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Infrastructure and Traffic Construction

High Standards - Coatings for Corrosion Protection

In everyday life, we encounter large and visible steel structures, especially in infrastructure. Motorway, road and railway bridges are particularly eye-catching. They cross rivers, gorges, roads or railway tracks, connect us with each other and help to shorten routes. Every bridge is individually designed – tailor-made engineering for local conditions. Whereas bridges were mainly made of wood and stone in earlier centuries, steel dominated as a primary building material well into the 20th century. Most of these bridges are still in use today. However, reinforced concrete is now often used in the construction of new bridges – in combination with numerous steel elements, such as struts, wire ropes, beams or hollow bodies and orthotropic road surfaces.

Corrosion Protection Coating Systems for Traffic Construction

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All systems at a glance

Your Advantages

All areas of application
Detailed information and systems
and many more

International According to ISO 12944

APPLICATION AREAS

All steel structures and visible surface
Complete corrosion protection in the factory or complete renewal on the site
Primer and intermediate coat in the factory, top coat on the construction site
Coating of weld joints

CHARACTERISTICS

Few weather-dependent operations
Fast applications
Extremely strong layer bond
Excellent shear resistance

APPLICATION AREAS

Complete refurbishment on the construction site
Repair or partial renewal of old coatings
Coating of weld joints
Partial and limited surface preparation

APPLICATION AREAS

Steel surfaces in contact with water and soil (piles, steel columns, sheet pile walls)
No longer accessible areas of steel structures
Internal coatings of drainage rings and pipes
Road closures

Friction surfaces of threaded and of riveted connections

Threaded friction connections are traditionally used in steel construction whenever slippage and deformation in the screwed connections must be minimized.

ADVANTAGES

1-pack system
Friction surface class A according to EN 1090-2 (Coefficient of static friction µ ≥ 0.5)
Very good corrosion protection also with exposure to water and moisture
Fast drying, dries even with relative humidity < 50 %
Versatile recoatable with 1-pack and 2-pack coating materials

APPLICATION AREAS

Horizontal and vertical surfaces made of steel in direct contact with track ballast

CHARACTERISTICS

Durable corrosion protection with the highest mechanical requirements
Highly resistant due to special binders
Can also be applied using an airless spray application (Elastomastic™ Airless)
Fast drying times during repair work

Despite strong vibrations, the elastic and thick-layer coating materials are resistant and offer long-lasting corrosion protection. In addition, they enable colouring and thus contribute to the overall aesthetic concept of the bridge.

APPLICATION AREAS

Coating, sealing and injecting materials for corrosion protection of fully closed ropes and cables
Cable-stayed bridges & suspension bridges

CHARACTERISTICS

Elastic, thick-layer corrosion protection
High mechanical load capacity even with strong temperature fluctuations
Compatible with common rope filling materials
Very good corrosion protection properties

Where asphalt is too heavy, high-quality, wear-resistant thin films are called for. Depending on the application area and requirements, different layer thicknesses of the top covering and different aggregates as well as sprinkling material are used.

APPLICATION AREAS

Roadway:

Lifting bridges
Bascule bridges
Movable bridges

Footpaths and bicycle tracks:

Pedestrian walkways
Stairways
Pedestrian and cycle bridges

CHARACTERISTICS

Corrosion protection for the steel plate
Weight reduction compared to mastic asphalt
High abrasion resistance on pavement and roadway
Slip resistance on pavements and cycle paths

Sealing under mastic asphalt has a long tradition. Sherwin-Williams innovative sealing system recombines proven products with a modified hot melt adhesive granulate. This provides reliable sealing with a damping effect for long-term protection of the orthotropic steel plate.

SEALING WITH ADHESIVE LAYER

The melt adhesive granulate is scattered into the undercoating as an adhesive layer. When asphalting, the adhesive layer is subjected to temperatures of around 180 °C. As a result, the adhesive granulate melts and expands and a damping system with excellent adhesion to the mastic asphalt is created.

YOUR ADVANTAGES

Few weather-dependent operations
Fast applications
Extremely strong layer bond
Excellent shear resistance

Germany According to ZTV-ING

Corrosion Protection for Civil Engineering Structures

The task of the BASt is to continuously improve the safety, environmental compatibility, cost effectiveness and performance of infrastructure in Germany. This is made possible in five departments through research projects, testing, certification, approval and recognition activities in the field of traffic planning. The corrosion protection of steel structures and steel components of the federal infrastructure is also regulated by the BASt. Among other things, it contributes the additional regulations for the federal structures and is also responsible for updating the regulations on the basis of the further development of the state of the art, the experience of the experts and its own investigations.

www.bast.de

Few weather-dependent operations
Fast applications
Extremely strong layer bond
Excellent shear resistance

ZTV-ING

The BASt has developed "Zusätzliche technische Vertragsbedingungen und Richtlinien für Ingenieurbauten" [Additional technical terms of contract and guidelines for civil engineering works]. Companies who want to be a part of such projects must ensure that they and their products comply with these rules.

Among other things, basic regulations for the preparation, implementation and checking of corrosion protection measures on structures are defined in these guidelines. Detailed descriptions and assignments of corrosion protection systems for different structures and components are also defined according to corrosion protection requirements.

The ZTV-ING (Additional technical terms of contract and guidelines for civil engineering works) define detailed descriptions and assignments of corrosion protection systems for various structures and components, depending on the corrosion protection requirement:

Corrosion protection of steel structures, ZTV-ING Part 4 Steel construction, steel composite construction, chapter 3
Corrosion protection of ropes and cables, ZTV-ING Part 4 Steel construction, steel composite construction, chapter 5
Seal an orthotropic track plate, ZTV-ING Part 7 Bridge coverings, chapter 4
Road surface and sidewalks, ZTV-ING Part 7 Bridge coverings, chapter 5

TL/TP-KOR STEEL STRUCTURES

A set of rules closely linked to the ZTV-ING are the "Technischen Lieferbedingungen und Technischen Prüfungsvorschriften für Korrosionsbeschichtungsstoffe für Stahlbauten" [Technical Terms of Delivery and Technical Test Regulations for corrosion protection coating materials for steel structures].

They define requirements and property characteristics for coating materials and systems for the corrosion protection of steel structures in accordance with the ZTV-ING and describe the respective test procedures. The focus is quality control and quality assurance with a durability of at least 25 years.

The additional technical terms of delivery and test regulations of the respective section in the ZTV-ING describe the corrosion protection systems, the coating materials and the test criteria depending on the composition or properties of the respective system. The individual systems for general steel construction from the ZTV-ING part 4 section 3 are described in so-called TL sheets.

RI-ERH-KOR

Guidelines for the maintenance of corrosion protection of steel structures

DBS 918084

Technical Terms of Delivery and Technical Test Regulations for coating materials for ballast trough coatings (sheet 84).

Only coating systems that meet these requirements are approved for use for initial coatings, partial and complete refurbishment. Such approved coating materials, together with their composition, are listed as systems by the BASt.

TL-Sheets According To TL/TP-KOR STEEL STRUCTURES

Mechanically highly loadable coating systems based on epoxy resin combination are listed on sheet 81. These are used in areas where steel is exposed to particular stresses. For example, in areas in contact with soil, concrete or water.

APPLICATION AREAS

Steel surfaces in contact with water and soil (piles, columns, steel sheet piles)
Areas of steel structures that are no longer accessible and no longer reachable
Internal coatings of drainage rings and pipes
Bearings and bearing parts
Road edges

CHARACTERISTICS

High corrosion protection even under mechanical stress
Very good adhesion even to galvanized surfaces
Very good resistance under water and moisture loads

For strong adhesion and fast drying, coating materials based on ethyl silicate with zinc dust are particularly suitable. The products listed according to sheet 86 are characterised by their simple processing and high efficiency and are used for temporary auxiliary constructions or, with extended testing, also for non-slip screw connections.

APPLICATION AREAS

Single-layer corrosion protection for:

Small auxiliary bridges
Auxiliary bridges
Pillar devices
Temporarily used components
Friction surfaces of non-slip screwed connections

CHARACTERISTICS

1-component system
Sliding surface class A according to EN 1090-2
Very good corrosion protection even under water and moisture loads
Fast drying, dries even at humidity < 50%
Can be versatilely reworked with 1-component and 2-component coating materials

For atmospheric environments, the TL-Sheet 87 is the standard for civil engineering structures in Germany. These coating materials protect all relevant structures against corrosion. They are used where aesthetics and durability are required, such as bridges, airports and railway stations.

Notes/ Recommendations

In case of low temperatures, it is recommended to use the coating materials according to sheet 97. In case of high humidity, it is recommended to use 1-component moisture-curing polyurethane coatings according to sheet 89.

APPLICATION AREAS

All steel structures and visible surfaces
Complete corrosion protection in the factory or complete renewal
Priming and intermediate coating in the factory, top coat on site
Coating of welded joints

CHARACTERISTICS

Very high corrosion protection for all atmospherically stressed surfaces
Long reworking intervals of intermediate and top coat
Top coat with high weather and light resistance

In case of low temperatures or high humidity, coatings according to sheet 89 are called for. The 1-component coating materials are particularly suitable with high humidity or at low temperatures, as they harden merely when in contact with humidity. Coating work on the building site is possible even in difficult weather conditions.

APPLICATION AREAS

All steel structures and visible surfaces
Initial protection ex works or complete renovation on the building site
Touch-up of the factory coating on the building site
Coating of welded joints

CHARACTERISTICS

1-component system
Very short overcoating intervals
Can be applied in difficult weather conditions
High durability > 25 years

The coating materials according to sheet 94 are surface tolerant and environmentally friendly. This makes them suitable not only for initial coating in shop, but also for repair work, where only limited or partial surface preparation is possible.

APPLICATION AREAS

Initial protection of steel components ex works
Full renovation on the building site
Touch-up/partial renewal of old coatings based on drying oils, AK as well as EP and PUR
Coating of welded joints
Partial and limited surface preparation

CHARACTERISTICS

Surface tolerant
Low-solvent coating system
Highly efficient due to few work steps (3-layer system)

If it has to be fast, coating materials according to sheet 97 are called for. Due to their fast curing, they are particularly suitable when short coating intervals are required. Especially at low temperatures, they are an alternative to sheet 87.

Compatible with sheet 87

Since the introduction of ZTV-ING, part 4 of 12-2012, sheet 97 and sheet 87 are equivalent. The individual products are compatible. For example, the factory coating can be performed with sheet 87 and the welds can be carried out on site with sheet 97.

APPLICATION AREAS

All steel structures and visible surfaces
Complete corrosion protection in the factory or complete renovation on the building site
Priming and intermediate coating in the factory, top coat on site
Coating of welded joints

CHARACTERISTICS

Very good, long-lasting corrosion protection
Highly efficient due to fast drying
Hardens down to -10 °C
Long reworking intervals from intermediate to top coat

ZTV-ING

The Deutsche Bahn Standard (DBS 918 084) for surfaces of railway bridges in contact with ballast forms the basis for sheet 84. According to this standard, coating systems must exhibit very high wear resistance and at the same time high elasticity.

APPLICATION AREAS

Horizontal and vertical surfaces made of steel in direct contact with track ballast

CHARACTERISTICS

Durable corrosion protection with the highest mechanical requirements
Highly resistant due to special binders
Can also be applied by using an airless spray application
Fast drying times during repair work

APPLICATION AREAS

Coating, sealing and injecting materials for corrosion protection of fully closed ropes and cables
Cable-stayed bridges & suspension bridges

CHARACTERISTICS

Elastic, thick-layer corrosion protection
High mechanical load capacity even with strong temperature fluctuations
Compatible with common rope filling materials
Very good corrosion protection properties

SEALING WITH ADHESIVE LAYER

YOUR ADVANTAGES

Few weather-dependent operations
Fast applications
Extremely strong layer bond
Excellent shear resistance

Where asphalt is too heavy, high-quality, wear-resistant thin films are called for. These are regulated in ZTV-ING part 7, chapter 5. Depending on the application area and requirements, different layer thicknesses of the top covering and different aggregates as well as sprinkling material are used.

APPLICATION AREAS

Roadway:

Lifting bridges
Bascule bridges
Movable bridges

Footpaths and bicycle tracks:

Pedestrian walkways
Stairways
Pedestrian and cycle bridges

CHARACTERISTICS

Corrosion protection for the steel plate
Weight reduction compared to mastic asphalt
High abrasion resistance on pavement and roadway
Slip resistance on pavements and cycle paths

Infrastructure in Austria

Coating systems according to RVS 15.05.11 and RVS 08.09.02 - The directives and regulations for road transport (RVS) in Austria are the counterpart to ZTV-ING.

THE FSV

The counterpart to the BASt

The Forschungsgesellschaft Straße - Schiene – Verkehr (FSV) [Road - Rail - Transport Research Association] provides a platform for professionals involved in the planning, construction, maintenance, operation and use of transport systems. It sees itself as a centre of excellence open to all experts from business, science and administration. As a point of contact for the public and private sectors in the traffic planning.

www.fsv.at

ESSENTIAL DIFFERENCES

The first top coat (PUR) is always applied in the factory
No primers containing zinc phosphate
The edge protection is executed with the top coat containing micaceous iron oxide
Optionally, a design coating without micaceous iron oxide can be applied to the second top coat

COATING SYSTEM

Standard system for steel structures

SUBSTRATE: Steel Sa 2 1/2

1. PRIMING COAT

Zinc Clad® R
(2-component, low solvent, epoxy resin-based coating material rich in zinc dust)

2. INTERMEDIATE COAT

Macropoxy® EG-1 VHS N
(2-component, very high solid, epoxy resin-based coating material containing micaceous iron oxide)

3. TOP COAT

2x Acrolon® EG-4 VHS
(2-component, very high solid, polyurethane based coating material containing micaceous iron oxide)

OPTIONALLY AS A DESIGN COAT

Acrolon® EG-5
(2-component, acrylic polyurethane coating material in RAL shades)

The illustration shows an example of a coating system.

Maintenance and repair

With Repacor™ SW-1000, our research department has succeeded in developing an abrasion-resistant, innovative 2-component coating material. It meets all requirements for the touching up or repair of (mechanically) damaged coating surfaces.

Easy to handle repair coating

Thanks to its practical mixer cartridge, this solvent-free, innovative 2-pack coating for maintenance or repair of mechanically damaged coating areas meets all requirements for a fast repair. Originally developed as a repair coating for rough offshore conditions and succesfully tested in practice for many years, the product is also very suitable for use on other industries, like steel bridges or hydraulic steel construction. Whenever a fast, but high quality and durable repair coating is needed.

2-pack repair coating with ultrafast curing

Repacor™ SW-1000 fulfills all the requirements for touching up or repairing (mechanically) damaged coating surfaces in just one operation. This outstanding repair product is solvent free, UV resistant and can be handled as a single coat filler.

Learn more about Repacor™ SW-1000 in our video:

Repacor™ SW-1000 | Corrosion Protection Offshore Repair Kit (youtube.com)

Further brochures

Repacor™ SW-1000

Product Information Sheet

Systems according to RVS

All our systems listed acc. to RVS at a glance

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Reference Projects

HASELÜNNE-FLECHUM

2016

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