Content Notice

The following articles are taken from the MC aktiv publication and curated by Buidling Chemical Supplies Ltd. Content contained is therefore the property of MC-Bauchemie Müller GmbH & Co. KG.

Comprehensive systems and sophisticated solutions

The "RatingerTor" multi-storey car park in Dusseldorf has been extensively repaired and refurbished.

Climatic influences and dynamic and static loads give rise to various forms of damage in multi-storey car parks. Expertise and experience such as that available from MC is in high demand when it comes to ensuring the lasting repair and refurbishment of such structures - as in the case of the "Ratinger Tor" multi-storey car park in Dusseldorf, Germany, and another example in the central Ruhr town of Bochum.

A special coating prevents the build-up of electrostatic charge at the entrance of this Bochummulti-storey car park.

Dusseldorf's "Ratinger Tor" multi-storey car park exemplifies the high regard in which quality system solutions from MC are held for this kind of repair and refurbishment project. Damage such as reinforcing steel corrosion and high levels of moisture content that endangered both the structural integrity and the service life of the car park meant that extensive repairs were urgently needed.

Carpark Exterior in Dusseldorf

The main objective was to prevent any further soaking and chloride penetration of exposed structural zones so as to eliminate at least one cause of reinforcing steel corrosion in which the contributory mechanisms are the de-passivating effect of the concrete and the presence of water and oxygen- and to significantly extend the remaining service life of the structure as a multi-storey car park. This decision had to be taken as the total removal of al l the damage-causing phenomena would have been virtually impossible, given the size of the structure and the scale of the work involved. The repair work was subject to numerous regulations and reqrements. A repair system, tested and approved by the building authorities and offering certified effectiveness, was required for implementation of the work.

Because of this, MC product systems had already been included in the tender specification as reference solutions. Given t heir reliability to satisfy the complex requirements of the protection and repair measures to be applied to a wide, range of substrates, numerous MC products were used for this major project. Using injection and PCC concrete replacement systems, fine fillers and mortars, renders, primers and coatings from the MC portfolio, the multi-storey car park underwent comprehensive refurbishment during the period from April 2013 to April 2014- with the additional impediment that the car park had to be allowed to continue operating.

Carpark Interior in Dusseldorf

Clever customisation

A recent project involving a multi-storey car park in the Ruhr town of Bochum provided a stark illustration of the fact that completely unexpected problems can also arise to add to the usual challenges. Car drivers found that they were getting painful electric shocks when they pulled their ticket from the machine at the car park entrance. The machines themselves showed no sign of damage. The cause was in the floor which, particularly under conditions of low air humidity, underwent a build-up in electrostatic charge as the car tyres rolled over it. Because the floor did not have an electrostatic conductive plastic covering, electric shocks were inevitable. The Bochum municipal infrastructure company Entwicklungsgesellschaft Ruhr-Bochum (ERB) heard of a similar case in a multi-storey car park in Trier, also Germany, in which the problem was successfully solved with a sealing coat of MC-DUR 2095 ESD. ERB therefore decided in favour of a new covering with this proven PU resin from MC. The electrostatically conductive sealant has been especially developed for application in ESD (Electro Static Discharge) areas, such as encountered in the electronics industry, and for the economic refurbishment of conductive floors. Following completion of the re-coat work, voltmeter measurements confirmed that car drivers would, in future, be spared any further unpleasant shocks.

Author: ulrich.lange@mc-bauchemie.de

MC-Durofloor - Elegant under Pressure

In today's working environment dusty, pitted, unhygienic floors are unacceptable to workers, factory owners and in many cases the relevant regulatory bodies. Production areas and showrooms need to be presentable, portraying a good company image. Industrial floors have to be able to withstand chemical and mechanical stresses, perform a protective function and still look good after years of use.

MC has developed MC-Durofloor, a system that fits the bill. Its unique properties meet all important technical and safety requirements. Ample styling and design possibilities can create distinct flooring meeting individual needs.

It is available in a range of colours, textures, matt or gloss finishes. Corporate logos, safety signs and production area markings can be incorporated if desired.

Munich Arena

MC-Durofloor has many functional advantages. The material is solvent-free, can be applied without joints, leaving a uniform finish free of pores. It will stand up against heavy duty chemical and mechanical stress. Safety approved, this flooring is suitable in critical industrial areas. It is almost impossible to ignite, physiologically harmless, easily decontaminated and can be textured to achieve varying degrees of slip resistance. These qualities make it highly suitable for the food and drinks industries. For instance, 5,000 m2 of flooring have been laid at drinks manufacturer Stute, Paderborn/Germany, and 4,000 m2 at food producer Cadbury Adams in Dublin/Ireland.

MC Durofloor at Henkel in Vienna

High-profile brand products, such as "Persil", are part of the famous Henkel portfolio. It goes without saying that a company like Henkel will only give contracts to companies that can demonstrate a similar level of performance quality in their own products.

henkel Manufaturing in Vienna

Towards the end of 2006 the section producing liquid detergents at Henkel's washing powder factory in Vienna, required the renewal of their shop floor. A decisive factor in securing the flooring contract was MC's long-standing business relationship between MC's Frank Schbntaube, and Henkel's projects and planning engineer Karl-Ludwig Limbert. Another important factor was that MC DUR systems had already impressed Henkel management on several previous flooring projects at other Henkel plants: in Lamazzo (Italy), Nemours (France), Shanghai (China), Genthin (Germany), and at their headquarters in Dusseldorf.

Depending on the area of application a floor coating must meet various technical, functional and aesthetic requirements. For the Vienna project, Karl-Ludwig Limbert and Martin Bachmayer, Head of Civil Engineering at Henkel, put together specifications with regard to hygiene, chemical and mechanical resistance, colour and ease of cleaning.

The floor laying had to be carried out while production continued as usual, with only very short downtimes. A detailed planning of individual working stages was therefore compiled beforehand, which scheduled the actual floor laying works for the weekends.

As a first step three quarters of the old screed was removed and replaced by a coat of the new epoxy resin screed MC DUR 1390 VK. The necessary gradient was incorporated into this screed. Then a coating of Durofloor with MC DUR 1202 was applied which was subsequently sealed with a clear, non-yellowing resin, MC DUR 1204.

henkel Manufaturing in Vienna

This project was yet another Henkel contract completed to the client's full satisfaction. Messrs. Limbert and Bachmayer praised MC's high standard of advice and the excellent teamwork between the planners and the applicator, SBD from Angath (Tyrol). Mr. Limbert stressed: "Perfect technical advice customized to suit the individual requirements of the project always comes first at MC. And it never matters where this takes place, whether it's Germany, Europe or Asia."

Bespoke Flooring

Bespoke Designer Flooring

Modern floor protection systems must meet high demands with regards to chemical and mechanical stresses. In addition architects and engineers require that the floors are aesthetically pleasing.

MC-DuroDesign concept offers a range of design possibilities that simultaneously combine functionality with pleasing appearance.

An interesting project which used this innovative MC system is the large, ultra-modern kitchen of LSG Sky Chefs at Frankfurt am Main airport. Here, the whole floor area had to be installed and look good to the employees and visitors. The tender specified a durable and aesthetic floor that demonstrably had to be liquid-proof, chemical-resistant and resilient and which should conform to slip resistance category R12 V4. Also required was fire class Bl (flame resistant).

As early as 2003 first talks regarding this project were held in Frankfurt/M between LSG and the consultants KuAConsult, Riedstatt. Based on the past experiences MC was recommended by the engineering firm as the flooring supplier and were involved right from the beginning at the design stage.

Christoph Schulz, specialist advisor at MC, introduced the various MC coating systems that were suitable for the specified areas. After examining the various properties of the materials it was decided to use MC-Durofloor for the large kitchen area. The deciding factors here were both the visual and technical advantages, especially with regard to meeting slip-resistance and ease of cleaning requirements. In order to create a dynamic appearance, grey blue quartz sands were scattered throughout the coating and finally sealed with a transparent sealer coat. In the technical rooms where heat-radiating water treatment devices were installed, the high-temperature- resistant coating "MC-DUR HTR" was used.

The ease with which the floor could be cleaned was to comply with EU Directive 2002/72/EC for food processing enterprises. Following extensive consultations and a practical presentation MC's special cleaning agent "MC-Duroprop B" was selected as the preferred product.

Before the coating could be applied, the existing system had to be removed right down to the base concrete. A new levelling screed was applied and due to the use of special admixtures from MC was quickly ready to be over coated with the selected systems, which greatly accelerated the entire process.

The flooring works were carried out by Leipziger Saurebau GmbH, a specialist flooring applicator. Good teamwork between all parties, trained applicators, excellent material handling properties and attention to detail at planning stage contributed to a successful job. At the end of the project in May 2007 the representatives of LSG Sky Chef declared their total satisfaction with the finished product.

A Match for all Impacts

Robust Flooring for the Fuchschen Brewery

Master Brewer Frank Driewer (left) and owner Peter Konig with the "Armie" robot arm, the main component of the new barrel cleaning and filling plant at the Fuchschen Brewery.

In food-producing companies, particularly high demands are placed on industrial floors because they are exposed to thermal, chemical and mechanical stresses. For this reason, the Dusseldorf-based Fuchschen Craft Brewery decided to coat their floor with MC-DUR 2500 as part of their bottling plant modernisation.

The "lm Fuchschen" Brewery is one of the last four craft breweries in the Dusseldorf Altstadt and looks back on a long tradition. As early as 1640, beer was brewed at this location. Since 1843, the Brewery has carried the name "Fuchschen", meaning "little fox" as, at that point, the facade was decorated with a fox instead of the house number. In 1908, the brewery was taken over by the Konig Family, who still operate it today. It is now, under the management of Peter Konig, in its fourth generation.

First and foremost, the Fuchschen brews Altbier, a top-fermented dark German beer typical of Dusseldorf, using a secret recipe and in accordance with the German purity law of 1516. The beer is put into flip-top bottles or barrels of varying sizes. The Altbier is served in the Brewery's own guesthouse, which also serves hearty home-made specialities from Rhenish cuisine. In addition, drinks retailers and selected guest houses in the region are also supplied with products from the Fuchschen Brewery.

Due to increasing demand, the Brewery had reached its limits especially in terms of bottling. For this reason, Peter Konig initially contemplated relocation to the "open countryside". However, when he was able to purchase a neighbouring parcel of land with industrial premises, he made the decision in favour of its traditional location in Dusseldorf's Altstadt. Costing about 2 million Euros, a cleaning and bottling plant was built to the highest technical specification.

"Armie" lifts Barrels

Its core is an industrial robot with six engines and six axes, which lifts the empty beer barrels from pallets and sets them down in the cleaning and bottling plant. Consequently, the robot arm with the nickname "Armie" has taken on the job, which had previously been done laboriously by hand.

At the same time, the process has considerably accelerated. While, previously, approximately 30 barrels per hour could be filled, "Armie" lifts three times this amount, effortlessly ensuring an annual production of 3,000,000 litres of beer.

However, before the robot could begin its work, the newly acquired premises were completely renovated. The floor, especially, needed to be replaced, as in the existing building it had been seriously affected by countless installations and renovations and could no longer be used for the new purpose. So, the contracted company, F & L GmbH from Dusseldorf, initially had to dismantle and remove about 110 tonnes of old flooring. Then, a quick-drying cement screed was applied to the remaining concrete foundation as a bonded screed.

High Demands on Flooring

High demands were placed on the flooring: consequently, the owner wanted a jointless solution. In addition, it had to be non-slip as, according to the guidelines of the Berufsgenossenschaft (BGR 181), an Rll anti-slip category floor must be installed in drinks companies. In addition, it had to withstand thermal, chemical and mechanical stresses, as the 85°C solutions, used to clean the barrels, can end up on the floor. The greatest mechanical impact comes from fork lift trucks, with which the palletised barrels are transported within the plant.

On this basis, Ulrich Lange, Special Coatings Product Manager at MC in Bottrop, together with the applicator, Kunststoff Schrader GmbH from Heemsen, developed a solution tailored for this use. They planned to coat the 300m2 surface with MC-DUR 2500. This is a hybrid screed system, which was especially developed for industrial flooring in the food industry. It is jointless, impact-resistant and, anti-slip and resistant to chemicals and temperature. In addition, it also safely withstands very short cleaning intervals.

After the screed had dried, the floor coating was applied within five working days. A special feature is the connection of the flooring to the walls. This was designed as isolated slabs, which makes it possible for the floor panels to shrink without any tearing at the wall interfaces.

Successful Endurance Test

The flooring already passed its first endurance test after the inauguration of the new plant. At the beginning of May 2010, the "Armie" robot was ceremoniously put into operation in the presence of a Terminator double. Two days later, there was an "open-house" day. For both events, so many people crowded into the hall that the floor could no longer be seen.

Reebok Flooring

Sponsor Floored by MC-DUR

Successful use of the MC-DUR system in the Reebok shop in the Morumbi stadium in Sao Paulo

Football is Brazil's national sport. Those who have ever been to a stadium in Brazil will have experienced the ultimate football enthusiasm. There's an atmosphere of euphoria that's without equal - a stadium full of spirited fans that exude football passion. The entire stadium resembles a folk festival. The national team has lifted no less than five world cup titles, making Brazil the most successful football nation in the world. Many Brazilian players such as Ronaldo, Kaka or Ronaldinho impress fans in many clubs around the world with their technical skills and creative play.

Just like the Brazilian footballers, the stadiums too are well known around the globe. The Estadio Cfcero Pompeu de Toledo for example, commonly known as the "Morumbi" stadium, is home to the Sao Paulo Futebol Clube. At one time the stadium was able to seat 140,000 spectators. After an extensive restoration its capacity was cut down to 80,000 for safety reasons. The Morumbi is the largest privately owned stadium in the world and offers in addition to great sport events also a shopping and adventure centre.

Particularly impressive is the "Rbk Concept Store" of main sponsor, Reebok, on the ground floor of the Centre with an overall area of 1,200 m2. The sales area comprises 700 m2 and offers the complete range of Sao Paulo FC's fan products and various exclusive products and souvenirs. A special feature of the store is its VIP lounge, from where matches can be watched.

Since September 2007 the Reebok store has a new attraction: the floor of the shop has been renovated and now shines in the eye-catching Reebok Red. The tender for the restoration of the floor areas did not only specify the realisation of the colour concept, but also the fulfilling of important functional specifications.

The initial renovation of the shop floor was not handled professionally and the concrete quality was deemed to be unacceptable. It was then decided to use MC systems for the restoration of the shop's floors.

"We had to completely remove the existing floor and repair the old concrete in some places, before we were able to apply the new coating", says one of the engineers from Seta Construcao Ltda., responsible for the restoration of the store.

MC-Bauchemie Brazil was awarded the contract for the floor coating because of its special know-how and long list of well-known references. The resin coating MC-DUR 1200 was chosen, as it features many technical advantages and offers attractive design possibilities. "On one hand we needed a material that can withstand the vibrations of the stadium in order to avoid cracks and other damages, and on the other hand one that is representative of the Rbk Concept Store", explains the General Manager of Reebok. Andre Figueiro, expert in floor coatings, was their MC contact.

The self-levelling system MC-DUR 1200 achieved both the specific Reebok-Red colour concept and also the required wear-and-tear and slip resistance. The plan is to restore further Reebok stores in accordance with the same specifications.

Not just Reebok themselves, but also its customers are impressed with the new floor design. The system has already been recommended for use in other VIP lounges in this stadium, for instance for Camarote do Rai and Coca Cola.

The Morumbi stadium is a high-calibre reference, with which MC evidences its competence in the area of technically demanding and design oriented floor coatings. Further interesting shop projects were also the outlet centre "The Globe" in Den Haag, a Benetton shop in Budapest and the Customer Centre of Club Med in Brussels.

MC Makes Highly Sensitive Micro Electronics Safe

Who has not experienced it: you open your car door, turn in your seat and get out and when you touch the car's bodywork you feel an electric shock in your fingertips. Especially in dry winter weather the body experiences a static charge of several thousands of volts. If tingling sensation is experienced, it indicates a charge of at least 3,000 volts. The spark that is created during the discharge is not just unpleasant, but can potentially cause low-speed detonation in explosive surroundings – for example in immediate vicinity of the fuel inlet pipe. Walking on carpet also creates static, which discharges for instance when touching a door knob.

While in everyday life a startled response is the usual result, such discharges can potentially cause a fire in explosive areas and cause great damage. In industrial plants that deal with flammable liquids or gases anti-static floors have been legally required for years to prevent electrostatic discharge as a source of ignition. The objective "explosion protection" has been reliably achieved since the 1980s with various anti-static coating systems from MC. Electrostatic charge must stay below 2,000 volts so that no sparks can occur during discharge.

The issue is much more problematic in production areas where electronic components are produced and/or processed. These are much more sensitive to discharge than the human body. Electronic devices with semiconductors are by now a fixed part of our daily surroundings, whether in mobile phones, computers or in the car. The ready-to-use appliances are unsusceptible, he individual boards (e.g. the graphics card of a PC or the accelerator sensor to inflate an airbag) and components, however, may even be damaged by low static of under 100 volts

Electrostatic charging and discharging processes happen thousand-fold and go unnoticed, because the amount charge lies below the human perceptibility threshold of approx. 2,000 to 3,000 volts. Getting up from an office chair alone can cause a charge of up to 800 volts, for instance.

Micro Electronics Flooring

In addition to static charge, which is difficult to measure, another problem exists: damage of the components or boards cannot even be detected with the extremely sophisticated quality assurance systems used in the electronics industry. The building components appear to be functioning as usual initially, but then start to fail after just a short time. If such a pre-damaged board is then installed in, let's say, a car, it could potentially lead to malfunctions that are difficult to determine ("Monday Car”). Not infrequently, such as defects are the result of electrostatic discharge, causing extremely expensive and troublesome recalls by automobile manufacturers.

Therefore a comprehensive electric discharge via the floor in all areas of micro-electronics is indispensable. The only strategy to minimise damages resulting from electrostatic semi-conductors is to limit electrostatic charging to a degree that is safe for the building components. This process is called Electro Static Discharge or ESD for short. Decisive is permanent electrostatic discharge by way of consistent earthing of aII surfaces. As a consequence, special technical requirements are put on production surroundings in the electronics industry: it starts with packaging, comprises all objects involved in production such as tools, furniture, work clothes an continues right down to the floor, which must possess particular discharge capability.

Any person present in the ESD protection zone, the so-called Electrostatic Protected Area or EPA, are generally connected with the earth potential by way of special static dissipative footwear and a particularly static dissipative floor. This way static charge is already dissipated at the early stages of developing. The electric properties of the floor are here decisive for the functioning of all ESD protection measures. The objective is to limit charging to a maximum of 100 volts (currently the normative threshold).


Step-by-step to a safe solution

As a specialist enjoying decades of international success in the area of industrial flooring MC has with MC-DUR 1850 ESD an ultra-modern special ESD system that is proven to achieve the necessary dissipative levels.

What's needed in order to discharge electrostatics permanently and reliably to the earth potential and to produce a chemically resistant and mechanially loadable industrial floor?

First of all it must be ensured that the floor coating with potential equalisation, i.e. electric connection with the building earthing is in fact connected. The implementation of this decisive detail frequently led to problems. The MC-Earthing-Kit makes safe, and simple application possible;the connecting points contained therein are corrosion-resistant and can be loaded mechanically. The special tool included• additionally reduces the risk of mistakes significantly. The next working step is the application of a conductor matrix made from copper spray. This MC antistatic spray can be applied with extreme speed using the antistatic dispenser and is even more cost effective than the classic copper strips, which are laboriously stuck on. The conductor matrix ensures that charging at any point in the floor surface is transported to the next connection point.

Then the conductive primer MC-DUR GLW on the basis of water-dispersing epoxy resins is applied, which safeguards the discharge of the static via the top coat horizontally to the nearest point in the conductor matrix.


Decisive discharge-capable top coat

The heart of the system is actually the discharge-capable top coat, which must meet further requirements in addition to discharge capability and colour design, depending on the respective use of the .area. Top coats suitable-for explosive areas are only described by way of their earthing resistance and can still expected to have static tension of 200 to approx. 1,500 volts (depending heavily on humidity). This is too much for most semi-conductor elements. MC-DUR 1850 ESD is a self-levelling ESD top coat, which also meets the maximum static tension in the walking test with great accuracy in addition to meeting the threshold system resistance. Furthermore, the MC-DUR 1850 ESD system has approval according to the Water Resources Act (German WHG) as a certified sealing system.

It is as simple to-use for applicators as other self-levelling topcoats. Additional sealing or coating is not necessary. The discharge of electrostatic charge starts at the surface of the top coat. In order to maintain the initial properties of the system no insulation layers must be applied to the top coat - not unknowingly, which could happen for instance when cleaning agents are used that contain polymer or wax dispersions. Without question electric functionality must have priority over aesthetics, such as sheen, in this case. Long-term tests in the system were carried out on the MC cleaning products Duroprop B (stripping) and Duroprop N (maintenance cleaning).


Comprehesive customer service

With MC-OUR 1850 ESD MC has developed a reliable solution for the automotive and electronics industry for ESD applications. Even long term the electric measurements remain stable as practical experience and external reports certify. MC experts also offer complete support on this aspect: from advice in the preliminary stages to the selection of experienced employees right down to measuring the electric characteristic values in the installed floor. Many well-known companies have made good use of this service, such as Bosch (Reutlingen), Continental (Regensburg), Daimler-Benz (Sindelfingen), ZF (Schwabisch Gmund), and Omron Elektronik (Nufringen).

Aesthetic Flooring in Brussels

Brussels, a city with many different facets: here, at the seat of the European Union, international life is pulsating, creating a multi-cultural metropolis. Like no other European capital, Brussels is continually in the eye of public interest. Hence, the appearance of any new buildings or con versions must be synchronised.

This makes Brussels a highly suitable market for the industrial flooring concepts of MC. Two flooring examples that stand out because of their appearance are introduced in the following.


Bank of New York Mellon

Right in the centre of Brussels is the Axa building, which attracts attention with its coloured glass façade. Behind it, the famous New York Mellon bank is located. Particular consideration was given to the flooring when the foyer was re-designed. Being a part of the overall concept, the floor had to be representative of and emphasise the premises’ sophisticated appearance.

Jointly with one of the largest screed applicators in Belgium, Enterprise Miot & Brescanni (EMB), MC specialist advisor of Belgium, Benoit Verbiest, was able to convince the tendering estate agent Confinimmo of the superior technical and aesthetic performance of MC-DUR Terrazzo. In addition to he special product properties, mainly the assurance of comprehensive technical support and above average customer services during the project phase were decisive in gaining the contract.

Brussels

Problematic floor conditions and the angled geometry of the space proved challenging for the applicator, particularly the sanding was far from easy. Benoit Verbiest and DR. Peer Heine (Product Manager Industrial Floors) assisted with p[practical tips and advice on several occasions. Jointly, and optimal sanding process was devised for this building project that was to ensure an exciting finished look of this floor. The desired sheen was achieved using a special Terrazzo binder coupled with quality blue glass aggregates and a matching superior sand mixture. A special surface finish ensures that the beautiful appearance is retained long term, even after high traffic and with less cleaning effort.


Club Med Travel Centre

A prestigious project in a class of its own was also Club Med in Brussels. The refurbishment of the travel centres was ordered by the French travel company according to an integrated standard concept. Since the refurbishment of the offices in Paris through a local applicator did not deliver a satisfactory result, the company was seeking a more competent solution for Belgium.

The individual design of the floor area as part of the overall design concept was of great importance. In addition to applying a special colour, high technical requirements in terms of mechanical resistance and ease of cleaning had to be met.

Benoit Verbiest and Dr. Peer Heine outlined the high performance capability of MC’s floor coatings in consultations with the architect.

The floor area of the travel centre was re-designed using MC-DUR 1212 VB in brilliant blue, whereby the grain edges of the sand remain visible in the blue coating. This achieves the appearance of an azure-blue sea by a sandy beach.

The good teamwork between MC and the companies involved resulted in a successful implementation of the demanding concept. The customer was so satisfied with the result that they arranged publication of an article featuring this project in a well-known magazine, where the floor is named Terrazzo Aqua.

After Brussels the Club Med centres in Antwerp and Luttich are also to be refurbished. It is likely that there the beautiful appearance of MC-DUR solutions will serve as the yardstick, too.

A Unique Hotel Floor

Slovakia is getting ready to host the 2011 ice hockey championships. This of course also includes expanding and modernising hotel facilities. An outstanding example in this context is the Hotel Yasmin in Kosice, which has now been transformed into a 'boutique hotel'. Particularly eye-catching is the lobby floor which incorporated products from MC.

In addition to Bratislava, Kosice in eastern Slovakia is another venue for the ice hockey championships in 2011. So as to ensure visitors from home and abroad that come to see this sports event are having a pleasant stay, investment in infrastructure has been dramatically increased. Primarily this means creating a sufficient number of accommodation facilities. Against this background Kosice is seeing the construction of several new hotels and the modernisation of existing ones such as the Hotel Yasmin.

Architectural plans intended conversion into a four-star boutique hotel. After almost two years of construction works the hotel re-opened in April 2009. It now has 153 luxury rooms equipped with the latest mod-cons, plus 13 suites, two restaurants, a congress centre and seven conference halls. A wellness spa complex rounds off the hotel's facility portfolio.

A Mosaic Made from Chinese Coarse Gravel

The architects Mimolimit based in Prague were particularly eager to create a sophisticated look and ambience in the design of the lobby. In this area a unique floor that had never been done before anywhere was to be created. The architect in charge, Milos Munzar, opted for a round gravel mosaic using coarse Chinese gravel. This material is 8 to 10mm high and is supplied fixed to netting for easier fitting. The problem was the interspacing between the individual gravel pieces that needed to be grouted after the laying. Due to the irregular structure of the gravel mosaic the percentage of jointing mass was 40% per m2.

Standard joint mortar could not be used in this case as it would not have the necessary stability. In addition, the floor was meant to be extremely hard-wearing and withstand extreme loads.

Hotel Flooring

Tailored Solution

Pavol Basti from the Slovakian MC-Bauchemie s.r.o. was consulted as early as the planning phase. He developed a bespoke solution that sought to execute the interspaces between the gravel pieces with MC-DUR 1252. This product is a very resistant epoxy resin coating that is also used in multi-storey parking areas and for industrial floors. In this particular case it offered the advantages of having great load and UV-resistance. What's more, the material has a certain degree of flexibility, so that even with irregular and large joint gaps crack formation is not expected to develop. "Initially we produced a few samples with the product and presented these to the architects", explains Pavol Basti, "They then decided on the actual composition and the colouring of this resin material, which was quartz grey (RAL 7039). Based on this I subsequently compiled a completely new service specification for this construction measure." The floor was installed by Z.O.S. spol.sr.o., a specialist for industrial flooring based in Kosice.

An area of 121m2 was laid with gravel mosaics within the space of one month. Works were subject to extreme time pressures as the deadline for the reopening of the hotel was looming. Following the application of MC-DUR 1252, two fitters from Z.O.S. spol.sr.o. took six days to sand the floor as per works schedule. During this time Pavol Basti was at hand to support the work's progress.

After the sanding the transparent high performance epoxy resin sealer MC-DUR 1204 was applied. It served to level small unevenness contained within the gravel stones. The result is a floor that is second to none, featuring an exciting structure and a completely smooth and level surface that impresses hotel guests.

A Match for all Impacts

Master Brewer Frank Driewer (left) and owner Peter Konig with the "Armie" robot arm, the main component of the new barrel cleaning and filling plant at the Fuchschen Brewery.

In food-producing companies, particularly high demands are placed on industrial floors because they are exposed to thermal, chemical and mechanical stresses. For this reason, the Dusseldorf-based Fuchschen Craft Brewery decided to coat their floor with MC-DUR 2500 as part of their bottling plant modernisation.

The "lm Fuchschen" Brewery is one of the last four craft breweries in the Dusseldorf Altstadt and looks back on a long tradition. As early as 1640, beer was brewed at this location. Since 1843, the Brewery has carried the name "Fuchschen", meaning "little fox" as, at that point, the facade was decorated with a fox instead of the house number. In 1908, the brewery was taken over by the Konig Family, who still operate it today. It is now, under the management of Peter Konig, in its fourth generation.

First and foremost, the Fuchschen brews Altbier, a top-fermented dark German beer typical of Dusseldorf, using a secret recipe and in accordance with the German purity law of 1516. The beer is put into flip-top bottles or barrels of varying sizes. The Altbier is served in the Brewery's own guesthouse, which also serves hearty home-made specialities from Rhenish cuisine. In addition, drinks retailers and selected guest houses in the region are also supplied with products from the Fuchschen Brewery.

Due to increasing demand, the Brewery had reached its limits especially in terms of bottling. For this reason, Peter Konig initially contemplated relocation to the "open countryside". However, when he was able to purchase a neighbouring parcel of land with industrial premises, he made the decision in favour of its traditional location in Dusseldorf's Altstadt. Costing about 2 million Euros, a cleaning and bottling plant was built to the highest technical specification.

"Armie" lifts Barrels

Its core is an industrial robot with six engines and six axes, which lifts the empty beer barrels from pallets and sets them down in the cleaning and bottling plant. Consequently, the robot arm with the nickname "Armie" has taken on the job, which had previously been done laboriously by hand.

Robust Flooring for the Fuchschen Brewery

At the same time, the process has considerably accelerated. While, previously, approximately 30 barrels per hour could be filled, "Armie" lifts three times this amount, effortlessly ensuring an annual production of 3,000,000 litres of beer.

However, before the robot could begin its work, the newly acquired premises were completely renovated. The floor, especially, needed to be replaced, as in the existing building it had been seriously affected by countless installations and renovations and could no longer be used for the new purpose. So, the contracted company, F & L GmbH from Dusseldorf, initially had to dismantle and remove about 110 tonnes of old flooring. Then, a quick-drying cement screed was applied to the remaining concrete foundation as a bonded screed.

High Demands on Flooring

High demands were placed on the flooring: consequently, the owner wanted a jointless solution. In addition, it had to be non-slip as, according to the guidelines of the Berufsgenossenschaft (BGR 181), an Rll anti-slip category floor must be installed in drinks companies. In addition, it had to withstand thermal, chemical and mechanical stresses, as the 85°C solutions, used to clean the barrels, can end up on the floor. The greatest mechanical impact comes from fork lift trucks, with which the palletised barrels are transported within the plant.

On this basis, Ulrich Lange, Special Coatings Product Manager at MC in Bottrop, together with the applicator, Kunststoff Schrader GmbH from Heemsen, developed a solution tailored for this use. They planned to coat the 300m2 surface with MC-DUR 2500. This is a hybrid screed system, which was especially developed for industrial flooring in the food industry. It is jointless, impact-resistant and, anti-slip and resistant to chemicals and temperature. In addition, it also safely withstands very short cleaning intervals.

Brewers

After the screed had dried, the floor coating was applied within five working days. A special feature is the connection of the flooring to the walls. This was designed as isolated slabs, which makes it possible for the floor panels to shrink without any tearing at the wall interfaces.

Successful Endurance Test

The flooring already passed its first endurance test after the inauguration of the new plant. At the beginning of May 2010, the "Armie" robot was ceremoniously put into operation in the presence of a Terminator double. Two days later, there was an "open-house" day. For both events, so many people crowded into the hall that the floor could no longer be seen.

"We sell customer-specific solutions"

MC-Bauchemie has a long established reputation for providing sound advice, practical solutions and special products for special cases. Especially in the field of surface protection, consultants and applicators often approach the company with special requirements. "MC aktiv" spoke with the product manager of Special Coatings, Ulrich Lange, about this:

MC aktiv:Mr. Lange, as the product manager of Special Coatings, you deal with MC customers, whose projects require very special solutions. What does this entail?

Lange:My field of work comprises protective systems for walls and floors in structures. There are usually special requirements with • regards to chemical resistance, thermal exposure or mechanical loading. This includes cases, for which special installation conditions or requirements must be taken into account. And finally, I deal with surfaces, on which no electrostatic charge must occur due to risks of causing of explosion or ESD protection of semiconductor components.

MC aktiv:How are these projects distributed in terms of new construction and renovation?

Lange:In about 60% to 70% of the projects we deal with repairs or retrofits in existing buildings.

MC aktiv:When repairing constructions, must the substrate be prepared for the wall or floor coating first?

Lange:That is right. To successfully apply a coating, the substrate must normally fulfil certain conditions with regards to adhesion, compressive strength and moisture level. In the absence of such conditions our system MC-FLEX 2097 plus is brought into play. Throughout the procedure we only use the static load bearing capacity of the wall or floor and supply, as it were, the coatable substrate in the system. In doing so, a geo-composite made of polypropylene fleece, which is thermally laminated on a polyethylene grid, is plugged with anchor panels on the untreated substrate. Then, the plug heads are prefilled and the cover layer made of chemically resistant elastomers is applied manually or with a two component extruder.

Interview Photo

The building owner no longer needs to retrofit the substrate and he thus saves a considerable amount of time. If the substrate must be re-profiled, moisture is reintroduced into the structure with the mineral mortar, so that the coating can only be applied after a two to three-week drying period.

MC aktiv:When working with this system, what happens with the moisture that is still in the substrate?

Lange:The drainage ability of MC-FLEX 2097 plus makes it possible for gaseous or fluid substances, such as water, the residue of substances from the previous use to outgas or be collected and drawn off from a low point in the soil. This guarantees that they do not cause any damage.

MC aktiv:For which other applications do you use special material technology?

Lange:We can, for example, coat floors of refrigerated warehouses without having to warm these up and without the risk of an odour transfer to the goods stored there.

And MC-DUR 2500 is a coating system, which is used if the floor's requirements are stretched to the limit through frequent heating or abrupt temperature changes, for example by emptying containers with hot liquids.

Normal duromers fail here as they change into the thermoplastic state between 50 and 55°C, consequently losing a majority of their stability and mechanical properties. If this thermal shock load occurs several times a day, the coating loses its connection to the substrate. Cracks occur, in which the hot fluid can then penetrate.

MC aktiv: And there is no risk with MC-DUR 2500?

Lange:No, this system is a thick film duromer hybrid screed with a temperature resistance up to 120°C. In addition, it is insensitive to mechanical effects and chemical loads. However, extensive advice is needed so that the different materials do not cause tensions between the concrete and screed or between the screed and installed drainage elements. This allows us to assist planners, processors and operators.

Furthermore, we also carry out special quality-assurance inspections on-site at the request of our customers. For example, we evaluate the electrical properties of ESD coatings or check the peel resistance of elastic coatings. So, we sell customer-specific solutions, as well as offering an extensive range of services.

A New Benchmark in Industrial Floor Coating

Floor coating systems for commercial and industrial premises not only have to meet high expectations towards resistance, more important they have to fulfil economic expectations. Thus, especially in buildings with running operations, the down time factor counts. In certain industries appearance is also very important. With the MCDUR SL system all expectation were met, when Vistakon Ireland, the contact lens manufacturer, upgraded its floors.

At Vistakon Ireland in Limerick over 650 employees have been manufacturing disposable contact lenses for the European and international markets since 1995. Originally this subsidiary of the US company Johnson & Johnson Vision Care, Inc. had five production lines in operation. Today, as a result of constant modernisation and expansion, there are 30 production lines turning out a wide range of different contact lenses. The production process is fully automated and by necessity takes place in a clean room, as the finished product has direct contact with the human eye.

Vistakon Flooring

Progressive maintenance of floors

After 15 years of operation the flooring in the production, storage and transport areas was showing signs of damage, some of it considerable. A large scale to maintenance was inevitable. Section by section a total of about 23,000m2 of flooring was to be renewed. This included three production halls with surface areas of between 4,765 and 8,585m2, as well as various storage, engineering and adjoining rooms with surface areas ranging from 65 to 625 m2.

The planning and project management was entrusted to John Sisk & Son Ltd., one of Ireland's largest construction companies. Steve McCormack of the Irish company MC-Building Chemicals was also involved at an early stage to develop, in association with the general contractor, a solution that would best fit the project. At the same time account had to be taken of the range of specifications required by the client with regard to hygiene, good cleanability, and an attractive appearance. Furthermore, the new floor- despite a change of system- was to have the same colour scheme as the old one.

Application in one stage

Finally decision was taken in favour of MC-DUR SL, a decorative flooring system resistant to moderate mechanical loads and chemical contamination. It is very easy to clean, impervious to fluids and UV-resistant. In addition, an individual colour design is possible with a variety of ascent colours. "However at the end of the day the decisive factor was that MC-DUR SL can be installed very quickly, as the client wanted the minimum interference with the production processes", says Steve McCormack.

Traditional flake systems have to be installed in three time-consuming stages: first the scatter layer is applied, then the decor flakes are added, and finally there is the transparent sealing. This gives MC-DUR SL a clear edge in terms of time, as it can be applied immediately after mixing in a single operation, saving a lot of time and money. The preparation effort is reduced dramatically, since in most cases priming is sufficient, while a scratch-coat can be skipped. The de-aeration process can be carried out as little as ten minutes after application of MC_DUR SL, while the surface sealing with MC-DUR 2095 M follows the next day. In summary the number of individual operations is minimised.

Before starting work Steve McCormack had trial surfaces applied, on which scratch and wear tests were carried out with encouraging results. The execution of the work was finally entrusted to M.V. O’Halloran Ltd, a nationwide company specialised in coating application.

Meanwhile more than 3,000m² of floor have been covered with MC-DUR SL – mainly of a long central corridor from which all production areas can be accessed.

MC-DUR SL a clear edge in terms of time, as it can be applied immediately after mixing in a single operation, saving a lot of time and money. The preparation effort is reduced dramatically, since in most cases priming is sufficient, while a scratch-coat can be skipped. The de-aeration process can be carried out as little as ten minutes after application of MC-DUR SL, while the surface sealing with MC-DUR 2095 M follows the next day. In summary the number of individual operations is minimised. Before starting work Steve McCormack had trial surfaces applied, on which scratch and wear tests were carried out with encouraging results. The execution of the work was finally entrusted to M.V. O'Halloran Ltd., a nationwide company specialised in coating application. Meanwhile more than 3,000 m2 of floor have been covered with MCDUR SL- mainly of a long central corridor from which all production areas can be accessed. The next stages have already been planned, the entire floor area will be renewed by early 2012.

Metro Flooring

Easy to Clean and Anti-skid Flooring in Metro Depot

The Brazilian megacity Sao Paulo totals almost 20 million inhabitants and seven million vehicles. Traffic jams and long journey times are therefore quite normal. The only alternative is an effective local public transport system, whose backbone is the Metro. The network has been continually extended for years and parallel to that the most varied maintenance measures are been carried out on existing inventory. In the case of the latter MC-Bauchemie products are also very frequently used.

The Metropolitano de Sao Paulo, known colloquially as Metro for short, conveys roughly four million passengers every day. With eleven passengers per square metre vehicle space it is the most crowded underground system in the world. And yet the operating company continues to register increasing numbers of passengers, for the Metro is considered to be reliable, fast, safe and clean.

The 74.5km long transport network consists of five lines with a total of 62 stations and is constantly being extended. At the moment lines 2 and 5 are being extended and the new line 4 has been under construction since 2004. The first section between Luz and Butanta was inaugurated in May 2011. The "Linha 4" is the first metro in the whole of Latin America with driverless and fully automatic operation. During these construction projects concrete admixtures such as MC-PowerFlow are used in the manufacture of liner segments.

112 km new rail tracks

A further 112km of new lines is planned for the future. This includes a further extension of Line 2 from Vila Prudente to Cidade Tiradentes, which are designed as elevated monorails just like the new lines 16 to 18.

However, the operator Companhia do Metropolitano de Sao Paulo also has substantial conservation work carried out on the inventory as well. Over the past ten years the MC-Bauchemie Brazil has assisted the company in partnership during many projects. Primarily the injection technology, repair mortar, concrete finish and systems for floor coatings are used here.

Metro depot Jabaquara

A current example is the Metro depot in Jabaquara. It is one of a total of six rail depots, which are generally situated at one of the final points of a metro line. In this case, Jabaquara is situated at the south end of Line 1 from Tucuruvi to Jabaquara which was opened in 1974. A total of 348 carriages are assigned to this line, of which six are joined up to form a train each. Their cleaning and maintenance is carried out exclusively in the Jabaquara depot. It has large storage sidings with 19 tracks on the open air ground. Next to that is a multi-rank maintenance and repair hall, to which further eleven tracks lead.

The floor of the hall was previously made up of unprotected concrete that showed signs of strong contamination in many places. That is why the operator wanted a floor coating system that would protect the base from dirt and at the same time be easy to clean. In addition, it should be anti-skid in order to increase the workers' safety at work. Together with the processor Pires Giovanetti Guardia the floor coating team of MC-Bauchemie Brazil developed a customized solution for this project.

7.700 m2 floor coating

A total of around 7,700 m2 flooring was coated in the Jabaquara depot. 4,300m2 here were in the workshop area. The other surfaces are in hall wings that are equipped with repair pits or elevated tracks.

In the case of strongly contaminated surfaces a thorough cleaning was carried out first of all. Then the substrate was grinded. In the workshop area a 2 mm thick, self levelling coat, consisting of the priming coat MC-DUR 1200 VK and the epoxy resin coating MC-DUR 1200, was applied. The maintenance pits were even given a 5 mm thick coat because of the heavy duty. In the case of strongly contaminated base surfaces MC-DUR 1365 HBF was used as special primer coat. Afterwards, the priming as carried out over large surfaces with the highly robust materials MC-DUR 1200 or MC-DUR 1212VB.

The areas that were not treated in Jabaquara are soon to be treated with a MC-floor coating system as well. Another 5,000 m2 are to follow 2012 in the ltaquera Depot of Line 3.

Extending the working period in wintry weather

Until now, applicators have often been left twiddling their thumbs in the cold and wet season as the coating of floors, whether indoors or outdoors, becomes impossible. The new high-performance roller coating MC-Floor Top Speed, however, can be simply and reliably applied even under wet conditions and at chilly temperatures down to 2° C, Moreover, MC-FloorTopSpeed can also be used without difficulty in damp tropical conditions at temperatures up to 35 ° C, revolutionising the floor coatings market at both ends of the thermometer.

The following situation is bound to be familiar to painters, decorators and applicators everywhere. It is winter, wet and cold, and they have an order to fulfil involving the outdoor coating of several balcony floors in an apartment block. The general coning noises, expecting the order to be completed as soon as possible. A quick glance up to the skies on the trip to the site leaves little doubt that it is about to rain - poor conditions for this kind of work, because conventional coatings based on polyurethane and epoxy resins can usually only be applied at temperatures between 8 and 30°C. At cooler temperatures and in the wet, or even where atmospheric humidity is high, undesirable side effects can occur such as lack of adhesion, reduced long-term bonding, bubbles, pits and porosities- all leading to a less than perfect surface finish. And this lack of aesthetic appeal is also the most frequent cause of complaint. Which means a whole day's work may have been for nothing.

Finished Flooring Application Finished Flooring Application

Easy to apply even under difficult ambient conditions

Now, MC-FloorTopSpeed offers applicators new possibilities, helping them to avoid such dilemmas. The innovative high-performance roller coating from MC-Bauchemie enables application work to be carried out simply, reliably and quickly, even under critical environmental conditions. In developing this product, MC made use of a special material technology from the power plant sector- originally used in the coating of cooling towers- adapting it to the requirements encountered in internal and external floor coating applications.

Special material technology

Rather than having an adverse effect on the curing reaction of this product, moisture and wet conditions actually accelerate the curing process, increasing both adhesive strength and resistance to abrasion and scratching. Neither low nor high temperatures have any negative effect on the application result: MC-FloorTopSpeed can be readily applied at temperatures from 2 to 35° C, making it suitable for all conditions, summer or winter. Once mixed, the roller coating also has a pot life of up to two hours, leaving plenty of time to get the job done properly without the usual stress.

Fast curing and quickly ready for foot traffic

Once applied, the coating cures really quickly. It is rain-proof after 30 minutes and ready to walk on or for the next stage of work after around two hours. In half a day, the surface can take a full mechanical load. The benefits here are obvious: fewer interruptions, less downtime, minimised waiting and fewer trips to the site. All of which ultimately means savings in time and money for the applicator.

MC-FloorTopSpeed produces impressive results even under hot and cold conditions, with easy handling, short drying times and fast usability. Finished Flooring Application

Resistant to scratching and abrasion

While speed and reliability are important during the application work, the focus in the in-use phase is on durability in terms of both function and an attractive visual appearance. MC-Floor TopSpeed offers exceptionally high UV-stability, which means it remains protected against yellowing, even when constantly in use and exposed to sun radiation. It also exhibits optimal scratch resistance and a high level of abrasion hardness compared to conventional coatings. All these properties serve to protect heavily used floors - both internal and external - on a long-term basis. Its abrasion resistance per EN ISO 5470-1 is 100 times better than the minimum value specified in EN 1504-2. Similarly, its impact resistance certified per ISO 6272-1 at 8 Nm is 100% better than the value required according to EN 1504-2.

Wide application range

MC-FloorTopSpeed is available in various colours, with different finishes using decorative chips and coloured quartz sand included in the range. Anti-slip floor coatings can also be provided. Combined with the exceptional product properties of this high-performance roller coating, these various options create a wide spectrum of application possibilities including balconies, access landings, terraces, garages, basements, stairways, even entire workshops, plus many more such underfoot surfaces.

MC-Bauchemie launches marketing offensive for MC-FloorTopSpeed

The kick-off for the sales offensive was a personalised mailshot sent at the beginning of October to the owners and senior managers of some 600 painting and decorating firms in Germany, Austria and Switzerland. As well as providing information on the product, the mail shot offered a free 1 kg sample of MC-FloorTopSpeed for the addressees to request and trial. At the same time, a two-page A4 supplement appeared in the October editions of major painting and decorating magazines. A press release was also sent out to specialist German-language media and published on the MC website. The campaign is being supported by an especially created microsite, www.mc-topspeed.com, which offers full information on the product system together with an application video. An applicator handbook has also been produced.