sikakorronews was used; the 1,200 m2 three-sto- ... kam corrosion and fire protection intercompany...

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 ap-plied both with and without a primer, tailored precisely to the different re-quirements 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-sto-rey building is protected by Sika® Unitherm® Platinum only. The new R & D Centre is modern and equipped for the needs of the employees and their re-search, and partly replaces a 100-year-old 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 coat-ed with Sika® Unitherm® Platinum was the extension building of the well-

continued page 2

Sika® Unitherm® Platinum – Sustainable and cost-effective for the futureThe success story of an innovation

SikaKorroNews INTERNATIONAL

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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 conven-tional function it has further outstanding properties that allow fire protection coating in the factory.

SIKA® UNITHERM® PLATINUM AT A GLANCEUses

• Solvent 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

• Film thickness up to 4 mm per application

• 100 % total solid state, wet film thickness = dry film thickness

• High mechanical impact, shock and abrasion-resistant,

therefore no transport damages

• Shortest application and drying time

• Shop application under defined climatic conditions

• Applicable with or without primer

• Applicable without top coat in interior and exterior areas

• Cleaning of the coated surface possible with a high-pressure water jet washer

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 protec-tion behaviour according to B-s2, d0 (EN 13501-1). In addition, the steel fire pro-

The new Sika Liquid Plastics R & D Centre in Preston

Magazine for Corrosion-, Tank- and Fire Protection

2 KorroNews INTERNATIONAL 01 | 2015

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 foot-ball 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 cost- effective and sustainable solutions for the protection of steel against fire.

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 be-cause of the long escape routes in case of fire. The 2-pack Epoxy formulation of Sika® Unitherm® Platinum* is capable of bear-ing high mechanical loads as a work-shop 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 fast-cure properties. This simplifies and ac-celerates 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 contin-uously, allowing completion of the pro-ject within 24 weeks. On average about 350 m² were installed each day.

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 coat-ed 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.

Sika® Unitherm® Platinum* offers fire and corrosion protection in one and has been tested according to DIN EN ISO 12944 for corrosivity class C5 M/I. Since ice rinks are exposed to special weather conditions, various ice rinks have been coated with our innovative product, for example 600 m² of steel at the Ilfis ice rink in Langenau (CH) or 4,000 m² of steel at the EgeTrans- Arena in Bietigheim-Bissingen (GER).

This interesting building is shaped by distinctive, modern architecture and a circular geometry. With a diameter of almost 85 m and a height of 16.5 m, the arena seats up to 4,500 spectators. The construction of the new ice rink was completed in late 2012 after only few months. The hall support structure con-sists of fish-belly-shaped frame gird-ers spaced at distances of 5 m to each other, resulting in a steel consumption of around 65 to 70 kg per m². Sika® Unitherm® Platinum received a top coat of polyurethane based SikaCor® EG5 in RAL 5012. The visible construction thus has a radiant blue appearance.

International demand has constantly in-creased since the introduction of the in-novative product. Many different struc-tures have already been coated with the Sika® Unitherm® Platinum steel fire protection system, so that many experi-ences have been amassed. Very recently completed or current projects include,

Extended Car Logistics building of the Galliker freight forwarding company

24 hours after coating the components are mounted

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® Uni therm® Steel W-60 and Sika® Unitherm® Steel W-120, innova-tions from the waterbased research line of our developers. At the same time we fall back on known elements, modifying or expanding their efficiency: The char-acteristics 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 KorroNews describe how our cus-tomers are writing their success stories today with Sika products – whether prov-en 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

The exhibition hall 3A in NurembergMunicipal library in Bad Vilbel

* Sika® Unitherm® Platinum in the coating system:

Categories of corrosivity according to DIN EN 12944:• Without primer and

without top coat: C3• With primer and with top coat

up to C5-M / C5-I

CONTENTSika® Unitherm® Platinum The success story of an innovation

NewsSika products – proven or innovative

SikaCor® Elastomastic® typesRenovation of the intersection at Frankfurt-West railway station

Bridge construction in the ChiemgauGermany’s first heatable steel bridge

The Pretziener WehrA technical masterpiece

Offshore Wind farm ButendiekFirst park with solvent-free coating

News – New product development

SikaWindServiceTeamAlways 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 departmentYour contact – all over the world

Cleaning with high-pressure cleaner

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KorroNews INTERNATIONAL 01 | 2015 3

PRODUCT OPTIMISATIONSikaCor® 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

NewsIce rink EgeTrans-Arena

KEY ACCOUNT MANAGEMENT FIRE PROTECTION

Sika fire protection experts have gained a wide range of experience through many years of involve-ment 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-CarciuKAM Corrosion and Fire Protection [email protected]+ 49 (0) 171 7640553

Product features / Benefits

• 1-coat system directly on steel

• UV- and weather resistant

• Tough-elastic and solid, non-brittling

• Shock and impact resistant

• Excellent chemical resistance

• Fast curing, even at low temperatures

• Unger Stahlbau Ges.m.b.H. A-7400 Oberwart, about 156,000 m²

• Stahlbau Brehna GmbH D-06796 Brehna, about 25,000 m²


• New binding agent technology

• Very fast drying (faster than solvent-based systems)

• VOC 0 g/l

• Supports the highest DGNB stage

• Simple application

• Workable down to +5 °C

• Low film thicknesses, hence very economical

NEW PRODUCT DEVELOPMENTSika® Unitherm® Steel W60 and Sika® Unitherm® Steel W120 – a brand-new generation of water borne fire protection products

The water-based fire protection coat-ings 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.

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, Preston (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

• Zentrum für Angewandte Luftfahrtforschung (ZAL) GmbH, ZAL-TechCenter, Hamburg Finkenwerder; 10,000 m2

• etc.


On the basis of the project described, a digression regarding the requirements for possible protective systems should be allowed at this point

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 expen-sive restrictions to the timetable. All the more important, therefore, is a perma-nent functionality of the corrosion pro-tection.

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 coat-ing 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 tem-peratures in winter and very high tem-peratures in summer.

In addition, accessibility is greatly limit-ed, 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 in-clude checking adhesion after alternat-ing hot/cold loads and the fatigue limit with ballast. These testing methods are described in Sheet 84 and in future in DBS 918084.

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 protec-tive 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 ac-cording 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.

Intensive development took place in the 1980s on the basis of these specifica-tions, basically producing two different coating systems:

1. Solvent-free epoxy resin with polyurethane as co-binder: SikaCor® Elastomastic® TFand2. 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 air-less 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 re-quires greater care with regard to sur-face cleanliness where moisture and care of the spraying equipment are con-cerned. 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

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 pro-tect blast-cleaned steel surfaces from weathering.Both coating types have proven them-selves over a period of many years and have established themselves on the market as German Sheet 84 Appendix in TL/TP-KOR-Stahlbauten.

Planning

For this project it quickly became clear that only the polyurethane hot-spray grade could be used, as the posses-sion 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, howev-er 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.

Sequence of work

Contrary to the original planning, the work sequence had to be complete-ly changed after the removal of the ballast, since the base not only had to be partially repaired, but an addi-tional 1,490 m² had to be stripped and 4,000 μm² re-coated with SikaCor® Elasto mastic® HS – this with an UN-CHANGED 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 ad-hered better in some places than oth-ers. 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 sur-faces were treated using a shot-blast-ing device with the addition of grit in

SikaCor® Elastomastic® typesRenovation of the intersection at Frankfurt-West railway stationThe 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.

Re-coated ballast-trough

Project description

Section 3611 Frankfurt main station (low) – Friedbergkm 3.381 – km 3.679 (track 1 / 11) km 3.381 – km 3.673 (track 2)

2-track intersection built in the 1960s, the overall length of the 2 throughs is approx. 550 m.


Scope: Welded and riveted steel bridges with and without ballastApplication: 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 8 h 45 min

Can be ballasted at + 20° C after

3 days 24 h 6 h

Slip resistance class R13 / V10 Smooth,* 13 / V10 Smooth

* when broadcasted with quartz sand 0.7 – 1.2 mm

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.

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

notice. The total amount of material consumed was around 15 tonnes. The project was a challenge for everyone in-volved in terms of time!

Supervision

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 inspect-ed and the layer thickness was meas-ured. Rework was carried out where the layer thickness was insufficient.

In principle, this building site proved the following: In case of a necessary and planned track renewal, even the renew-al of the trough coating can be accom-plished within a very short time frame by a competent specialist company with the right coating material.

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 ele-ments 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 as-sembly, the bridge was to be given a non-slip trafficable surfacing in October 2012.

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 prod-ucts for ramps in multi-storey car parks. The SikaCor® Elastomastic TF product also applied in steel construction is used with this system. Following positive ex-periences in multi-storey car parks, the idea arose to use the STELOramp sys-tem in modified form for the first time on a steel bridge. STL Böden + Design GmbH developed a radiant heating sys-tem on the basis of a thin film which was tested in accordance with German ZTV-ING Part 7 Section 5 (ZTV-RHD-ST).

In order to meet the electrical safety requirements, a double potential equal-isation was integrated into the system,

once underneath and once above the heating level. Twelve electrical heating circuits, which can be activated modu-larly according to needs, were necessary for the complete road surface. Numer-ous temperature and moisture sensors are integrated in the system. They con-trol the switching on and off of the sur-face heating system. If there is a danger of frost and accompanying moisture, the sensors react and start the heat-ing process. As soon as the moisture sensors signal dryness, however, even at sub-zero temperatures, the heat-ing 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 tem-peratures from the road surface and the heating only switches on when mois-ture is additionally present. The use of de-icing salt also becomes completely unnecessary, so no aggressive corro-sive 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 environmen-tal protection.

Innovative bridge deck surfacing

The combination of RHD coating and radiant heating system works in a sim-ilar 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 ad-vance, and the insulating layers with potential equalisation is laid on the sub-strate, 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® EGSystem, a high-quality corrosion protection sys-tem according to German TL/TP-KOR- Stahlbauten, Page 87.This proven system is suitable for high loads and consists of an epoxy-resin zinc

Spectacular bridge construction in the ChiemgauGermany’s first heatable steel bridgeThe 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.

dust primer (SikaCor® Zinc R), a double intermediate coat of epoxy resin mi-caceous iron oxide (SikaCor® EG1) and a polyurethane top coat in the colour RAL 9006 (SikaCor® EG5).

For the Marquartstein town council it was a great advantage that the sur-face heating and coating could be im-plemented 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 plan-ning 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 represent-atives 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 struc-tures. Marcus Rybarski, Marketing Services Flooring /Waterproofing

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

Facts and figures:

Construction period:September/October 2012

Client:Marquartstein Town Council

Area:150 m2 bridge covering, heated500 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


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 pro-tected 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

High tide (weir open)Normal water-level (weir closed)

© www.pretziener-wehr.de

a four-coat system with a total thick-ness of 290 microns (SikaCor® EGSystem). Apart from an additional edge protection with epoxy zinc phosphate (SikaCor® EG Phosphat), all rivet heads (100,000 pieces) had to be brought for-ward before airless spraying with the respective material. The actual protec-tive system was applied on an epoxy zinc rich primer (SikaCor® Zinc R) with a heavy-duty corrosion protection sys-tem based on a total solid epoxy resin (SikaCor® SW500) and a polyurethane m.i.o. topcoat (SikaCor® EG4).

It was thus possible to retain an engi-neering masterpiece from the 19th Cen-tury as an important component of the flood protection concept of the state of Saxony-Anhalt.

By the way, the Pretziener Wehr is situ-ated on the international Elbe cycle path and a visit is recommended to anyone interested in technology. Barbara Rößner, Henrik Timm

The Pretziener Wehr – A technical masterpieceFreshly renovated monument protects people in 2013 from a flood disasterA 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.

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


Weir bridges assembly (incl. winch carriages and old small parts)

Load according to Tab. 1 of EN ISO 12944-2: Category of corrosivity C2 – lowSubstrate: new steel constructionPreparation: Blast derusting Sa 2½ according to Appendix A, EN ISO 12944-4

System 1:

Film Material NDFT Product SikaPrimer EP-zinc dust 50 μm SikaCor® Zinc REdge protection EP-zinc

phosphate – SikaCor® EG Phosphat

(CH)1. intermediate coat EP 80 μm SikaCor® EG-12. intermediate coat EP 80 μm SikaCor® EG-1Top coat EP-micaceous

iron oxide80 μm SikaCor® EG-4

(C: DB 601)Total dry film thickness 290 µmCH – Colour change; C – Colour

Seal assembly (loose frames, small parts)

Load according to Tab. 2 of EN ISO 12944-2: lm 1 – fresh waterSubstrate: new steel constructionPreparation: Blast derusting Sa 2½ according to Appendix A, EN ISO 12944-4

System 2:

Film Material NDFT Product SikaPrimer EP-zinc dust 50 μm SikaCor® Zinc REdge protection EP high solid 1) – SikaCor® SW-5001. intermediate coat EP high solid 250 μm SikaCor® SW-500 (CH)2. intermediate coat EP high solid 250 μm SikaCor® SW-500 (CH)Top coat EP-micaceous


(C: DB 601)Total dry film thickness 630 µm1) 1) manual pretreatment of the edges with the coating material of the subsequent coating in a different colour

System 3:

Film Material NDFT Product SikaPrimer EP-zinc dust 50 μm SikaCor® Zinc RIntermediate coat EP high solid 250 μm SikaCor® SW-500 (red)Top coat EP high solid 250 μm SikaCor® SW-500 (black)Total dry film thickness 550 µm

Seal assembly – sluices

Load according to Tab. 2 of EN ISO 12944-2: lm 1 – fresh waterSubstrate: new steel constructionPreparation: Blast derusting Sa 2½ according to Appendix A, EN ISO 12944-4

System 4:

Film Material NDFT Product SikaKantenschutz EP high solid1) – SikaCor® SW-5001. intermediate coat EP high solid 250 μm SikaCor® SW-5002. intermediate coat EP high solid 250 μm SikaCor® SW-500 (CH)Top coat EP-micaceous


(C: DB 601)Total dry film thickness 580 µm1) manual pretreatment of the edges with the coating material of the subsequent coating in a different colour

Additional stainless steel parts (protective covers, intercom)

Load according to Tab. 1 of EN ISO 12944-2: Category of corrosivity C2 – lowSubstrate: new steel constructionPreparation: Sweep-blast derusting according to Appendix C EN ISO 12944-4

System 5:

Film Material NDFT Product SikaPrimer EP 80 μm SikaCor® EG-1Top coat EP-micaceous


(C: DB 601)Total dry film thickness 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 – lowSubstrate: Hot-dip galvanising according to EN ISO 1461, minimum coating 85 μmLightly blast surfaces

System 6:

Film Material NDFT Product SikaPrimer EP 50 μm SikaCor® EG-1Intermediate coat EP 80 μm SikaCor® EG-1 (CH)Top coat EP-micaceous


(C: DB 601)Total dry film thickness 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

Coating systems for hydraulic steel structures of Pretziener Wehr – Total area approx. 4,000 m², thereof 1,600 m² locking device

Detail seal fence1:5

Cross section1:50

Partial view with chack construction

1:50


areas and a great deal of experience – that allows us to work in a goal-oriented manner.”

Numerous coating contracts in the off-shore sector for transformer platforms such as Baltic 1 and 2, Meerwind, Sylwin and many more as well as over 500 tran-sition 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 experi-ence.

Sika has also handled extensive projects with Krebs in the past years, so that the “Butendiek challenge” became a profes-sional partnership-like co-operation.

The coating work for Butendiek was car-ried 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 Sika-WindServiceTeam 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 op-timal support at all times.”

Barbara Rößner, Marketing Services

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 Ger-man 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 con-tract 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 princi-ple ‘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

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 foundation coating

• First park with interior monopile coating (2 × 300 μm)

Offshore Wind Farm ButendiekFirst park with solvent-free coating


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, white1 × 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 yellow1 × 60 μm Sika® Permacor®-2230 RAL 7032

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

Offshore References of Sika Deutsch land 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 Period Coating object Area

Ormonde Northwest coast of England, Irish Sea

2011 Steel tower coating inside and outside

36,000 m²

Eastern North Sea 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


69,000 m²

Thornton Bank 3 Off the coast of Zeebrügge, Belgium North Sea


41,500 m²

Due to our long-term experience in the field of corrosion protection with solvent free epoxy products for hydraulic engi-neering projects and offshore windfarms two new products are introduced into the market. They are consistent further developments and modifications of our well-established SikaCor® SW500.

NEW PRODUCT DEVELOPMENTSikaCor® SW501

SikaCor® SW501 is a new me cha ni c - ally resistant epoxy-resin coating with 100 % volume solids for hydraulic steel structures.


• Applicable in 1 layer up to 1000 microns (standard layer thickness: 500 microns)

• Tough hard, abrasion resistant

• Solvent-free

• Highly dT-resistant

PRODUCT MODIFICATIONSikaCor® SW500 GF

SikaCor® SW500 GF is a glass flake re-inforced epoxy-resin coating with 100 % volume solids. It is a high build corro-sion protection for areas, where resist-ance against heavy corrosive media is also required as high resistance against abrasion and mechanical wear, such as splash zone areas for offshore struc-tures, foundations, transition pieces.


• Tested and approved acc. to Norsok M-501 rev. 6, system no. 7A and 7B at the Teknologisk Institutt as, Oslo

News


All of those demands that exist with wind turbines present themselves in an increased or more difficult form off-shore.

Accessibility of 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 Sea Survival Certificate – nothing is possible without that. Our SikaWindService Team 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 SikaWindService Team 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 partici-pants learn, for example, their person-al ‘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

Always there for you, even offshore – the SikaWindServiceTeam

INDUSTRIAL COATINGS – OUR SPECIALISTS FOR WINDENERGY

Head of KAMKAM Offshore Stefan Luipers

Market Field Manager WindClaus Ackfeld

Market Field Manager Hydraulic Steel StructuresAxel Petrikat

Application SpecialistThomas Krug

Application Specialist and Market Development WindKay Fischer

Key Account Management Wind

KAM OnshoreMatthias Winkler

KAM Global Enercon OnshoreAchim Fries

Technical Support

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.

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 natural-ly qualified as FROSIO inspectors in ac-cordance with NS 476 FROSIO.

This certification is based on Norwegian standards, is recognised worldwide and conveys knowledge about corrosion pro-tection and surface treatment.

Thomas Krug meanwhile trains prospec-tive FROSIO inspectors and, in addition to the Sea Survival Certificate, also has a qualification as a professional and in-dustrial 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.

This SikaWindServiceTeam accom-panies you offshore to your objects, analyses problems and actively helps to find individual solutions – worldwide!

Carina Jauch, c/o Marketing Services

KAM Offshore MaritimeRoland Jonas


Sealing of the ‘Berliner Brückenzug’ by a new system on steel without buffer layerApproval extension: SikaCor® HM Primer + SikaCor® HM Mastic + Sikalastic®-827 HT

The widening of the A59 motorway to six lanes between the motorway junc-tion Duisburg (A40) and the motorway junction Duisburg North (A42) is cast-ing 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 super-structures and the concrete bridges was found than the State Office of Road Construction in North-Rhine/West-phalia 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 com-pletion of the reconstruction, above all on the eleven bridges along this sec-tion, 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 bridges on the A59 federal motorway bridge ‘Berliner Brückenzug’ was carried out by the building contractors Matthäi Bau - unternehmen GmbH & Co. KG Freien-hufen using the new Sika bridge deck waterproofing system on steel accord-ing to German Standard ZTV-ING, part 7

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 name Harbour bridge over canal

Place Düsseldorf (GER)Period March 2014Area 200 m2

Object name Pedestrian and cyclist bridge

Place Mühlberg (GER)Period July to August 2014Area 120 m2

Object name BW 56 slip road A59Place Düren (GER)Period July to October 2014Area 775 m2

Object name WeyersbergbrückePlace Saarbrücken (GER)Period July to October 2014Area 150 m2

chapter 4, design 1. No buffer layer is re-quired 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, Sikalastic®827 HT is sprinkled on the freshly applied base layer in the form of pel-lets (see illustration), approx. 1 kg/m², to ensure the adhesion and the shear strength.

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

* System: (acc. to German Standard ZTV-ING, part 7 chapter 4, design 1)

Primer:1 x SikaCor® HM PrimerBase layer:1 x SikaCor® HM Mastic Adhesive layer:Sikalastic®-827 HTProtective and wearing layer: Mastic asphalt


YOUR CONTACT ALL OVER THE WORLD

Sika Deutschland GmbH has redesig-ned its website and placed the needs of its customers further in the spot-light. The new Sika website is online at www.sika.de with a fresh appearance, high recognition value and extended offerings.

The goal is to further improve access to the extensive information that has al-ready been made available in the past.

The application fields of Industrial Coa-tings – corrosion protection, fire protec-tion and wind energy – are now also di-rectly integrated into the Sika Deutsch-land 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 Eng-lish application areas with just a click.

Overall the website presents itself to visitors with a considerably tidier and vi-sually clearer appearance. Division-span-ning information can be found in a ge-neral section covering Sika Deutschland. Information on locations, job & career as well as the comprehensive subject of sustainability is available here.

Sika Website – simple, fast and practicable

A simple menu with simple user guidance helps visitors to the website to orient themselves quickly. For example, products are arranged according to ap-plications 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.

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.

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 struc-tural 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.

A tight network of sales partners guarantees expert promotion 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.

Head of ExportManfred [email protected]+49 173 677 4774

Export AssistantEri Jones

[email protected]+49 7042 109 5301

KAM Corrosion and Fire Protection Intercompany

Marius [email protected]

+49 172 240 7613

KAM Corrosion and Fire Protection Russia

Kurt [email protected]

+49 172 260 0832

KAM Corrosion and Fire Protection Intercompany

Dieter [email protected]

+49 173 677 4775

Coordinator and Sales Services ExportBernd Pommerening

[email protected]+49 173 677 4773 All technical examination above was carried

out under laboratory conditions. Product proper-ties upon practical use are indicated in the cur-rently valid product data sheet available under www.sika.de.

Editor: Sika Deutschland GmbHRieter Tal · 71665 Vaihingen/Enz, GermanyPhone +49 (0) 70 42/109-0, Fax: +49 (0) 70 42/109-180E-Mail: [email protected]

Overall responsibility: Thomas KerkmannRieter Tal · 71665 Vaihingen/Enz, Germany

Editorial office: Sika Deutschland GmbH

Concept: DIE CREW AG, Advertising agency

Layout, Typesetting, Lithography:come medien ag

Flag

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

& Composites and Concrete through to Industrial Coatings. Through a user-friendly application using a wind tower, the visitor can find the desired products, contacts and information according to his requirements. In addition, the Sika-WindFilm graphically illustrates Sika’s expertise in wind energy.

We look forward to your visit to our homepage and hope you will very much enjoy exploring it!

Steffen Walz, Marketing Services

Extract from the new wind application

INDUSTRIAL COATINGS

MACHINEPARTS AND -HOUSING

STEELTOWER EXTERIOR

REPAIR ANDMAINTENANCE

STEELTOWERINTERIOR

FOUNDATION STRUCTURES OFFSHORE

NEW!

Market Development Manager ExportSteffen Walz

[email protected]+49 173 678 2820

sikakorronews was used; the 1,200 m2 three-sto- ... kam corrosion and fire protection intercompany...

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