction in North-Rhine/Westphalia had initially assumed. Numerous
cracks and extensive corrosion were
found in particular at the edges of the
bridge and in the crash protections at
the edge.
This highly-stressed motorway carries
around 80,000 vehicles per day and in
order to make driving safe until completion of the reconstruction, above all
on the eleven bridges along this section, one carriageway of the motorway
was completely closed to traffic at all
times during this period. This allowed
work to proceed on the respective other
carriageway without a break and very
quickly. It was necessary to adhere to
the tight construction schedule of only
6 months.
The waterproofing of the steel b
­ ridges
on the A59 federal motorway bridge
‘Berliner Brückenzug’ was carried out by
the building contractors Matthäi ­Bau­unternehmen GmbH & Co. KG Freienhufen using the new Sika bridge deck
waterproofing system on steel according to German Standard ZTV-ING, part 7
chapter 4, design 1. No buffer layer is required for the innovative system, since
approx. 20,000 kg of Sikalastic®-827 HT
hot melt adhesive granulates were used
as the adhesive layer.
The application of SikaCor® HM Primer
and SikaCor® HM Mastic takes place in
the same way as before.* Instead of
Esha Isoton buffer layer and sprinkling
with Taunus quartz, however, Sika­
lastic®-827 HT is sprinkled on the freshly
applied base layer in the form of pellets (see illustration), approx. 1 kg/m²,
to ensure the adhesion and the shear
strength.
*System:
(acc. to German Standard ZTV-ING,
part 7 chapter 4, design 1)
Further references for the new Sika bridge sealing system on steel:
SikaCor® HM Primer + SikaCor® HM Mastic + Sikalastic®-827 HT
according to German Standard ZTV-ING, part 7 chapter 4, design 1
Object nameHarbour bridge
over canal
Place
Düsseldorf (GER)
Period
March 2014
Area
200 m2
Object namePedestrian and cyclist
bridge
Place
Mühlberg (GER)
Period
July to August 2014
Area
120 m2
Object name
Place
Period
Area
Object nameWeyersbergbrücke
Place
Saarbrücken (GER)
Period
July to October 2014
Area
150 m2
BW 56 slip road A59
Düren (GER)
July to October 2014
775 m2
rimer:
P
1 x SikaCor® HM Primer
Base layer:
1 x SikaCor® HM Mastic
Adhesive layer:
Sikalastic®-827 HT
Protective and wearing layer:
Mastic asphalt
Without the elaborate installation of a
buffer layer and its sprinkling, it was
possible to lay the mastic asphalt
­directly on the Sikalastic®-827 HT.
Beyond that, more than 5,000 tonnes of
SikaTop® ES were applied on a total area
of 42,000 sqm of concrete bridge in the
period from May to October. Not only
logistically an amazing feat.
Steffen Walz, Marketing Services
12
KorroNews INTERNATIONAL 01 | 2015
Sika Website –
NEW!
simple, fast and practicable
Sika Deutschland GmbH has overhauled its website and now presents itself with an up-to-date look and simplified access to the
­information. New at www.sika.de: The extra page for wind energy.
Sika Deutschland GmbH has redesigned its website and placed the needs
of its customers further in the spotlight. The new Sika website is online at
www.sika.de with a fresh appearance,
high recognition value and extended
­offerings.
& Composites and Concrete through
to Industrial Coatings. Through a userfriendly application using a wind tower,
the visitor can find the desired products,
contacts and information according to
his requirements. In addition, the SikaWindFilm graphically illustrates Sika’s
expertise in wind energy.
The goal is to further improve access to
the extensive information that has already been made available in the past.
We look forward to your visit to our
homepage and hope you will very much
enjoy exploring it!
The application fields of Industrial Coatings – corrosion protection, fire protection and wind energy – are now also directly integrated into the Sika Deutschland homepage. In order to overcome
language barriers, a button has been
placed on the top of the start page with
which you can select the respective English application areas with just a click.
Steffen Walz, Marketing Services
INDUSTRIAL COATINGS
MACHINEPARTS AND
-HOUSING
STEELTOWER
EXTERIOR
Overall the website presents itself to
visitors with a considerably tidier and visually clearer appearance. Division-spanning information can be found in a general section covering Sika Deutschland.
Information on locations, job & career
as well as the comprehensive subject of
sustainability is available here.
A simple menu with simple user
guidance helps visitors to the website to
orient themselves quickly. For example,
products are arranged according to applications and market segments and of
course also alphabetically. The suitable
product can thus be found with a few
clicks via various methods of access.
The visitor can then gain access to the
individual market fields and their areas
of application via tiles with a clear visual
arrangement.
The ‘Sika World’ section and the
Wind Energy page have been newly
created.
In the Sika World the user can find
all Sika Deutschland applications in a
­clearly arranged card.
The newly created Sika Wind page
contains all applications and products
that Sika offers for the wind industry.
All divisions are clearly represented,
from Gluing and Sealing to Tooling
YOUR CONTACT ALL OVER THE WORLD
Head of Export
Export Assistant
Eri Jones
jones.eri@de.sika.com
+49 7042 109 5301
Manfred Baur
baur.manfred@de.sika.com
+49 173 677 4774
REPAIR AND
MAINTENANCE
STEELTOWER
INTERIOR
FOUNDATION STRUCTURES
OFFSHORE
Extract from the new wind application
Flag
Editor:
Sika Deutschland GmbH
Rieter Tal · 71665 Vaihingen/Enz, Germany
Phone +49 (0) 70 42/109-0,
Fax: +49 (0) 70 42/109-180
E-Mail: industrial-coatings@de.sika.com
www.sika.de
Overall responsibility:
Thomas Kerkmann
Rieter Tal · 71665 Vaihingen/Enz, Germany
Editorial office:
Sika Deutschland GmbH
KAM Corrosion and
Fire Protection Intercompany
Marius Gulyas-Carciu
gulyas-carciu.marius@de.sika.com
+49 172 240 7613
KAM Corrosion and
Fire Protection Russia
Kurt Mann
mann.kurt@de.sika.com
+49 172 260 0832
KAM Corrosion and
Fire Protection Intercompany
Dieter Neubrand
neubrand.dieter@de.sika.com
+49 173 677 4775
Coordinator and
Sales Services Export
Bernd Pommerening
pommerening.bernd@de.sika.com
+49 173 677 4773
The Sika Deutschland GmbH Industrial Coatings product ­division develops, produces and markets high quality coatings for
heavy-duty corrosion protection and fire protection. The highly specialized research and development department and
production facilities are located in Vaihingen/Enz, Germany. Products are marketed predominantly in the field of structural engineering, infrastructure, oil and chemical plants, hydraulic structures and wind energy market. Sika Industrial
Coatings is the experienced partner you want for the protection, safety and design of building structures.
Concept:
DIE CREW AG, Advertising agency
Layout, Typesetting, Lithography:
come medien ag
All technical examination above was carried
out under laboratory conditions. Product properties upon practical use are indicated in the currently valid product data sheet available under
www.sika.de.
A tight network of sales partners guarantees expert p
­ romotion in all significant markets around the globe.
Our Industrial Coatings export department is your contact in the field of corrosion protection, tank protection and fire
protection. Exemplary focal points can be found not only in heavy-duty corrosion protection, but also in the potable water
sector, in the coating of gas pipelines, or in the construction, protection and maintaining of infrastructures. The primary
concerns of the team are the provision of international services and technical consultation for customers from all over the
world. Another major task is the support and training of other Sika internal local subsidiaries. Due to long-standing global
experience, close cooperation with expert departments, permanent customer contact and the awareness for needs ands
requirements beyond national borders, the export team is the right partner for versatile fields of application.
Market Development Manager Export
Steffen Walz
walz.steffen@de.sika.com
+49 173 678 2820