MC Inside
MC logo lights upthe Bottrop skyline Page 3
MC News
Bridge repair undertough conditions Page 5
MC Innovation
New concrete replacementfor hydraulic structures Page 13
MC News
Artistic fair-faced concretein Reykjavik Page 14
THE MAGAZINE FOR
EMPLOYEES AND CUSTOMERS
OF MC-BAUCHEMIE
2-2018
3D concrete printing MC Report
A brave new world of building Pages 8 - 10
2 | MC aktiv 2_2018
MC NewsMC Editorial
Contents Cover
CreditsPublisher:MC-Bauchemie Müller GmbH & Co. KG
Am Kruppwald 1–8
46238 Bottrop, Germany
Tel. +49 (0) 20 41/1 01-0
Tel. +49 (0) 20 41/1 01-688
www.mc-bauchemie.com
Managing editor/ Conception:
Saki Moysidis, MC-Bauchemie
Editing:
Saki Moysidis, MC-Bauchemie
Thomas Haver, Leitpunkt Kommunikation
Design:
iventos – Agentur für Marketing, Bochum,
Germany
The "Digital Building Fabrication Laboratory"
(DBFL) at TU Braunschweig university of sci-
ence and technology, a digitally controlled
machining centre that enables coordinated
operation of a 5-axis CNC portal milling ma-
chine and an integrated heavy-duty robot
with a total of nine degrees of freedom.
Here, various robot-supported techniques
can be used for the production of geomet-
rically complex, three-dimensional concrete
components, such as the combination of
wet-spraying and milling, with concrete tech-
nology know-how and product solutions
from MC-Bauchemie making an essential
contribution.
Photo: ITE, TU Braunschweig
both mobile and desktop. I believe we have succeeded in this quest.
This issue of our MC aktiv features an exciting range of products and
solutions that have enabled us to contribute to the success of con-
struction and maintenance projects worldwide. As ever, I am
delighted to commend this edition to you, which closes with a
feature under the “Personnel” heading that underlines the impor-
tance the company attaches to attracting and developing new talent.
I feel sure that once again you will find plenty to interest you in this
edition of MC aktiv and I wish you an enjoyable read!
Kind regards,
Dr.-Ing. Claus-M. Müller
PS: As I am sure you are aware, we can only present a small selection of features in any one issue of MC aktiv. If you would like to be kept more regularly up to date with MC’s activities, please follow us on Facebook, LinkedIn or Xing!
Building with a 3D printer may
have sounded like the stuff of
fantasy two decades ago, but
today it is already a reality. Over
the last 15 years, research projects
around the world have been
testing 3D concrete printing
for user suitability, with good
progress made towards process
maturity for upscaling to series
and even mass production. Our
concrete technologists are making
their own contribution with two research projects at the universities of
science and technology TU Braunschweig and TU Dresden. You can read
more in this edition’s MC Report.
Digital communication is also central to future success, which is why
we are delighted to announce that our new website went live this June,
replacing our previous site which had served us faithfully for the past
seven years. Our goal was to create a modern, technically and aestheti-
cally appealing digital presence, allowing our users to access information
on our products, solutions and the company quickly and intuitively via
Dear Reader,
MC Editorial
MC Inside3 MC logo lights up the Bottrop skyline New website goes live
MC runs
MC News4 A new national stadium fit for the Champions League For the new National Stadium in Bratislava, the client specified concrete surfaces featuring both functional quality and the highest level of aesthetic appeal.
5 Bridge repair under tough conditions The rehabilitation of a bridge in Germany’s Saarland required an extremely tight timeframe, with special MC products employed for sealing the caps and deck panels.
6 Rehabilitation of the potable water tank in Lozenets Two chambers of a potable water tank in Bulgaria required essential repair and refurbishment of their ceilings and walls.
7 MC-FastKick – a cinema success Thanks to MC-Fastkick 111, MC's new hardening accelerator, a major multiplex cinema in Den Bosch in the Netherlands was finished and able to open on time – despite a very ambitious deadline.
11 Successful highway development with Nafuflex Thick bituminous coating systems from MC are being used on a large scale for the extension of the route to Haifa on the Mediterranean coast.
14 Artistic fair-faced concrete in Reykjavik The fair-faced concrete of a new build in Iceland’s capital city was visually upgraded and protected with products from MC.
Wonderfully refurbished A poorly concreted new building in Linz, Austria, was given a fine facelift with concrete replace- ment systems from MC.
MC Report8 3D concrete printing: A brave new world of building As recently as the start of this decade, 3D concrete printing seemed like a fanciful blend of science fiction and niche technology for a select few com- panies. But things have since changed – dramat- - ically. Today, it’s not just construction compo- nents that can be “printed”. Now, 3D concrete printing can be used to complete entire buildings, with MC's concrete technology know-how widely sought after for current research projects into the technology.
MC Innovation12 New rapid screed New finish coatings
13 New concrete replacement for hydraulic structures
MC Personnel15 Welcome to the team Trainees starting at MC Creative concrete workshop on Girls’ Day 2018
3MC aktiv 2_2018 |
MC PersonaliaMC NewsMC InsideMC Inside
MC employees aged 30 – 50 ran in teams made up from various divisions,
once again impressively demonstrating what a great unifier sport can be,
fostering inter-generational team spirit and reaching beyond departmen-
tal boundaries. And the results achieved were highly commendable: Our
TopSpeed team achieved 6th place in the Mixed Relay ranking, overcoming
a demanding elevation profile with an outstanding time of 3:46:09 hours.
Just behind them, Team Exzellent came in 8th with 3:57:48 hours. And the
PowerFlow team reached the finishing line in 20th place after 4:12:44 hours.
Mid-June saw us go online with our new website in both English and German.
On 27 May 2018, three MC teams participated in the 6th VIVAWEST Marathon and achieved excellent times in the scorching summer heat.
The aim was to create a modern, interactive and aesthetically pleasing
digital experience. One that helped customers, business partners and
stakeholders to more readily access information and content about MC,
our service and our product portfolio from both their desktop PCs and –
critically – their mobile devices. And we think we have succeeded in this
endeavour. We offer users various entry options while affording them even
faster, more reliable access to the right solution, the right products and
the right data sheets. If you haven't done it yet, please visit our website
and give us your feedback! :-)
New website goes live
Your link to our homepagewww.mc-bauchemie.com
From April this year, the 54 metre tall MC powder tower in Bottrop has featured an MC logo that is visible from miles around.
MC’s 54 metre high powder tower makes an immediate impact on
anyone who passes Bottrop via the A42 motorway or approaches
the Am Kruppwald industrial area. Together with the Tetrahedron
on the slagheap on Beckstrasse, it dominates the southern Bottrop
skyline. In the first quarter of this year, MC installed a 20 by 4 metre
MC logo on one side of the tower at a height of around 50 metres,
ensuring that it can be seen from quite a distance. MC commis-
sioned an experienced team of industrial climbers who, little by
little and whenever the weather allowed, firstly installed the sub-
structure and then the letters of the MC slogan "Be sure. Build sure.”
Finally, the MC logo was installed at this dizzy height during winter
temperatures dipping below 0 °C.
The oversized logo shines at night and enhances the importance of
MC’s powder tower as a stand-out landmark in Bottrop South. "In the
truest sense of the word, we have created the largest ‘billboard’ and
thus the largest-ever advertisement featuring MC-Bauchemie – and
are absolutely delighted with the impression it creates," says a satis-
fied Nicolaus Müller, Managing Director of MC-Bauchemie.
MC logo lights up the Bottrop skyline
MC aktiv 2_2018 | 3
Slovakia’s new national sta-dium is currently being built in its capital, Bratislava, with its precast concrete elements con-structed using MC-PowerFlow 3130 and Ortolan Premium 702 to ensure the highest standards of quality and appearance are achieved.
The Štadión Tehelnépole, which
roughly translated means “Brick Field
Stadium”, has been designed as
a soccer venue that corresponds
to the highest possible UEFA sta-
dium category of 4. This makes it
suitable for international matches,
as well as European and Champi-
ons League games. It is currently
being erected at a cost of around
75 million euros on the same site as
the old stadium, which was demol-
ished in 2013. The clients are the
Slovak state and the local soccer
club Slovan Bratislava, which will play
its home matches at the National
Stadium in the future.
Structure made of precast components With preparatory work on the con-
struction site commencing as early
as 2016, production of the stadium's
precast elements began in 2017.
The new building is made entirely
of precast concrete components,
almost all of which are one-offs.
The client specifications are aligned
not only to functional quality but
also to ensuring the highest aes-
thetic appeal of the concrete sur-
faces. The Slovakian subsidiary of
STRABAG SE, based in Bratislava,
won the tender for the production
of the prefabricated parts and con-
sulted MC's concrete technologists
for formulation development.
Getting the right mixIncluded in the concrete to ensure
the required properties, MC-Pow-
erFlow 3130 is a high-performance
superplasticiser based on the latest
MC polymer technology. Through
accelerated adsorption at the bind-
ing agents, its liquefying effect sets
in after just a short mixing time.
MC-PowerFlow 3130 is free of cor-
rosion-promoting components,
enables above-average water sav-
ings and promotes early strength
development, enabling high-den-
sity and high-quality surfaces to
be quickly achieved. With these
advantages, MC-PowerFlow 3130
is perfectly suited for the produc-
tion of exposed concrete surfaces
and high-performance, high-resist-
ance and high-resilience concretes.
However, it is in the production of
precast components that it really
comes into its own.
Superb surfacesExceptional results have been
produced by the interaction of
MC-PowerFlow 3130 with the con-
crete release agent Ortolan Pre-
mium 702, which has been specially
developed for the production of
high-quality exposed and fair-faced
concretes of grades SB 3 and SB 4.
Ortolan Premium 702 can be used
on smooth, non-absorbent form-
work and heated formwork up to
80 °C. It is easy to spray and forms
a thin film on the surface. It also
protects and helps maintain steel
formwork. Thanks to its excellent
release effect, Ortolan Premium 702
reduces pores and cavities to leave
a surface of exceptional quality.
MC's concrete cosmetics are also being
used on the construction site. This
ensures that any small defects occur-
ing during transportation or assembly
are quickly and effectively rectified.
The aim is to create an appealing
overall visual effect that will delight
both the clients and future specta-
tors in equal measure.
The new national stadium in Slovakia con-
sists entirely of precast concrete elements
manufactured with high-performance su-
perplasticisers and release agents from MC.
A national stadium fit for the Champions League
MC News
The new national arena in Bratislava is set to be awarded the highest UEFA stadium category, qualifying it as a venue for international soccer matches, as well as European and Champions League games.
4 | MC aktiv 2_2018
MC News
4 | MC aktiv 2_2018
In Germany’s Saarland region near the town of Merzig, a bridge on the A8 motorway was found to be in urgent need of rehabilitation. Due to an extremely tight timeframe, two special MC products were used for sealing the caps and deck panels.
The winter months make rehabili-
tating structures a challenge, espe-
cially when it comes to road const-
ruction. Any restrictions to the flow
of traffic need to be kept as brief
as possible, yet quality and dura-
bility are essential requirements
that must be fulfilled despite any
unfavourable weather conditions.
The repair and restoration of a motor-
way bridge near Merzig-Wellingen in
Germany’s Saarland region, sched-
uled by Landesbetrieb für Straßenbau
(the state road construction com-
pany) for February and March 2018,
was no exception. Temperatures of
2 to 3° C, invariably below the dew
point, high humidity in the Saar valley
and the application of materials on
a dew-damp substrate meant that
conditions for execution of the work
were far from ideal.
Simple and safe sealing of caps and deck panelsThe bridge repair work included the
renewal of the waterproofing under
the caps and along the deck over an
area of around 1,100 m². A system
tested in accordance with German
code ZTV ING Part 7 Section 1 had
to be used in order to enable sim-
ple, safe and time-saving applica-
tion on the construction site without
the need for additional hardeners or
accelerators. The system also had to
facilitate the subsequent torch-weld-
ing of the bitumen sheeting without
long overcoating times.
New development with outstanding propertiesGiven these constraints, the spe-
cialist application company Köh-
ler Sonderbau GmbH & Co. KG of
Trier, Germany, opted for MC’s new,
high-temperature-resistant specialty
polyurethane resin MC-DUR LF 680
as the under-cap sealant. It is ap-
proved for priming, sealing and scratch
filling under asphalt pavements on
the concrete of roadway panels and
parking decks in accordance with
German code TL/TP-BEL-EP; it also
cures quickly, largely regardless of
moisture and temperature influences.
This two-component, red-transpa-
rent speciality resin enables a com-
plete waterproofing campaign to be
carried out in a single day. After the
substrate had been prepared by shot
blasting, the caps were primed with
MC-DUR LF 680 and subsequently
sealed in a further operation involv-
ing the same material. Since the
overcoating waiting time is only
two and a half hours even at 2° C,
the waterproofing membranes could
be applied very quickly. The fact that
MC-DUR LF 680 can be used with
almost all known bitumen mem-
branes is a further advantage.
Patrick Eilens, senior manager of Köh-
ler Sonderbau GmbH & Co. KG, said:
"Besides the very good properties,
we also found the easy handling of
MC-DUR LF 680 particularly impres-
sive.” Like a conventional epoxy resin,
it can be applied without the addi-
tion of catalysts or other auxiliaries
and offers obvious advantages over
three-component products when
mixing – even in adverse weather.
As the weather returned to normal,
the epoxy resin MBC-VT 116 from MC
was used for further waterproofing
work on a deck surface measuring
around 4,000 m². With this combina-
tion, Köhler Sonderbau was able to
keep to the tight construction sched-
ule despite the unfavourable condi-
tions, completing the refurbishment
work on time to the satisfaction of
all involved.
Bridge repair under tough conditions
[email protected] [email protected]
Due to temperatures of 2 to 3° C and high humidity during the repair work, MC’s new special polyurethane resin, MC-DUR LF 680 was used to replace the bridge waterproofing membrane.
5MC aktiv 2_2018 |
MC PersonaliaMC News
MC aktiv 2_2018 | 5
MC-DUR LF 680 cures quickly and reliably,
largely regardless of moisture and tem-
perature influences.
There were distinct signs of increasing deterioration in the walls and ceilings of two cham-bers of the potable water tank serving the district of Lozenets in the Bulgarian capital Sofia. The operator therefore decided to carry out a comprehensive overhaul of the facility, placing particular reliance on the per-formance capabilities of the MC-RIM PW product system.
The 90-year-old potable water sto-
rage tank in Sofia boasts an 18,500 m³
capacity and a turbulent past. Its
chambers defied the bombings of
the Second World War and survived
numerous earthquakes in the region
unscathed. But now the sands of time
had taken their toll, with the structure
so dilapidated that a thorough rehabil-
itation campaign was imperative for
its survival. MC had already coopera-
ted successfully in the past on the Rila
Water Supply Pipelines Project with
Sofiiska Voda, the local supplier and
operator of the facility, and had been
invited back in 2015 for an inspection
of the potable water tank together with
another specialist supplier.
Cracks and spallingThe masonry of the structure revealed
numerous cracks, some of which had
already developed leaks and were water-
bearing. There were also fractured and
spalled areas and exposed reinforce-
ment, especially in the ceiling area.
Discounting a repair system based on
waterproof PE panels suggested by the
competitor bidder, the project plan-
ning company TIA Engineering and
representatives of Sofiiska Voda opted
for M C 's solution proposals instead.
Decisive factors included the prevailing
application conditions of only 6 – 8°
C due to the high humidity and low
ambient temperatures prevailing, and
the fact that the installation of rigid PE
panels in the caverns with their many
columns and different wall and ceiling
shapes presented a huge challenge.
Waterproofing perfectionIn June 2016, the chosen applicator
Opel Neshev started work on the rehab
project. The cracks were repaired using
MC-Injekt GL-95 TX, a low-viscosity, soft
and flexible sealing injection resin offer-
ing easy application at low temper-
atures. This meets the requirements
issued by the UBA (German Environ-
mental Agency) for repair systems in
contact with potable water and is best
suited for sealing joints, cracks, cavities
in masonry and concrete with perma-
nent water contact.
Hygienically soundFor the further repair of the ceilings and
walls of the chambers, the project team
opted for the MC-RIM PW 20 concrete
replacement system and MC-RIM PW
10 special protective coating, which
have proven effectiveness in providing
enduring protection in the potable water
sector. The cement-bonded concrete
replacement system was used to level
the wall and ceiling surfaces and in-
crease the concrete coverage. This was
followed by a finish with the mineral
surface protection coating MC-RIM
PW 10. Highly sulphate-resistant and
chloride-proof as well as carbonation-
inhibiting, this product is impermeable
to water yet open to vapour diffusion.
Both chambers were thus successively
and successfully repaired to the abso-
lute satisfaction of the customer within
a period of just three months.
The cracks in the potable water tank were
repaired with MC-Injekt GL-95 TX, the
low-viscosity, soft-elastic injection resin
sealant from MC.
Rehabilitation of the potable water tank in Lozenets
[email protected] [email protected]
The 90-year-old potable water storage tank in Sofia has been made fit for the future with proven injection and repair systems from MC.
MC AktuellMC News
6 | MC aktiv 2_2018
[email protected] [email protected]
The 90-year-old potable water storage tank in Sofia has been made fit for the future with proven injection and repair systems from MC.
In Den Bosch in the Netherlands, a 7-screen multiplex cinema has been built to accommodate a total audience of around 1,000 people. Despite a very ambitious schedule, the cinema was able to keep to its opening date in summer 2018 – thanks not least to MC-FastKick 111, MC’s new hardening accelerator.
Kinepolis Den Bosch is a super-modern
multiplex cinema equipped with cut-
ting-edge laser projection techno-
logy and digital sound systems. It
is operated by the Kinepolis Group.
Founded in 1997, this listed corpora-
tion currently boasts 95 cinemas in
Belgium, Canada, the Netherlands,
France, Spain, Luxembourg, Switzer-
land and Poland.
High standards, tight timingThe construction project in Den
Bosch was planned against a very
ambitious schedule. The client was
under time pressure and required con-
cretes with rapid strength develop-
ment so that the cast components
could be stripped on site and the con-
crete slabs smoothed as quickly and
early as possible. The chosen ready-
mixed concrete manufacturer Voets-
Langeraap B.V. consulted MC to see
if there was a particularly effective
concrete formulation to help accel-
erate the construction process and
improve productivity. The challenge
was to retain the concrete’s required
consistency as it travelled from the
mixing plant to the installation site
and then to achieve rapid strength
development within the first few hours
to allow early smoothing.
Two-phase efficiencyThe MC experts recommended
MC-FastKick 111, a product launched
in 2017. The chloride-free hardening
accelerator initially has a strong lique-
fying effect, but then ensures rapid
hardening with controlled reduction
in the setting time of concrete and
mortar. In addition to increased early
strength values, the new hardening
accelerator from MC also results in
higher final strengths due to a special
activation mechanism which causes
the concrete matrix to become ever
denser and more solid over time.
In the first active phase, MC-FastKick
111 combines with a PCE-based super-
plasticiser to offer a consistency exten-
sion of up to two classes without
influencing the stiffening behaviour.
In the second phase, MC-FastKick 111
exerts a positive effect on the crystal
growth of the calcium silicate hydrate
phases in concrete. This leads to an
appreciable increase in the crystalli-
sation rate and significantly increas-
ed early strength values – without
negatively affecting the other con-
crete properties. The result is an early-
setting, high-strength concrete ideal
for this type of project. These pro-
perties also make MC-FastKick 111
the perfect choice for winter con-
struction projects and for the precast
industry, where the major reduction
in cycle times is an obvious bene-
fit. The challenge during construc-
tion in Den Bosch was successfully
met thanks to these MC admixtures,
enabling the multiplex to open its
doors on June 25, 2018 as planned.
MC-FastKick – a cinema success
Thanks in no small measure to MC-FastKick
111, the state-of-the-art multiplex cinema
in Den Bosch was able to open as planned
on June 25, 2018.
The rapid setting and the increased early and final strengths achieved with MC-FastKick make it the first choice for both precast production and winter construction projects as well as
for projects with highly ambitious schedules like the construction of the large multiplex cinema in Den Bosch.
[email protected] [email protected]
MC PersonaliaMC AktuellMC PersonaliaMC AktuellMC AktuellMC News
7MC aktiv 2_2018 |
© Xavier den Dekker
The printed buildStructures straight from the printer?
While it may appear rather strange at
first glance, 3D printing is one of the
major technology-related topics of
tomorrow in the construction indus-
try. Experts, planners and contrac-
tors worldwide are looking for new
concepts to help create a building
process that is as quick, cost-effec-
tive and environmentally friendly as
possible. This applies as much to the
sprawling metropolises of industri-
alised nations as it does to the bur-
geoning megacities of developing
and emerging countries.
In the USA, UK, China and not least
in Germany, there are a significant
number of research and develop-
ment projects aimed at creating a
3D concrete printing process suitable
for mass production. For example,
"Beton3D-Druck” [Concrete 3D Print-
ing] is exploring the fundamentals for
the introduction of a new construc-
tion process as part of the “Zukunft-
Bau” [Future of Building] funding pro-
gramme run by the Federal Institute
for Research on Building, Urban Affairs
and Spatial Development. MC’s spe-
cialists are providing concrete tech-
nology know-how and support to
these research projects, as well as
highlighting innovative develop-
ments in products including con-
crete admixtures including hard-
ening accelerators and even fibre-
reinforced mortar.
Three different approaches currently
dominate discussions relating to the
3D concrete printing of structures
and components: powder bed tech-
nology, the currently more wide-
spread extrusion technique and the
wet-spray process.
Powder bed The powder bed technique is being
advanced in two different directions:
Either a mixture of aggregates is bond-
ed to a composite by local applica-
tion of cement paste or consolidation
is achieved by selective application
of water to a mixture of aggregates
and cement. With both techniques,
even intricate structures can be pro-
duced without any problems. However,
with larger components especially,
a considerable number of layering
cycles is necessary, making the pro-
cess relatively slow.
ExtrusionIn extrusion technology, a die head lays
material strands of different shapes, heights
and widths on top of each other in layers.
It is likewise referred to as an additive
technique. This process comes closest
to established conventional 3D printing
with plastics. Although the procedure
is faster, it also has a weak point – in
the truest sense of the word. Since the
material strands are individually deposit-
ed on top of one another, bonding
is only achieved by pressing each
new strand against the one below it.
As recently as the start of this decade, 3D printing seemed like a fanciful blend of science fiction and niche technology for a select-ed few companies. But things have since changed – dramati-cally. New applications are now appearing on the scene on an almost daily basis. However, one particular field is proving to be especially exciting: 3D concrete printing, a technique that can be used to create individual compo-nents and even entire buildings. The number of research projects in this area means MC's concrete technology know-how is now in constant demand.
1
23
4
5
The extrusion processes that exist can be divided into five different categories:1. Gantry solutions, 2. Cable-suspended solutions, 3. Swarm solutions, 4. Robotics solutions and 5. Folding and self-assembly.
MC Report
8 | MC aktiv 3_20168 | MC aktiv 1_20168 | MC aktiv 2_2018
3D concrete printing:A brave new world of building
This can therefore lead to problems
in terms of flexural or shear strength
and the amount of mechanical stress
the construct can bear.
Wet sprayingThe wet-spray process is also an additive
process and is similar to the extrusion
technique. Here, too, the premixed wet-
spray material is pumped to a spray
nozzle, accelerated by compressed air
and applied layer by layer to the sub-
strate. Offering high deposition rates
and process speeds, this technique is
very well suited for the production of
large-format components. In contrast
to the extrusion process, the applica-
tion angle of the concrete spray noz-
zle can be varied vertically and hori-
zontally. This leads to new possibilities
with regard to the geometric shapes
that can be generated. However, the
ability of this technique to produce
intricate structures is very limited. More-
over, the biggest advantage of the
process also poses a challenge: While
the high pressures brought to bear
during application ensure an extraor-
dinarily high level of material compac-
tion, they also give rise to more resi-
dues in the form of dust and aerosol
pollutants requiring effective control.
So all three techniques have their
strengths and weaknesses. Reason
enough for two German research proj-
ects to focus more intensively on process
optimisation in 3D concrete printing.
Research at TU BraunschweigUnder the guidance of ITE, the Insti-
tute for Structural Design at TU Braun-
schweig, an interdisciplinary research
group involving TU Braunschweig,
TU Clausthal and LU Hannover has
been developing a robot-controlled
shotcrete technology for the form-
work-free production of complex con-
crete components. From the begin-
ning of the research it was found
that the current techniques used in
the production of precast concrete
parts have not evolved beyond those
established on the market for de-
cades. This is in contrast to many other
areas of manufacture, where digitally
supported production is already well
advanced. A lot of potential has thus
fallen by the wayside – not just in
respect of creative and constructive
possibilities, but especially in terms of
economic and commercial progress.
This new manufacturing technology
enables architects to implement com-
pletely original designs for geometri-
cally complex concrete components,
providing a level of creative scope
that is not available with the tech-
niques currently in use. Beyond free-
dom in creative design, however, the
advantages extend to more efficient
material utilisation and the result-
ing implications for the sustainability
of the production process. And, of
course, the formwork-free produc-
tion of concrete components can
significantly reduce manufactur-
ing cost. Now, this potential is to
be developed using modern tech-
niques such as computer-controlled
3D concrete printing.
The goal of the project was to auto-
mate long-established shotcrete tech-
nology and to incorporate it into a
robot-controlled 3D injection printing
process called "Shotcrete 3D Printing"
(SC3DP). In addition to the develop-
ment of the entire process technology
from scratch, it was also necessary
to create a suitable shotcrete whose
properties could be adapted to the
respective components and 3D print-
ing process. MC was involved both
in an advisory capacity and with
the provision of suitable concrete
admixtures. The SC3DP research is
being conducted in the "Digital Build-
ing Fabrication Laboratory" (DBFL)
at TU Braunschweig university of
science and technology, a digitally
controlled machining centre which
enables coordinated operation of a
5-axis CNC portal milling machine
and an integrated heavy-duty robot
with a total of nine degrees of free-
dom. Here, various robot-supported
techniques can be used for the pro-
duction of geometrically complex
three-dimensional concrete compo-
nents, such as the combination of
wet-spraying and milling. This enables
additive and subtractive manufac-
turing approach and opens up new
ways of constructing complex com-
ponents with automated efficiency.
Continued on page 10
The "Digital Building Fabrication Laboratory" (DBFL) of TU Braunschweig university of science and technology. Photos left: Vertical spray test. Photos right: Spray-forming a wall with
single-face formwork (top) and a free-formed curved wall (bottom) Photos: ITE, TU Braunschweig
Graphic illustration of the CONPrint3D®
technique developed by TU Dresden.
Photo: Faculty of Construction Machinery,
TU Dresden
9MC aktiv 3_2015 |
MC Report
9MC aktiv 2_2018 |
3D concrete printing:A brave new world of building
Continued from page 9
With the CONPrint3D® process, a complete example storey of an apartment building could be erected four to six times faster than is possible with conventional construction methods,
and without the need for scaffolding or site cranes. The theory and the practice: Schematic diagram (left) and trial setup on the test site (right). Photos: Faculty of Construction Machin-
ery, TU Dresden
MC Report
10 | MC aktiv 3_2016
Project success at TU DresdenProfessor Viktor Mechtcherine and
his team of engineers and research-
ers at the TU Dresden have been
developing new technologies for 3D
extrusion printing since September
2014. The working title for the first
project read: "Feasibility studies for
continuous and formwork-free con-
struction processes by 3D forming of
fresh concrete". In contrast to previ-
ous approaches, this research project
focused on practical implementation
directly on the construction site (in-situ
concrete construction). The chosen
technical basis for the equipment
therefore consisted of established
construction machinery, and the
building materials employed were
the concretes commonly used in
solid construction.
Thus strictly aligned to current practice,
the research approach was highly
effective. To the delight of all in-
volved, the concept won the Research
category award at Munich’s 2016
Bauma, considered to be the world's
largest construction machinery trade
fair. During the project period, the
interest of media and companies in
this innovative technology grew so
strongly that TU Dresden registered
a trademark for the process dubbed
"CONPrint3D® - Concrete Onsite 3D
Printing" with the German Patent and
Trademark Office in order to protect its
research results. As the research project
progressed, technical solutions for
concrete delivery, the necessary print
head and the long-distance robotics
all underwent extensive development
and evaluation. At the same time,
concretes were specially developed
and optimised for 3D printing and
subjected to extensive rheological
and mechanical investigations in
their fresh and hardened conditions.
The construction process itself was
also analysed with a view to ongo-
ing optimisation. The CONPrint3D®
prototype site provided important
data, facilitating economic appraisal
of 3D concrete printing and proof
of its technical feasibility.
When printing a complete example
floor for an apartment building, the
speed of construction for the walls
proved to be 4 to 6 times faster than
conventional construction methods,
with further reductions in building
time conceivable through an increase
in layer thicknesses or speed of con-
crete placement. The calculations also
revealed a cost saving of around 30%
compared to the construction of
the same floor using conventional
masonry methods – not accounting
for the fact that the building shell
could essentially be erected without
scaffolding and construction cranes.
Development of the new process
is currently the subject of a follow-
up project under the “ZukunftBau”
umbrella, focusing on 3D printing
based on foamed concrete, with
MC foam generators integrated in
the process.
MC – research partnerResearch is also of great importance
at MC. Indeed, the company owes
much of its good reputation to the
ongoing development of innovative
construction chemical solutions. MC
chemists, mineralogists and con-
struction material specialists work
hand-in-hand with technical product
management and sales consultants
worldwide. MC also regularly partici-
pates in national and international
research projects and cooperates with
universities and external materials
testing institutes. Having produced the
best results after extensive trials, an MC
concrete replacement system specially
developed for the research project was
ultimately used for the concrete mix
applied by the TU Braunschweig team.
The research project in Dresden
also drew on the know-how of MC
experts. Extensive preliminary and
functional tests attended by rele-
vant university personnel in MC's
own laboratories in Bottrop led to
the supply of a range of concrete
admixtures including modified
acceleration systems. In addition to
providing advisory support of the
research project, MC specialists were
also asked to assess the commer-
cial opportunities for the developed
technologies on the world market.
Promising prospectsAlthough this technology is still
in its infancy, it has already exten-
sively proven its suitability on the
international stage. The world's first
fully printed office building opened
in Dubai in May 2016. The United
Arab Emirates are even pursuing a
state-sponsored "3D Printing Strat-
egy" – with the goal of introducing
3D printing for a quarter of all new
buildings in the Gulf state by 2030.
The Chinese company Win Sun is also
already using an industrial-scale 3D
concrete printing system in which
the individual parts of standardised
apartment buildings are produced in
the factory and then simply supplied
to the construction site for assembly.
Particularly topical is a project in
Milan, Italy, which took the form of
a single-storey demonstration building
measuring some 100 square meters,
constructed from 35 robot-produced
modular elements. The flexible 3D
printer required just 60 to 90 minutes
for each of the individual elements,
with the effective construction time
for the entire building a mere 48 hours.
3D concrete printing is therefore well
on its way to becoming an impor-
tant factor in the global construction
industry.
10 | MC aktiv 1_201610 | MC aktiv 2_2018
MC Report
MC Aktuell
Successful highway development with NafuflexThe Trans-Israel Highway, commonly referred to as Highway 6, is a toll motorway that runs through the state of Israel from south to north. Now, thick bituminous coating systems from MC are being used on a large scale for the extension of the route to Haifa on the Mediterranean coast.
Highway 6 is considered one of the
largest and most important infra-
structure projects in the history of
Israel. Currently, the officially named
"Yitzhak Rabin Highway" runs from
Be'er Sheva, the "capital of the Negev
Desert" in the south, over about 170
kilometres north to Jokne’am on the
south-eastern foothills of the Carmel
Mountains. From there, the highway
is being extended by a good 20 kilo-
metres in the direction of the port
city of Haifa, an important goods
transshipment centre on the Medi-
terranean. The aim of the project is
to create a more efficient transport
solution that relieves the congested
traffic arteries and further improves
accessibility to and from the area.
The extension of the route began in
mid-2016 and is scheduled for com-
pletion in 2019 at a total cost of close
to 600 million euros. The developer is
toll route concessionaire Shafir Engi-
neering Cross-Israel Highway Nord,
which has acquired the rights to toll
collection until 2049, with project
management responsibilities falling
to the Trans-Israel Highway Company.
First choice: NafuflexWhen selecting the waterproofing
materials, the client followed the recom-
mendation of a specially appointed,
independent expert and opted for
the sprayable polymer-modified thick
bituminous coating system Nafuflex.
It offers distinctive strengths in water-
proofing vertical, horizontal and inclined
surfaces under conditions of water
exposure corresponding to classes W1-E
(soil moisture and non-pressing seepage
water), W2.1-E (moderate water pressure
< 3 m), W3-E (non-accumulating water
on earth-covered roofs) and W4-E (splash
water at wall bases and capillary water
in and below walls in contact with the
ground). The material is available as a
single-component formulation, Nafuflex
Profi Tech 1, and in a two-component
version, Nafuflex Profi Tech 2. Both
variants are highly flexible and crack-
bridging and ideal for airless spraying
thanks to their consistency, as well as
solvent-free and therefore environment-
ally compatible. Thanks to its powder
component, Nafuflex Profi Tech 2 also
ensures that the waterproofing coat
dries particularly quickly. As a result
of these advantages, A.Z. Advanced
Building Technologies, the partner
company of MC in Israel, was readily
able to convince the contractor of the
suitability of this MC waterproofing
product family.
Strict controlsAccompanying the contractor, who
closely supervised the spraying work,
a client-appointed expert regularly
checked for correct surface prepara-
tion and appropriate application of the
waterproofing coating. This regime
also required the increased presence
of A.Z. and MC on the construction
site. Finally, the waterproofing work
on several twin tunnels, bridge foun-
dations, retaining walls, culverts and
vehicle transitways all successfully
passed a series of strict acceptance
test procedures.
[email protected] [email protected]
Several twin tunnels, bridge foundations, retaining walls, culverts and vehicle transits
were sealed on the new construction route of Highway 6 with thick bituminous coat-
ing systems from MC.
11MC aktiv 3_2015 |
MC PersonaliaMC Aktuell
11MC aktiv 2_2018 |
MC News
11
MC AktuellMC Aktuell
The new rapid formula screed from MC needs
only the make-up water to be ready for use.
Prepared and applied with commercially availa-
ble screed mixers or screed mixer/feed pumps,
Powerscreed RS is installed earth-moist and
offers a long processing time of two to three
hours. The low-shrinkage screed becomes
accessible to foot traffic after just four to six
hours, developing a compressive strength of
> 20 N/mm² and a residual moisture of < 2 %
(CM method) after 24 hours, by which time it
is ready for tiling. After a further 24 hours, the
residual moisture content falls to below 1.8 %
(CM method), so that parquet floors can also
be laid.*
Graded at CT-C35-F5 according to EN 13813, the
screed further exhibits higher compressive and
flexural strength values than standard screeds.
Powerscreed RS is ideal for jobs requiring quickly
coverable screeds and for repairs of small floor
areas. It can be installed on damp-proof course/
waterproofing/separating membrane, in com-
posites and on insulation and is suitable for
heated screeds, wet rooms and both internal
and external applications.
With Powerscreed RS, MC-Bauchemie has developed a new rapid formula screed that com-bines long open times with very fast strength development.
New, rapid formula Powerscreed RS
* Values indicated relate to an air temperature of 23 °C and a relative humidity of 50 %.
New MC-Estrifan Color finish coatingsThe new MC-Estrifan Color product range features high-quality glazes and sealants that offer screed and concrete surface optimisation as well as individual colour upgrades with enhanced durability.
A refreshed natural look or completely new colourMC-Estrifan Color is a single-component glaze
used to refresh, colour-match and enhance
absorbent mineral substrates such as visible
screeds, concrete floors and concrete slabs
or paving stones, with the natural structure
of the substrate being visually retained. Since
MC-Estrifan Color is readily resistant to both
frost and de-icing salts, the glaze can also be
used on outdoor, weathered surfaces.
Colouration and protectionAs a pigmented floor sealant, MC-Estrifan Color
Protect is ideally suited to a wide range of appli-
cations beyond floor refurbishment in cellars,
storage rooms and workshops. Its inherently
abrasion-resistance makes it a safe solution
wherever the floor is subjected to mechanical
wear and tear. The sealed surface also has good
stain resistance and is easy to clean.
MC-Estrifan Color Protect Pro is a two-component,
pigmented polyurethane sealant which, due to
its high mechanical resilience and good chemical
resistance, is primarily used for industrial floors.
Due to its balanced performance profile, this
premium member of the new product family
can even be used f.e. in warehouses as well as
in private garages.
Both products meet the requirements of
Germany’s AgBB code governing the health
and safety of building products, meaning they
are harmless to health and can therefore be
used indoors without hesitation.
MC Innovation
12 | MC aktiv 1_201612 | MC aktiv 2_2018
MC Innovation
Nafufill GTS-HS rapid –new concrete replacement for hydraulic structuresThe time window available for repairing hydraulic and sewerage structures is frequently very restrictive. For structures in tidal waters, time becomes even more critical, challenging planning skill, material selection and work execution alike. Now, with Nafu-fill GTS-HS rapid, MC-Bauchemie has launched a fast-setting special concrete replacement that can be permanently exposed to water after just one hour, making it ideally suited for the repair of hydraulic and sewerage concrete structures.
With its exceptionally early permanent water resistance, high resilience and wide range of applications, Nafufill GTS-HS rapid offers a reliable solution
for the repair of concrete structures exposed to fresh, salt and waste water.
The polymer-modified, low-shrinkage
concrete replacement from MC is
chloride-proof and highly resistant
to sulphate, temperature, frost and
de-icing salt, and can be applied
by dry spraying at air, material and
substrate temperatures of 5 to 35 °C.
Exceptionally early permanent water resistance and impressive stress resilienceNafufill GTS-HS rapid fulfils the require-
ments for mortar class R4 laid down
in EN 1504 Part 3, and is thus also
approved for upgrading structurally
relevant areas of a concrete build.
The new concrete replacement cures
extremely quickly and can be per-
manently exposed to pressing water
after one hour. It achieves flexural
and compressive strength values of
2.9 & 10 N/mm² respectively after 24
hours, 5.9 & 31 N/mm² after 7 days
and 10.9 & 62 N/mm²* after 28 days.
With the new MC concrete replace-
ment, fractured areas between the
low and high water marks can be
repaired with layer thicknesses of up
to 120 mm. The material can also
be applied as a wide-area coating.
The layer thickness in such cases is
10 to 30 mm per pass, up to a maxi-
mum total layer thickness of 60 mm.
Wide range of applications for all kinds of hydraulic structuresWith these properties, Nafufill GTS-HS
rapid offers a reliable and sustainable
solution for the repair of tidal, rein-
forced and unreinforced hydraulic
structures such as port infrastructure,
embankment walls, quay facilities,
locks and sluice works, as well as the
repair of sewerage structures, open
sewers and emergency basins etc.
© iStock.com/CreativeNature_nl
MC Innovation
13MC aktiv 3_2017 | 13MC aktiv 2_2018 |
* Values indicated relate to an air tempera-
ture of 23 °C and a relative humidity of 50 %.
Further information on new products
and product systems can be found
on our new website on the product
group pages and in the News and
Download areas.
Your link to our homepage:www.mc-bauchemie.com
© iStock.com/wildacad
© iStock.com/Darwin Brandis
Buildings with fair-faced concrete are a relative novelty in the Icelandic capital Reykjavik. This makes the new residential and commercial com-plex in its port district a real visual first, the success of which owes much to a wide range of MC products employed throughout the project.
The residential and commercial
complex at Tryggvagata 13 is locat-
ed in the downtown area of the re-
nowned port district of Reykjavik,
within sight of the Harpa Concert
Hall. The architect Hildigunnur Harals-
sdottir was commissioned by the cli-
ent Thorir Gunnarson and project
manager Kristján Guðmundsson to
design the façade in partly coloured ex-
posed concrete - a novelty not only
for Reykjavik but the whole of Iceland.
As a rule, the raw material available
locally does not guarantee sufficient
concrete quality for fair-faced con-
crete. Selected as concrete supplier,
the local company Steypustödin deci-
ded to play it safe. Not only did they
import Norwegian granite sand to
improve the concrete, they also used
MC products for the concrete cos-
metic work and flew in a German
applicator to ensure that this was
done with the utmost profession-
alism. Among the broad range of MC
products used were filler Emcefix F
Spachtel Lang and Emcefix Spachtel
Extra Fein in various colours, poly-
mer primer Murafan 39, universal filler
Nafuquick Uni, sealant Repacryl and
finish coatings MC-Color Proof Pure
and MC-Color Proof Vision. In total,
1,000 m² of external exposed con-
crete and approx. 400 m² of its inter-
nal concrete surfaces were reworked.
Sculptures by a well-known Icelandic
artist were incorporated to enhance
the appearance of the complex and
treated with MC-Color, the sculptor
having been most impressed by its
effective protection. Since its con-
struction, the building has been
making positive headlines through-
out Iceland, enormously boosting
the popularity of fair-faced concrete
within the country.
Artistic fair-faced concrete in Reykjavik
14| MC aktiv 3_2015
MC Aktuell
The use of poor-quality concrete in DPX’s new building in Linz, Austria, meant a major refurbishment was necessary. The company commis-sioned Leitner Bau to carry out repair work on 2,500 m² of ceiling and wall surfaces using Nafufill KM 250 and Nafufill KM 110 concrete replacement systems, together with MC's fine-fill mortar Nafufill SF.
Leitner Bau’s primary task was to prepare
the ceilings and walls for the subsequent
painting work. The first phase was com-
pleted in just four weeks back in 2016,
with the final phase following in May of
this year. With only four weeks sched-
uled once again, the timing was tight!
With clockwork-like efficiency, MC’s
logistics meant all the required materi-
als were quickly delivered. Leitner Bau
likewise made excellent progress, with
the completion date only marginally
overshot. The results were impres-
sive: The Nafufill SF treatment left
the ceilings and walls super smooth
and free of pores and cavities, which
meant the painters could get on with
their job without worrying about any
further filling work. Everyone in-
volved from the planning consultants
to the applicator and the building
operator was very pleased with the
final outcome.
Wonderfully refurbished
MC News
14 | MC aktiv 2_2018
Owner Thorir Gunnarson (r.) and Project Manager Kristjan Gudmundsson are proud of this mod-
ern residential and commercial complex. [email protected]
Before and after comparison: Nafufill SF served to make the ceilings and walls extra smooth.
MC Personalia
15MC aktiv 3_2015 |
MC Personalia
15
Wonderfully refurbished
MC aktiv 2_2018 | 15
MC Personnel
New employees at MCWelcome to the team
Carsten Kreuzer (34) assumed the posi-
tion of Head of Logistics at MC on 1 July
2018. A professionally qualified transport
manager and business economist, he pre-
viously worked for several years in senior
freight forwarding and branch manage-
ment positions for various international
logistics companies.
Low Huk Tuang (52) joined our com-
pany in Singapore on 1 February 2018 as
technical sales manager responsible for
concrete admixtures and infrastructure
projects. He brings eleven years of ex-
perience in similar functions to his new
position.
13 trainees start at MCAugust 2018 saw our new trainees commence their apprenticeships
in various commercial and industrial professions at MC in Bottrop. We
are delighted to welcome them to the company! Standing from left to
right: Cem Kaya (chemical technician), Jason Jäschke (chemical produc-
tion technician), Gurpreet Singh (chemical technician), Niklas Brachmann
(materials tester), Marco Adamek (warehouse logistics officer - finished
goods warehouse), Benedikt Schang (chemical production technician),
Moritz Scheuerer (industrial manager), Marco Nienzila (chemical produc-
tion technician) and Jonas Sutmann (laboratory assistant). Sitting from left
to right: Joana Tepelden (chemical laboratory assistant), Jeanine Simon
(industrial manager), Maxi Schellberg (industrial manager) and Johanna
Strangemann (industrial manager).
Jan Henning Höhnel (32) joined the
company on 1 May 2018 as Sales Manager
Region West of our Concrete Industry divi-
sion in Germany. The business economist
(BBA) last worked as technical sales man-
ager for a concrete release agent man-
ufacturer and is currently being prepared
as the successor for Jürgen Schmiemann
as he approaches retirement.
Creative concrete workshop on Girls’ Day 2018The company Züblin again took part in Girls’ Day in Frankfurt this year. The
aim of Girls’ Day is to offer a glimpse into male-dominated professions for a
day. A total of 16 girls had accepted Züblin's invitation to get acquainted with
life on a construction site, with visits to various locations around Frankfurt.
The highlight of the event was a workshop at the Züblin construction site
ARGE Exhibition Hall 12 in Frankfurt, where the participants were encoura-
ged to get creative with concrete under the direction of Züblin site manager
Susann Christ. MC helped to prepare the event and contributed various cas-
ting compounds to illustrate the colourful design possibilities that concrete
offers. After MC employees Stefan Hettwer and Benjamin Borth had briefly ex-
plained the basics of concrete production, the girls used prefabricated form-
work elements to create individual holders for office materials, showing plen-
ty of initiative and creativity in the process. The results were quite impressive,
so that at the end of Girls’ Day 2018, each participant had a solid souvenir of
her experience to take home.
When it comes to sealing concrete surfaces under asphalt pavements, epoxy resin-
based solutions frequently exhibit sensitivity to moisture, exacerbated by long curing
times. Now MC’s special polyurethane resin MC-DUR LF 680 offers a time-saving alter-
native specifically for this kind of work: Insensitive to moisture and with short curing
times, it improves your planning reliability and increases cost efficiency by accelerating
the entire waterproofing phase. With safety and reliability assured.
Simple. Fast. Impermeable.
EXpErtisEResin pRotection
speciality polyurethane resin primer, top seal and scratch coat for bridge paving applications
Mc-DUR LF 680
WAteRpRooFinG
coMpLeteD in
one DAY!