THE MAGAZINE FOR EMPLOYEES AND CUSTOMERS OF MC-BAUCHEMIE 3-2018
MC Report Fire-resistant for a mobile future
Rehabilitation of Hamburg’s Wallring Tunnel Pages 8-10
MC Inside MC News MC Innovation MC Personnel MC celebrates opening of new Expansion of MC’s Konudur Flexfit for water-tight Congratulations to our production facility in Brazil Page 3 Bottrop site Pages 4-5 liner attachment Page 13 long-service awardees Page 15 MC NewsEditorial Dear Reader, Tunnels play a major role in the new building work at our main site in Bottrop, we have significantly transport infrastructure of a country increased our manufacturing, warehousing and logistics capacities or a city. Every day, they guarantee with a view to driving future growth. We are proud of this progress the mobility of a society aligned to and look forward to further enhancing our service to our customers the division of labour, protect local while contributing to the success of their projects. How we have residents from road and rail traffic done this in recent months is once again illustrated in this issue of noise and generally contribute MC aktiv with reference to a selection of construction and repair to economic growth. This makes projects. As usual, we close the year-end edition with our long- the safety of a tunnel structure, service awardees, people whose commitment has been key to the including its resistance to fire, all success enjoyed by MC in past decades. And it is for this success the more important. In order to that I would also like, once again, to express my deepest gratitude ensure the future safety of the to you, our many customers and stakeholders. more than 50-year-old Wallring Tunnel, Hamburg’s municipal authority had to commit to a comprehensive campaign of repair and refurbishment. Finally, I wish all of you a restful holiday period and a prosperous, When it came to the concrete rehabilitation and fire protection require- successful and above all happy and healthy New Year! In the mean- ments, they put their faith in MC's expertise and the fire-resistant, structur- time, as ever, enjoy the read! ally effective PCC/SPCC concrete replacement Nafufill KM 250. You can read more about this fascinating project in this edition’s MC Report. Kind regards,
And I am sure that the other features relating to MC’s internal activi- ties and our latest projects will also be of interest. With the construction and opening of our new mortar production facility in Brazil and the Dr.-Ing. Claus-M. Müller
Contents Cover
Tunnel vision: Hamburg’s Wallring Tunnel un- derwent extensive repair and refurbishment MC Inside during the period 2014-2018. For concrete re- MC Report pair and fire protection, the client LSBG (“State 3 MC celebrates opening of 8 Fire-resistant for a mobile future: Department for Roads, Bridges and Waterways new production facility in Brazil Rehabilitation of Hamburg’s Wallring of the Free and Hanseatic City of Hamburg”), Tunnel with Nafufill KM 250 relied on MC’s fire-resistant, fibre-reinforced MC establishes new company in Denmark MC’s fibre-reinforced concrete replacement PCC/SPCC concrete replacement material Nafufill KM 250 played an important role Nafufill KM 250. In comparative tests involv- in the renovation of the Wallring Tunnel, ing SPCC concrete replacement systems from MC News one of the most important arterial connections other manufacturers, this proved to be the 4 Expansion of MC’s Bottrop site in Hamburg's city centre – providing both only candidate able to verifiably meet the ex- Completion of a 3,000 m² facility marks successful concrete reinforcement and fire protection tended 60-minute tunnel fire curve specified end to a major new-build project at MC’s main site. in one. in the applicable German ZTV-ING code. Photo: MC-Bauchemie, Bottrop 6 Restoration of Rathausen’s monastery MC Innovation Extensive repair work on damp- and salt-damaged monastery walls using Exzellent STP. 13 Konudur Flexfit for permanently Credits water-tight liner attachment 7 Compelling grounds for Powerscreed rapid Publisher: Replacement screed of a new FitX fitness studio in MC-Estribond uni – the new, highly MC-Bauchemie Müller GmbH & Co. KG Berlin laid and cured within the tightest of timelines. versatile adhesive primer Am Kruppwald 1–8 46238 Bottrop, Germany 11 Structural waterproofing of Duisburg’s heart clinic MC Personnel Tel. +49 (0) 20 41/1 01-0 Fax +49 (0) 20 41/1 01-688 Nafuflex Easy Tech 1 thick bituminous coating 14 Welcome to the team: performs under unusually high site temperatures. New employees at MC www.mc-bauchemie.com [email protected] 12 Stabilisation of a railway embankment 15 Congratulations to our At risk due to ground instability, a railway embankment long-service awardees Managing editor / Conception: in the southwest of England was made safe with a Saki Moysidis, MC-Bauchemie special MC consolidation resin. Editing: 14 Konudur – an island solution Saki Moysidis, MC-Bauchemie Coastal sewerage system on the Channel Island of Thomas Haver, Leitpunkt Kommunikation Jersey rehabilitated with MC tube liners and Konudur Design: 170 TL-NV. iventos – Agentur für Marketing, Bochum, Germany
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MC celebrates opening of new production facility in Brazil
On 16 August 2018, MC Brazil Before the official dedication, the nomic stagnation in South America's tour of the MC production site in officially opened the new mor- participants were offered an inter- largest country and the impending Vargem Grande Paulista, where they tar production facility at its esting lecture programme in the MC presidential elections. Afterwards also attended the opening ceremony Vargem Grande Paulista site in Events Centre with renowned speak- Ana Maria Castelo, economist from for the powder tower. With a height São Paulo, with over 130 cus- ers from the Brazilian construction FGV University, gave a lecture on of more than 47 metres, MC's new tomers, suppliers, partners and industry. After the opening address “Marketing scenarios and opportu- powder tower offers fully automated association representatives in by Jaques Pinto, Managing Director nities in the construction industry". capacity for the production of over attendance. of MC-Bauchemie Brazil and Regional Finally, Cláudio Conz, President of 150,000 tonnes of powder products Director of MC in Latin America, and Anamaco, Brazil’s National Associa- per year. “Our new mortar produc- words of welcome from Nicolaus tion of Building Materials Merchants, tion capability will enable us both to Müller, Managing Director of MC- gave a lecture on “Developmental increase our productivity and offer our Bauchemie Müller GmbH & Co. KG, Prospects for the Retail Trade Serving customers high quality with better the presentation programme began the Construction Industry". powder product availability," said Man- with Constantin Jancsó of Bradesco aging Director Jaques Pinto, adding: Bank talking about macroeconomic Increased productivity "The additional capacity will impart developments in the Brazilian market. After the technical part of the event, important momentum as we drive This was of particular interest given Jaques Pinto and Nicolaus Müller further growth in the region." the background of political and eco- took the participants on a guided
MC establishes new company in Denmark
At the end of August 2018, MC tors. Klaus Lebæk (55) most recently of the Danish company will enable founded MC-Bauchemie Danmark worked for more than ten years as sales us to pool all previous activities of ApS based in Slangerup in the manager for an internationally active MC in Denmark and the rest of Scan- Copenhagen area. manufacturer of building materials dinavia, rather than managing them and components. He will focus in remotely from Germany as was previ- Klaus Lebæk (right in the photo) and particular on the Building Distribution ously the case," Devue (44) explained. Walter Devue have been appointed as market segment (builders' merchants For more information, go to our website the new company’s managing direc- and DIY stores). “The establishment www.mc-bauchemie.com
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Expansion of MC’s Bottrop site New facility with visual appeal
A major new-build project at With the completion of the new July 2016. The six additional ramps an impressive symbiosis, combin- MC’s main site has now been entrance area with gatehouse and were then completed ready for oper- ing a solid and aesthetically pleas- brought to a successful conclu- truck weighbridge in March 2015, ation in December 2016. As early as ing concrete substructure with a sion. Step by step, MC has given the long-planned upgrade of the MC March 2017, the 1,100 m² of ware- light-flooded glass superstructure. itself a significant face-lift with company site in Bottrop was finally house and logistics space on the It nicely reflects our corporate phi- its new 3,000 m²-plus facility in full swing. However, the project ground floor and 1,200 m² on the losophy,” explains Nicolaus Müller. "We complemented by a whole series managers still had a couple of chal- first floor of the new building were are very pleased with the result – of structural modernisations and lenging years ahead of them. Various also put into service. This meant that having created an elegant building extensions. With its aesthetically parts of the site needed to be prop- a large portion of the new facility was that both reconciles and harmonises attractive carbon-concrete ap- erly adapted to current and future already being used for its intended a site landscape that has grown up pearance, the façade of the new requirements, and there was a com- purpose. The 800 m² office floor was rather organically over the decades.” building is quite striking. pletely new building to erect as an to be occupied at a later date. "The extension of the office and logistics whole project represented a major The glass superstructure of the build- facilities. After completion of the challenge and we would like to thank ing in which the office floor is located planning and approval phase, the Burkhard Schirmer, Thorsten Bockholt, symbolises a future characterised by structural work to erect the build- Max Hanke and the rest of the team transparency, clarity and unhindered ing’s shell began in January 2016. for the smooth and successful execu- communication. It offers plenty of tion of all the work involved," com- light and, with the interior concept Expansion build with mented MC’s two managing direc- adopted, ensures quick and easy infor- operations ongoing tors Nicolaus Müller and Dr. Ekkehard mation interchange between our peo- In order to minimise the impact on zur Mühlen in unison. Not only was ple. A special feature is the unusual deliveries during construction, the it necessary during the construction design of the two lower floors of the initial work was carried out in two phases to coordinate the activities of new building: With their anthracite phases. As the first phase, six of the a great many trades and companies, façade elements made of textile-rein- The large construction site for extension of the warehouse and logistics area of MC in twelve planned loading ramps were it was also essential to ensure that the forced concrete, they symbolise the Bottrop as it was in May 2016. constructed and commissioned in warehouse and logistics operations solid foundations underlying MC – could continue without disruption. the decades of expertise accumula- tion and technological achievement Architecture as a statement that have constantly provided the The planning work was consistently platform for MC's corporate success. accompanied by lively internal dis- cussions at MC in relation to the High-tech façade panels design of the building’s façade on The façade elements are intended its front-facing side. In mid-2016, the as a powerful statement underlining management decided on a unique MCs commitment to aesthetics and frontage concept made of special excellence in concrete technology and concrete slabs and glass elements as building construction per se. Manu- designed by the Bochum-based archi- facture of the unique façade panels tects SSP AG. "The concept offered used in the design was entrusted to
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Fair-faced concrete and “mock marble cosmetics” provided the modern office interiors with a prestige finish.
the Hering Group. Within its Archi- MC admixtures – the high-performance inner qualities as had been assigned Modern spatial concept tectural Concrete department, the superplasticiser MC-PowerFlow 3130, to its exceptional exterior. Inside, the Process Management, Logistics and the company from Burbach in Germany the shrinkage reducer Centrament concrete surfaces of six walls and entire Concrete Industry department unites innovative material concepts SRA 1 and the aluminosilicate Centri- 20 columns in the entrance area as have moved into the new office floor. with decades of experience in design- lit NC II – were used both to improve well as in the offices of the Process “As these departments work closely focused concrete façade construc- the homogeneity and density of the Management, Concrete Industry and together on a daily basis, this spa- tion. Just as well, because implemen- concrete and to increase its com- Product Management departments tial integration offers many advan- tation of the design specifications pressive and flexural strength values. were to retain their natural fair-faced tages and synergies," comments required adoption of a particularly Also used were the curing agent Em- appearance. Dr. Ekkehard zur Mühlen. The room tailored approach. Hence, the project coril Compact top, which prevents plan ideally reflects the associated was also supported by the Institute rapid drying and reduces physical Unfortunately, surface blemishes supply chain segment. The space for Solid Construction (IBM - Institut shrinkage, and Nisiwa L for hydropho- can never be ruled out in the pro- comprises modern, ergonomically für Massivbau) at the University of Sci- bising the façade panels. The inter- duction of such surfaces, with the designed single, double and group ence and Technology RWTH Aachen. action of all these various products result that pores, gravel pockets, offices and is intended to promote ensured achievement of the ulti- spacer holes and fractured edges all interdepartmental communication Textile-reinforced concrete – mate objective, namely to create a made an appearance. The company and fast decision-making with short a unique material high-density and high-strength con- Beko Betondesign from Düren was distances between important interface Textile-reinforced concrete has long crete that also exhibited a surface of therefore commissioned to rem- functions. The cutting-edge open- become established as a building great quality and aesthetic appeal. edy the defects using the con- plan design allows visual contact material for lightweight façade pan- crete cosmetic products of MC's and is intended to enhance team els. Those used for the new building A total of 409 elements were manu- Emcefix system. Careful cosmetic spirit and social interaction as well as in Bottrop are each 3 cm thick and factured in Hering's precast factory, concrete retouching produced a effective and efficient cooperation. measure 0.50 x 0.77 to 1.13 x 3.67 including 30 specimens for the IBM perfect match, with both the filled metres. Two different types were man- at the RWTH Aachen. The university and the non-filled concrete sur- Fast move ufactured: Blank façade panels, into department concerned duly tested faces taking on the look of a fine, The newly created workspaces were which a fine-weave, rubber-impreg- them, with submission of an inde- homogeneous fare-faced finish. ready to receive their occupants in nated carbon textile with a mesh pendent analysis so as to obtain the October 2018, with the company- size of approx. 2 cm was embed- required single-case building author- A further highlight comes in the internal move completed in just 48 ded; and perforated panels, which ity approval. Once this was granted at form of three walls in office and hours – a tremendous logistical achieve- were reinforced with a coarse-weave, the end of February 2018, production meeting rooms, which have been ment for all involved. Since then, the rubber-impregnated carbon textile went into full swing. In late autumn upgraded with MC’s “Marble Cosmet- new facility has remained a visual with a mesh size of approx. 15 cm. 2018, the last panels were finally fit- ics” system. With Emcefix-Spachtel highlight in MC’s worksite landscape. In order to obtain the same strength ted by the specialist façade install- F fine filler, available in seven dif- of reinforcement as with the blank ers Hölscher Metallbau of Geeste. ferent shades, and the transparent slabs, thicker individual strands were MC-Color Proof pure glaze, the surfaces used in the latter case. The concrete The fairest of were given a cloudy and marbled employed was a very fine, self-com- fair-faced concretes finish with a concrete look and feel. [email protected] pacting and high-strength grade with Needless to say, as much emphasis Hence, MC’s expertise has also found [email protected] a maximum aggregate size of 5 mm. needed to be given to the building’s expression in the building’s interior. [email protected]
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Right: The monastery complex fully scaffolded for the renovation work. Above: The cloister in the inner courtyard following renovation with Exzellent STP.
Restoration of Rathausen’s monastery
Renovating old buildings often Dating from 1254, the masonry of the The effect of Exzellent STP floor-wall connection by that Exzellent means rehabilitating damp listed monastery of Rathausen near Between 2015 and 2017, each of the STP skirting. The cloister was also com- masonry and dealing with the Lucerne had suffered severe struc- walls of the Rathausen monastery was pletely rehabilitated inside and out. salts dissolved therein. These tural deterioration. Both inside and repaired inside and out by the con- need to be neutralised or elimi- outside, significant damage to plas- struction company Knöchel + Pun- Easy-to-use yet innovative nated as, with time, they can ter and masonry had to be repaired gitore AG, with Exzellent STP render salt transport render make a building uninhabitable. in order to ensure the continued, being applied from ground level to Exzellent STP has been designed in This was very much the case with needs-based use of the building the lower window line. First of all, such a way that moisture, including the Rathausen monastery com- complex by SSBL, the Swiss charity the base area around the building dissolved salts, is released from the plex in Switzerland. However, for the severely disabled headquar- had to be freed from the old plas- masonry into the ambient air before thanks to comprehensive reno- tered in Lucerne. In order to protect ter. The subsequent render cover- any damage can occur – made possi- vation with Exzellent STP from the masonry from salts and mois- ing was applied using Exzellent STP ble by a unique network of intercon- MC, this facility has now been ture, an injection of paraffin was 540 as the pre-spray primer, Exzellent nected macro and capillary pores. The returned to its intended use. planned in the initial invitation to STP 500 as a machine-applied top salts crystallise on the plaster surface tender, together with application of coat and Exzellent STP 750 for the without damaging its structure and a restoration render. However, the required fine finish. The advantage can easily be brushed or washed off. high labour input and cost meant of the salt transport effected with The Exzellent STP render system ena- that eventually this option had to be Exzellent STP is decisive, especially bles the fast and effective repair of rejected. Together with the Canton for building base areas carrying a damp and salt-laden masonry and of Lucerne and the heritage pres- high salt load. can be applied directly to the damp ervation authorities, the principals wall. It is resistant to all water-soluble sought an alternative solution, finally The salts are constantly attracted from salts found in buildings. The use of
The cloister in the inner courtyard opting for the moisture-control ren- the masonry to the surface of the ren- Exzellent STP also means that costly during and after refurbishment. der system Exzellent STP from MC. der without encountering any mean- waterproofing measures such as pro- ingful resistance. Thus the base is per- vision of a secondary damp-proof manently protected from salt-related course can be avoided. With the total damage. The façade above was repaired success of the renovation work, the where most needed, with the entire monastery building near Lucerne has surface then being painted with a returned to its former splendour and highly diffusion-promoting paint. In is very much back in service. the interior, an “STP strip” was installed together with a new floor on a damp-
proof course. The humidity is now [email protected] regulated over the area around the [email protected]
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Compelling grounds for Powerscreed rapid
The screed of a new FitX fitness studio in Berlin was found to be inad- equate for the free weights area. Immediate remedial work was essential and needed to be done within the tightest of deadlines – just the job for Powerscreed rapid, MC’s high-performance accelerator for cement screeds.
Even before the opening of a new saves a great deal of water, it also studio in Berlin, its operator, Essen- considerably increases the material’s based FitX Deutschland GmbH, was early and final strength values. Spe- confronted with a major problem: The cial microcrystals with a cement-like screed of the approximately 500 m² surface structure catalyse the hydra- free weights area on the ground floor tion of the cement, accelerating the had an average flexural strength of drying process. In addition, screeds only 4 N/mm² instead of the required with low w/c values can also be used 7 N/mm². Immediate rehabilitation to good effect. was necessary – with only a few weeks to go before the planned opening Customised formulation date in August. General contractor Together with screed specialist Schröder, André Bahnsch, Managing Director the MC team developed an individual of Bahnsch GmbH, commissioned screed mix for this special undertak- Sandro Schröder's specialist screed- ing. The aim was to ensure that the laying company in Pritzwalk to carry desired strength would be achieved out the work – with an immediate through increased use of cement com- start date. He in turn confidently pre- bined with the strength-enhancing sented the challenge to MC sales rep- Powerscreed rapid accelerator. The resentative Steffen Suenboldt, who risk: The application of higher cement was quick to provide the advice and ratios can inhibit workability. Yet here, assistance that the screed-laying spe- too, Powerscreed rapid showed its cialist required. capabilities by actually significantly improving the processing proper- A screed for special tasks ties of the screed, enabling the entire Not only was the timeline in Berlin 500 m² area to be completely re-laid extremely tight, the specified F7 flex- in just two days. ural strength (7 N/mm²) was also a difficult ask. Achieving such “bend- The site work was further supported ing tensile” strength values reliably by MC to ensure achievement of the often poses a problem for earth-moist required mechanical properties dur- screeds, due to the fact that com- ing the drying process. The screed paction is inherently low. However, exhibited a flexural strength value if the F7 target were to be missed of 6.16 N/mm² after ten days and a second time, it would have been 7.56 N/mm² after 28 days – needless a disaster – not least because the to say, very much to the delight of subsequent trades were by this time the screed layers, the site manager already behind schedule. The solu- and the client alike. And the studio tion to the problem? Powerscreed did indeed open on schedule in rapid. This high-performance hard- August 2018. ening accelerator for the production
[email protected] of screeds that allow early walk-on Thanks to Powerscreed rapid, the screed replacement work at the FitX studio in Berlin met all [email protected] accessibility and overworking not only [email protected] the top performance criteria specified.
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Fire-resistant for a mobile future Rehabilitation of Hamburg’s Wallring Tunnel with Nafufill KM 250
The final opening of the two A major traffic artery Thorough renovation from the underlying section of sub- tubes of the Wallring Tunnel For Hamburg as a growing metropolis While the structure and its materi- way line 3 by a 22 cm thick reinforced to Hamburg’s traffic after four and logistics hub, an efficient infra- als were considered state of the art concrete slab, it was not possible to years of extensive modernisa- structure is and always has been a when the Wallring Tunnel opened provide a continuous drainage con- tion marked the end of a long vital prerequisite. The Wallring Tun- in 1966, its design falls well short of duit from Deichtorplatz to Ferdinands- period of suffering for many nel, built between 1963 and 1966 today's safety and fire protection reg- tor. Instead, a pumping station shaft motorists. During the successful from Glockengiesserwall to Stein- ulations. But it was not until 2013, with parallel, i.e. redundant, pumps rehabilitation of this important strasse, considerably reduces the when the Hamburg Senate initiated had to be built in each tunnel tube as inner link across the Hanseatic above-ground traffic congestion an about-turn in transport policy, that part of the refurbishment package in city, the experts from MC's Con- in Hamburg’s city centre near the the money was made available for order to ensure – at any time – that crete Repair division were once main railway station. With a daily the urgently needed renovation of accumulating water can be pumped again able to demonstrate the volume of around 40,000 vehicles, the ageing structure. The city state’s away via the subway tunnel system. true extent of their knowledge it is now one of the most impor- budget finally allocated to its reha- 12,000 m² of road surface were newly and experience. MC’s fibre-rein- tant inner-city traffic arteries in the bilitation was 30 million euros. Thus, asphalted, and a barrier system was forced concrete replacement Hanseatic metropolis. The tunnel in 2014, the LSBG (“State Agency for installed in order to close the tunnel product Nafufill KM 250 also consists of two tubes, each with Roads, Bridges and Waterways of the to traffic if this were ever deemed nec- played a key role in the renova- two carriageways. The central sec- Free and Hanseatic City of Hamburg”) essary. Much of the new technology tion project. tion houses supply facilities, a ser- was able to kick off the construction is reminiscent of that installed in the vice gallery and an escape route. project. Elbe Tunnel – and indeed the new The Wallring Tunnel was designed system is to be connected to the Elbe as a frame structure which is open The road construction activities began Tunnel operations centre from where at the bottom due to the fact that in 2014, with the safety and fire pro- the Wallring Tunnel will in future be it stands above the groundwater tection work in the two tunnel tubes monitored via an optical fibre link. level and therefore requires no bot- being initiated in 2016. Over the next tom closure. It was built using the two years, almost the entire electrical Organisational challenges cut-and-cover or open construction system was replaced, a loudspeaker The project team led by civil engineer method, with auxiliary bridges required system installed, video surveillance, Hanns Simons, responsible at LSBG
to carry entire road intersections. fire alarm cables and CO2 measure- for the “Wallring Tunnel Refurbish- It runs under Hamburg city centre ment equipment modernised, and ment Project” within the organisa- between the Alster and Elbe rivers, escape routes, emergency recesses tion’s “Civil Engineering Works” divi- is 550 metres long and crosses the and emergency call stations updated. sion, faced numerous severe obstacles: intersections at Georgsplatz, Spi- A total of 120 kilometres of cabling “The construction work required had talerstrasse, Mönckebergstrasse was laid. The particular features of to be carried out while keeping the and Steinstrasse. It passes close to the Wallring Tunnel’s architecture tunnel tubes operational,” he explains. a deep bunker at Steintorwall next to also required implementation of a This meant working a total of 700 the main railway station and passes number of tailored measures. As the nights over the length of the project. over three subway tunnels. tunnel floor is separated at one point In order to keep the traffic flowing
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Fire-resistant for a mobile future Rehabilitation of Hamburg’s Wallring Tunnel with Nafufill KM 250
The fire-resistant concrete replacement product Nafufill KM 250 was applied in a layer thickness of approx. 4.5 centimetres by the wet-spray method, ensuring low-dust and low-rebound proces- sing so as to keep environmental pollution to a minimum.
as much as possible, it was tempo- hazard made it imperative to uprate reinforcement must not heat up rarily routed through the two tun- the entire concrete structure. to more than 300 °C. This must be nel tubes on an alternating single- ensured by providing a concrete cover lane basis, with closing times shifted MC – the specialist for of sufficient thickness. Needless to to periods of low traffic density, i.e. concrete refurbishment say, in the case of tunnels in cities nights, weekends and school and The LSBG specified improving the with adjacent transport structures, public holidays. “We could have got- tunnel’s structural fire protection by the requirements set are particu- ten the job done more quickly, but increasing the thickness of concrete larly exacting. that would have meant completely cover on its walls and ceilings. It was closing the tunnel,” Simons adds. In at this juncture in 2014, two years In line with the engineer's duty of view of the traffic volumes encoun- before commencement of the actual care as specified in the relevant Ger- tered in Hamburg’s city centre – hard construction work, that Henning Völtz, man technical code ZTV-ING, Part 5, to cope with at the best of times – an experienced MC sales representa- and risk analyses based on longer fire such a project approach would sim- tive in the Infrastructure & Industry durations recently included therein, ply not have been feasible. division in Northern Germany (and, such tunnels and their reinforce- as of January 1, 2019, sales manager ment must be designed so that Hazardous interior cladding at MC’s Hamburg Service Centre) effective fire resistance is guaran- View of a finished tunnel wall after being However, the planning engineers had began supporting the project, ini- teed for a period of 60 minutes at sprayed with Nafufill KM 250. Aside from en- an even bigger headache relating to tially in an advisory capacity. He was 1200 °C followed by a 110-minute suring the required fire resistance, this con- the safety of the original concrete assisted in this role on an ad-hoc cooling phase, the purpose being crete replacement from MC is characterised by its very good flexural and compressive reinforcement within the tunnel basis by Werner Baumgart, Global strength behaviour (R 4 mortar to EN 1504 tubes. In order to improve the light- Product Manager, Concrete Repair Continued on page 10 Part 3) and high carbonation resistance. ing conditions inside the tunnel, the & Surface Protection. MC pools all walls had been covered with frost- of its specialist knowledge in rela- and acid-resistant white split-face tion to the rehabilitation of con- tiles, creating a cladding of between crete structures within its Concrete 3 and 4 cm in thickness on a 1.5 cm Repair & Surface Protection division. layer of mortar. While indeed bright- Aside from repair and refurbishment, ening the interior of the tunnel, this this encompasses PCC and SPCC cladding system was far below the concrete replacement systems and standards specified in modern fire coating systems for long-term sur- protection regulations. In the event face protection. of a severe fire in either of the two tunnel tubes, a temperature of more Stringent requirements than 500 °C would have occurred The fire protection specifications for at the reinforcement, jeopardising tunnel construction stipulate that, its structural integrity. This potential in the event of a fire, load-bearing
MCMC aktiv aktiv 3_2015 3_2018 | |99 MC ReportageReport
A mammoth task also in logistical terms: The fire-resistant concrete replacement product Nafufill KM 250, deliveries of which were restricted to the late night hours, was supplied in 101 truckloads over just a few weeks of application work. The total quantity delivered amounted to 2,100 tonnes.
Continued from page 9 to minimise the probability of failure of reliable structural fire protection in only ensures effective fire resistance always enough Nafufill KM 250 available the principal structure and also that of the Wallring Tunnel. The sprayable but also better protects the concrete on site for the ongoing spray-coating any adjacent structures. The construction polymer-modified cement mortar – representing a solution that is as work. The total quantity ultimately materials used for such applications (SPCC concrete replacement) speci- safe as it is economical. supplied was 2,100 tonnes delivered must correspond to building material fied for the job needed to verifiably in 101 truckloads. This constitutes a class A (non-combustible) according comply with the ZTV-ING tunnel fire A mammoth task huge success, achieved through to DIN 4102 and must not release any curve extended to 60 minutes. The Execution of the work was entrusted comprehensive advance planning substances that could be injurious to experts recommended the fire-resistant, to the French company EUROVIA, a and the friction-free interaction of either personnel or the structure itself. fibre-reinforced PCC/SPCC concrete world leader in road and transport all participants during the construc- replacement Nafufill KM 250 from MC. infrastructure construction. Schachtbau tion phase. Nafufill KM 250 fulfils Nordhausen Bau GmbH was com- every requirement Performed by the client’s planning missioned with the SPCC work and Successful project completion MC’s experts in Product Manage- engineers, a comparative test of SPCC began installing the Nafufill KM 250 This extraordinary project in Hamburg ment and Sales advised the client concrete replacement systems from replacement onto the prepared was completed on schedule and on LSBG and its planning engineers WvS various manufacturers for use in the surfaces in November 2016. A layer budget – something that has become Zivilingenieure Hamburg to choose Wallring Tunnel confirmed Nafufill KM thickness of approximately 4.5 cm rather a rarity in this day and age. an effective, tried and tested concrete 250 as the only SPCC mortar capable was to be applied by wet spraying. The former Hamburg Senator and replacement in order to achieve of compliance with the criteria implicit This technique ensures low-dust and State Secretary for Transport, Frank in the specified fire curve. This fibre- low-rebound processing compared Horch, expressed his satisfaction at reinforced concrete replacement is to dry-sprayable SPCC mortars, thus the inauguration of the tunnel in July MC field sales representative Henning Völtz also characterised by its very good also keeping environmental pollu- 2018: “This was a tough, demand- was there to support the project right from the start. flexural and compressive strength tion to a minimum. The target area ing project, but the decision to see behaviour (R 4 mortar to EN 1504 amounted to 21,000 m². The huge it through was absolutely right. With Part 3) and high carbonation resist- volumes involved also meant MC’s great speed, we have succeeded in ance. It is also resistant to de-icing logistics would feel the heat: In simple modernising mobility in our munici- salts and chloride penetration. Used terms, their task was to ensure that pality.” Hamburg’s road users will be in the refurbishment of Cologne’s a constant flow of Nafufill KM 250 delighted. With the repairs and mod- Grenzstrasse Tunnel in 2016, Nafu- was always available, even though ernising measures now 3extensively fill KM 250 had, moreover, already deliveries during the construction finished, the tunnel will doubtless make demonstrated its excellent suitabil- phase were limited to the night great inroads in relieving Hamburg’s ity for use in the rehabilitation of time. Due to the size of the project downtown traffic – another shining tunnels with special fire protection and the short construction period, example of safe and sound infrastructure. regulations. Compared to conven- this sometimes meant six 21-tonne tional fire protection systems such truckloads per week. However, the as panel cladding applied to the challenge was met in full: During the [email protected] concrete shell, Nafufill KM 250 not entire construction phase, there was [email protected]
1010|| MCMC aktivaktiv 3_2018 3_2016 MCMC PersonaliaMC Aktuell News
Despite the exceptionally high summer temperatures prevailing, the single-component thick bituminous coating Nafuflex Easy Tech 1 made execution of the waterproofing work relatively simple.
Structural waterproofing of Duisburg’s heart clinic
The renowned “Herzzentrum” heart clinics organisation is currently having a new building constructed in the city of Duisburg. Summer 2018 saw execution of the waterproofing work for the structure, approximately one year ahead of its planned opening date. For this, MC's thick bituminous coating Nafuflex Easy Tech 1 had to withstand the unusually high summer temperatures encountered during placement.
Affiliated to the hospital “Evangelis- Experienced team small measure to the weather condi- ible. In addition, the flexible special ches Klinikum Niederrhein”, Duisburg’s The specialist company M + M Pistohl tions prevailing in the area. With its sealing tapes Nafuflex DB 300 and “Herzzentrum” (heart clinic) is one of GbR from Senden near Münster was consistency specifically optimised MC-FastTape were applied to expan- the five leading centres of its kind in commissioned with the spray application for spray application using airless sion and building movement joints Germany. After the old building on work. The owners Manfred and Markus technology, or peristaltic or screw as well as the corner fillets present. Gerrickstrasse in Duisburg’s Meiderich Pistohl decided to use MC products pumps, this single-component bar- These tapes are fully compatible with district was deemed no longer able based on their many years of gratify- rier product remained easy to apply polymer-modified thick bituminous to meet modern-day demands, the ing experience with such solutions. even at the sometimes extremely coatings, ideally complementing the decision was taken to build a new Sales representative Waldemar Werner high temperatures of the unusually Nafuflex waterproofing system while centre elsewhere. Around 130 million and product manager Patrick Kohley hot summer of this year. Optimised also providing increased reliability. euros was therefore invested in an provided the comprehensive support consumption also meant that the extension of the hospital “Evangelisches required to ensure maximum success process was particularly economical. Despite difficult conditions, the work in Krankenhaus Duisburg-Nord” in the through all phases of the project. And Duisburg was completed on time and northern Duisburg district of Fahrn. Markus Pistohl was delighted at the However, it was the technical per- with impressive results in every respect. Measures for waterproofing the newly results of this collaboration: “With MC, formance of the product that really [email protected] constructed building were carried out you have everything you need. From impressed. As a highly flexible, [email protected] in August 2018. Sealing against the the products themselves to the tech- crack-bridging polymer-modified penetration of soil moisture and non- nical service the company provides.” bitumen, Nafuflex Easy Tech 1 can pressing water in the building (water even seal protrusions, light shafts impact class W1-E) was performed in Systematic waterproofing and interface connections quickly, accordance with the currently valid Nafuflex Easy Tech 1 is a polymer-modified easily and – above all – securely. The [email protected] German waterproofing standard DIN thick bituminous coating (PMBC). The absence of solvent also ensures that [email protected] 18533 over an area of around 300 m². decision to use this was due in no its use is environmentally compat-
MC aktiv 3_20183_2015 |1111 MC NewsAktuell
With the soil consisting of a poor-quality mix of mudstone and sandy silt, the injection lances had to be placed at depths of between 5 and 12 metres and in a tight injection grid with centres of just 1.5 metres. Stabilisation of a railway embankment
In Scorrier, a village in the south- The small village of Scorrier is located train safety that this potentially rep- requiring a tight grid of injection west of England, the embank- in Cornwall at the southwest tip of resented, line operator Network Rail points with centres of just 1.5 metres. ment of a railway line was England, some 5 km from the coun- initiated immediate action to restore determined to be at risk due to ty’s northern coast at Porthtowan. ground stability deep below the track. Injection success ground instability. In the course First mentioned by name in 1330, The injection lances were installed of the remedial work, a highly the village is located in the middle First choice for accordingly. Featuring a mix design adaptable injection resin system of the Gwennap Mining District, a ground consolidation aligned to the application require- developed by MC-Bauchemie tin mining area exploited for centu- The main contractor commissioned ments, the special two-component was found to be particularly ries by interests extending across the with planning the work was Balfour resin was then injected into the soil suitable for consolidating the Cornwall and West Devon regions. Beatty plc headquartered in London. together with foam stabiliser addi- underlying soil. The objective was to inject the soil over tives. With its short reaction time, Danger underground and inside the old mine to a stiffness the injection resin quickly set to high It was here that the integrity of a value above 70 kN/m², for which pur- compression and flexural strength rail embankment was in jeopardy: pose the SSI Services department of values. It also readily satisfied the prin- The soil under the embankment Walsall-based South Staffordshire plc, cipal ground injection specifications: had become unstable due to the proven specialists in this kind of work, With 24 tonnes of the specially formu- shaft of a tin mine apparently hav- was engaged. It was jointly agreed lated injection mix having been used in
Some of the injection work was carried ing been insufficiently infilled when that a low-viscosity polyurethane- the project, the ground stiffness value out at night. it was closed. Given the danger to based duromer resin should be used of > 70 kN/m² required by Network Rail in order to seal and consolidate the was reliably achieved throughout the voids and crevices in the loose ground. treated area. As a further safeguard, the stabilised soil was subsequently Sound preparation overslabbed with concrete, ensuring Initial training was provided in that rail operations could once again Nottingham by MC for the tech- return to smooth-running normality. nicians of the injection contractor [email protected] in order to ensure that the work [email protected] could be successfully executed [email protected] from the outset. Attention then switched to the site in Cornwall. With numerous probe tests having been completed, the requisite injec- tion depths were found to extend from 5 metres to a maximum of 12 metres. The ground of mudstone and sandy silt was of poor quality,
12 12| MC| MC aktiv aktiv 3_2018 1_2016 MC Innovation
Konudur Flexfit for permanently water-tight liner attachment
The attachment of pipe liners to drainage and sewer manholes is a highly sensitive area, one in which the occurrence of leaks is a constant con- cern. With Konudur Flexfit, MC-Bauchemie has now developed a reac- tive resin filler and sealant that can be used to provide a permanently flexible connection for attaching in-situ curing pipe liners to shafts and manholes easily, quickly and safely.
Developed as a special-purpose two- substrates of a sewerage system as tion to the attachment of in-situ pack Power-Tool, MC's air-operated component reaction resin, Konudur well as dry GRP laminates, and is curing pipe liners to drainage and two-component manual dispenser. Flexfit is characterised by its easy chemically and mechanically highly sewer manholes, Konudur Flexfit can The benefit here, of course, is that workability, its high moisture com- resilient. Under normal sewerage also be used for manual connection the use of disposable static mixers patibility during application, and its system temperatures, Konudur Flexfit of lateral inlets in downshafts and eliminates the need for a separate very rapid resistance to water. becomes water-resistant after just 25 accessible sewers as well as for filling mixing operation. to 30 minutes. This results in signifi- and sealing sleeves and couplings, [email protected] Simple, fast application, cant time savings in rehabilitation even in permanently flooded areas. high resilience work, as well as minimised traffic Once mixed, Konudur Flexfit can be disruption and drainage times, with Konudur Flexfit CS – easily applied – even overhead – with appreciable cost savings therefore the cartridge alternative a float, trowel or putty knife, with also ensuing. MC’s special reaction MC-Bauchemie also offers its new no unpleasant odours to cause a resin remains permanently flexible, reaction resin filler/sealant in double- nuisance. The stable reaction resin ensuring effective compensation chamber cartridges as Konudur Flexfit filler/sealant offers good adhesion for changes in liner length due to CS, a product that can be applied to all dry and matt-damp mineral shrinkage or temperature. In addi- directly on site with the MC-Fast-
New, highly versatile adhesive primer
With MC-Estribond uni, MC has launched another addition to this range of bond coats and primers.
MC-Estribond uni is a versatile, new aggregate, it offers a naturally keyed single-component adhesive primer surface structure to ensure opti- from MC-Bauchemie offering the mum bonding with subsequent [email protected] [email protected] benefits of a primer and adhesion coatings and levelling compounds. [email protected] promoter in one and the same prod- On absorbent substrates such as uct. It enables optimum results to concrete, masonry or screeds, be achieved on both smooth and MC-Estribond uni diluted with absorbent surfaces. MC-Estribond uni water at a ratio of up to 1:2 serves adhesive primer can be used undi- as an excellent primer for the sub- luted on smooth and non-absorbent sequent application of, for example, substrates such as old tile coverings a levelling compound. It also works or heavily compacted concrete. as an effective surface consolida- Formulated with a stabilising filler tor on slightly dusty substrates. [email protected]
MC aktiv 3_2018 | 13 MC AktuellNews
Konudur – an island solution
On the Channel Island of Jersey, The island of Jersey is the largest coast of Jersey were rehabilitated epoxy resin for impregnating and the coastal sewerage system and most populous of the Channel with Konudur Homeliner and Konu- fulling the DN 375 liners, because this is exposed to strong tidal vari- Islands. A British crown dependency, dur 170 TL-NV, MC's thermoreactive MC product offers proven benefits ations. In order to counteract it lies in the bay of St. Malo, famed epoxy resin. in the form of rapid, shrinkage-free this turbulence and prevent for its enormous tidal range of 12 curing and hardening combined with serious damage, the sewers are to 13 metres. The effect of seawater Trenchless sewer rehabilitation a long pot life. It also impresses with being rehabilitated with pipe on the coastal sewerage system has with the Konudur system its high strength and can be used on liners and Konudur 170 TL-NV, always been significant, with infiltra- Konudur Homeliner offers an ideal dry and damp mineral or metallic MC's epoxy resin. tion and exfiltration of waste water solution for trenchless sewer reha- substrates. It took just two weeks repeatedly occurring in the past. For bilitation. The system involves a to repair several hundred meters of 10 years, Drainway Services Ltd. has flexible hose carrier (=liner) made sewerage in this latest campaign. been responsible for the ongoing of corrosion-resistant synthetic and/or The rehabilitation measures in Jersey maintenance of the sewerage net- glass fibres being impregnated with improve not only the efficiency of work and the prevention of damage reaction resins and introduced via a the sewerage system, but also the to its components. Most recently, in shaft or pipe opening into the sewer seawater quality for bathers. April 2018, several hundred metres section to be rehabilitated. Drainway of sewers in the promenade area of Services Ltd. opted for Konudur 170 the small town of Gorey on the east TL-NV, a low viscosity, two-component [email protected]
Welcome to the team New employees at MC
John van Diemen (53) joined MC on 1 August 2018 as Head of Research & Development. In this function he bears respon- sibility for the further development of the entire product portfolio of the MC Group. Holder of a Masters’ degree in chem- istry, he was last Head of R&D at a manufacturer of speciality coatings, having previously worked for many years in various management functions for a globally active speciality chemicals group.
Henning Völtz (40) will, as of 1 January 2019, assume the position of Head of Infrastructure & Industry Sales at MC’s Ham- burg Service Centre. The state-certified technician for mechanical engineering has been working in MC's field service since January 2011 and during this time has been in charge of both the Mecklenburg-Western Pomerania region and the greater Hamburg area. In his new function he will be managing a team of six back office and field sales employees.
Hamed Jadidzadeh (41) ) took over the position of Segment Manager on 1 August 2018, with respon- sibility for the MC Fields of Expertise: Carpark, Industry and Injection. The business administration graduate had previously worked for a publicly listed manufacturer of chemical consumer goods for more than 12 years, most recently as Global Senior Business Development Manager.
141414|| | MC MCMC aktiv aktivaktiv 3_20183_20153_2018 MCMC PersonaliaPersonnel Congratulations to our long-service awardees
It is customary at MC for the management to honour long-ser- ance, keen to express his personal recognition to each of the awar- vice anniversaries with a traditional awardees’ banquet on the first dees, and thanking them for their long service and loyal commit- Thursday in December, held at the Gasthof Berger restaurant in Bot- ment to the company. He also presented gifts as further acknowl- trop-Feldhausen. Thus it was that, on St. Nicholas Day, 6 December edgement of the achievements of those present from Germany 2018, this year's anniversary celebrations took place at that venue and Switzerland, all of whom this year celebrated their 10th, 25th or for people within the MC Group, with Dr. Claus-M. Müller in attend- 40th anniversaries with the company.
10-year anniversary Zsolt Bazsó (HU) Peter Páleník (SK) Brigitte Bünter (CH) Robert Schnell (D) Mihail Todorov (BG) Róbert Karsai (HU) Javier Pastalle (SP) Kai Böndgen (D) Dr. Michael Schütz (D) Jürgen Armbruster (D) Ching Hsin Kwong (MAL) Anson Chen (TW) Janus Falszowski (D) Dr. Thomas Sieber (D) Guido Balgar (D) Gerjan Zwep (NL) Myhailo Barskyy (UA) Renate Fezer (D) Alexander Spies (D) Monika Böhmer (D) Małgorzata Dajerling (PL) Tamara Kupriyanova (UA) Jack Geenen (D) Dirk Teichmann (D) Julian Fleige (D) Marcin Mańczak (PL) Loreta Erum (UAE) Thomas Goretzki (D) Ramona Weidner (D) Uta Griesdorn-Kleinkoenen (D) Marcin Pietraś (PL) Thanh Ha Le (VN) Thomas Heck (D) Tom Jansen (D) Tomasz Rogowski (PL) Dr. Wolfgang Karl (D) 40-year anniversary Irena Karch (D) Marcin Smytry (PL) 25-year anniversary Heinz Dieter Labusch (D) Dagmar Hoerner (D) Marion Krämer (D) Magdalena Szczepaniak (PL) Richard Hamet (CZ) Peter Markolwitz (D) Jürgen Schmiemann (D) Swen Linning (D) Przemysław Szymkowiak (PL) Jochen Arndt (D) Waldemar Neumann (D) Reinhard Studnik (D) Yvonne Pohlhaus (D) Mirosław Walkiewicz (PL) Günter Josef Banko (D) Andreas Rainer (D) [email protected] Thomas Schuster (D) Krzysztof Zenker (PL) Dr. Dörte Bartel (D) Mathias Reck (D) Nicole Timp (D) Ana Catarina Ramos (PT) Frank Benten (D) Jost Reichenberg (D)
Congratulations to our awardees of MC Russia
On 20 November 2018, Evgeny Sokolov, Managing Director of MC Russia, and Regional Manager Hubert de Brichambaut congratulated 16 employees on their 10th anniversary with MC in Russia. Left to right: Egor Gureev, Alexey Ivanov, Alexey Strahov, Sergey Minko, Pavel Shamraev, Andrey Nevolin, Dmitrii Shvaenko, Evgeny Remyga, Mikhail Zhivihin, Elena Ivanova, Sergey Smirnov, Alexander Tyzengauz, Alexander Zinovyev, Mikhail Belyakov, Evgeniy Zakharin und Vitaliy Medvedev.
MC aktiv 3_20153_2018 | 15 Offering that little Extra for your more delicate work
Ortolan Extra 772 KS
The new generation of MC concrete release agents
With Ortolan Extra 772 KS, MC is able to offer you a highly effective, environmentally friendly concrete release agent for the precast production of semi-finished concrete slabs. After mechanical spraying, the self-levelling emulsion forms a homogeneous, thin separating film. And its built-in inhibitors also protect your moulds and formwork from corrosion. The result: Cleanly stripped, smooth concrete surfaces and undisrupted production automation.
Talk to us! You’ll find we can help when things get a little delicate.
EXpertise Release agents