Stuttgart 21 sets the future in train - MC tunnelling expertise in great demand - MC-Bauchemie
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THE MAGAZINE FOR EMPLOYEES AND CUSTOMERS OF MC-BAUCHEMIE 3-2019 MC Report Stuttgart 21 sets the future in train MC tunnelling expertise in great demand Pages 8-10 MC Inside MC News MC News MC Personnel CROM celebrates Cooling towers in Repair instead of demolition – Long-service 10-year anniversary Page 3 Opole make music Page 4 Jaguaré Bridge in São Paulo Page 11 awards Page 15
MC Editorial
News
Dear Reader,
It was just a year ago when we last That said, the other features in our current issue are equally interesting
featured a tunnel project as the in their own right and I commend them to you: From the refurbishment
focus of our magazine. Then it was and aesthetic upgrading of industrial buildings and the record-setting
the repair of the Wallring Tunnel repair of a subsiding bridge in Brazil to our unique concrete cosmetics
in Hamburg. This time around we and concrete technology know-how, each the subject of an article
are dedicating our headline MC that has a story to tell. As usual, we close our year-end edition with our
report to one of the projects of long-service awards in recognition of those whose loyalty and dedication
the century – Stuttgart 21. With have contributed so much to the successful development of MC over
Tunnelling among our Fields of the past decades. For this, I – on behalf of my colleagues on the Manage-
Expertise we have been able to ment Board – would like once again to express my deepest gratitude to
provide a wealth of know-how you, our people.
with regard to the associated
subprojects and construction phases, thus contributing to the success of Finally, I would like to wish all our readers the very best of seasonal goodwill
this enormous undertaking. Various MC technologies and product systems and a prosperous, successful and above all a healthy and happy New Year!
have been used, including special products for soil conditioning, superplas-
ticisers for lining segment production, injection systems for waterproofing Kind regards,
the tunnels and, last but not least, a completely new, cement-free annular
gap backfill grout – an innovation successfully developed in harness with
the special-purpose consortium ARGE ATCOST 21. You can read more
about this megaproject starting on page 8 of this edition of MC aktiv. Dr.-Ing. Claus-M. Müller
Contents Cover
14 Modern car park building
MC Inside at Zollverein colliery
View of the Filder Tunnel before the third
shield TBM drive. Turning the tunnel bor-
3 CROM celebrates 10-year anniversary The new car park was built using concrete release ing machine for the last pass represented a
agents, curing agents and concrete cosmetics major challenge. A large turning cavern was
MC summer festival in Bottrop from MC. built especially to allow the TBM to be turned
around underground. An unleached gips-
MC News MC Report
keuper was encountered in the rock strata
surrounding the lower Filder Tunnel. Since
4 Cooling towers in Opole make music this essentially consists of a swellable anhy-
The new cooling towers of the coal-fired power 8 Stuttgart 21 sets the future in train –
drite, a solution was required that would reli-
plant Opole II (Poland) offer a visible reminder from MC tunnelling expertise in great demand
ably eliminate the risk of swelling and ground
afar of the country's folklore. The Stuttgart-Ulm project, known as Stuttgart 21
uplift. MC-Bauchemie and PORR Bau GmbH
(S21 for short), is one of the largest infrastructure
developed a cementless annular gap backfill
undertakings in the recent history of the Federal
5 Industrial structure aesthetically upgraded grout which, after extensive testing, was used
Republic of Germany. In future, it will add Swabia’s
The façade of the district heating plant of a city for the Filder Tunnel boring operation, the
main metropolitan region to the high-speed
in Holland has now been not just repaired but also first application of its kind anywhere in the
“Magistrale for Europe” rail link, serving as an
visually enhanced with the MC-Color system. world.
important hub within the North-South and East-
West Trans-European Transport Networks (TEN-T)
Photo: DB/Arnim Kilgus
6 High-quality concrete surfaces criss-crossing Central Europe. The breakthroughs
for Hamburg’s HafenCity of the Filder Tunnel in September and the Alb-
Wherever upgrading exposed concrete surfaces
becomes part of the HafenCity megaproject remit,
vorland Tunnel in October 2019 marked the
successful conclusion of an important phase in Credits
MC's concrete cosmetics are invariably the first choice. this major project, not just for Deutsche Bahn, Publisher:
but also for MC and its tunnel specialists. MC-Bauchemie Müller GmbH & Co. KG
7 MC know-how integrated Am Kruppwald 1–8
in Bulgaria’s highest skyscraper MC Innovation 46238 Bottrop, Germany
Both the planning engineers and the constructors 13 MC-Injekt 2133 stops water fast
involved in this high-rise project have put their Tel. +49 (0) 20 41/1 01-0
Among other things, this fast-foaming single-compo-
reliance in MC’s expertise and concrete admixtures. Fax +49 (0) 20 41/1 01-688
nent injection resin is ideal for stopping strong flowing
water in both buildings and construction pits.
www.mc-bauchemie.com
11 Repair instead of demolition – info@mc-bauchemie.de
Jaguaré Bridge in São Paulo Geopolymer concrete –
After a possibly record-setting repair time, São concrete without cement
Managing editor / Conception:
Paulo’s Jaguaré Bridge was reopened to road traffic Geopolymer concrete is based on a binder system
Saki Moysidis, MC-Bauchemie
in April 2019. consisting of blast furnace slag, fly ash, plus special
activators and concrete admixtures from MC.
Editing:
12 Replica drift built at Zollern colliery MC Personnel Saki Moysidis, MC-Bauchemie
The deceptively realistic surface of the drift tunnel Thomas Haver, Leitpunkt Kommunikation
was stabilised and modelled with products of the 15 Long-service awards
MC-RockMortar (formerly Oxal RM) family. Design:
iventos – Agentur für Marketing, Bochum,
Germany
2 | MC aktiv 3_2019
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CROM celebrates 10-year anniversary
The tenth annual edition of the from the Faculty of Construction of courses at a time when the topic CROM courses is that all content is
study course series “CROM – Cer- Engineering and Management – and of manhole rehabilitation was still first taught theoretically by experts
tified Rehabilitation of Manholes” MC-Bauchemie offers sound expert somewhat neglected in terms of from both academia and the field, and
will once again be available as of knowledge on manhole and shaft training and certification. then applied, extended and consoli-
February next year. Since 2010, more rehabilitation in theory and practice. dated in a series of practical modules.
than 700 employees from planning “We are delighted at the response to “Together with TU Kaiserslautern, “Every course participant thus also
and engineering offices, tendering date and are also more than a little we have developed a unique con- has the opportunity to practice all
sewerage network operators and proud that our training course concept cept that offers an unprecedented the essential steps and skills of the
specialist rehabilitation firms in is still so well received – so much mix of in-depth knowledge transfer rehab process,” says Sven Messmann.
Germany have taken part in the so, that CROM is now perceived as a and hands-on practice,” says Sven
CROM courses. kind of seal of approval for manhole Messmann, Global Product Manager
rehabilitation in the marketplace," ombran/Underground Sewer Systems
The collaborative seminar series jointly says Professor Körkemeyer. at MC-Bauchemie. The aim of the series
provided by TU Kaiserslautern (Kai- of courses is to improve the quality
serslautern University of Science and TU Kaiserslautern and MC-Bauche- and safety of manhole rehabilitation
Technology) – under the direction mie were pioneers in this field and measures from planning to imple-
of Prof. Dr.-Ing. Karsten Körkemeyer developed and marketed this series mentation. The special feature of the
MC summer festival
in Bottrop
Attended by around 600 employees and their families, the MC summer festival
took place on the Am Kruppwald site in Bottrop on 7 September, 2019. The
weather could not have been kinder – although rain had been forecast, the
skies not only remained dry, the sun also made a lengthy appearance, sending
the temperature to a comfortable 20 °C so that attendees young and old
could remain “al fresco” as they enjoyed the many culinary delicacies on offer.
Use the video link below to get
a taste of the summer festival
for yourselves. Here are the code
and address:
https://bit.ly/2s9AO1V
MC
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For the design of the cooling towers, the client PGE chose an artistic concept from among competing ideas submitted by local schools, with rainbow and sun motifs and musical notes
from the Polish folk song “Little Caroline has gone to Gogolina”.
Cooling towers in
Opole make music
After a construction period of The operator PGE had the interior a surface area of around 40,000 m2 sively dirt-repellent. The prefabri-
five years, two new energy- and exterior surfaces of the two inside the cooling towers. The pig- cated components of the columns
generating units of the Polish cooling towers – each measuring a mented, UV-resistant top-section and cross-members of the supporting
coal-fired power station Opole II good 182 m high – coated with MC sealant MC-DUR VS PUR was then structure for the water distribution
were commissioned in Septem- surface protection systems and vis- applied over the upper third. system within the cooling towers had
ber 2019, ensuring a secure ually enhanced with artistically styled been factory-coated with MC-DUR
electricity supply to 4 million musical notes from a Polish folk song Striking visuals, top protection 2496 CTP. This special, fast-curing resin
private households in the years from the region. For the design of the 45,000 m2 exter- sealant based on KineticBoost-Tech-
to come. MC not only contrib- nal surfaces, the client PGE chose an nology® had been successfully used
uted its know-how from its Ther- Cooling tower inner artistic concept from among compet- for the first time four years earlier for
mal Power Plants FoE (Field of shells protected ing ideas submitted by local schools, the repair of an older cooling tower
Expertise), it also had significant The general contractor, Polimex, and the with rainbow and sun motifs and in Opole and has since been applied
input in the elaboration of the coating subcontractor Beroa/Domin- musical notes from the Opole region as a coating for many such cooling
external design. ion had already gained good experi- folk song “Poszła Karolinka do Gog- towers worldwide.
ence with MC’s systems, in particu- olina” (“Little Caroline has gone to
lar during a similar project involving Gogolina”). The hyperboloid cooling The operators are delighted with both
Europe’s largest thermal power site towers made application of the exte- the technical quality and the visual
of Bełchatów in Poland’s Łódź region. rior design more difficult and posed design of the two giant cooling tow-
a real challenge for all those involved ers in Opole and are pleased to have
The transparent epoxy resin sealant – one that was, however, overcome been instrumental focusing attention
MC-DUR 1277 WV, which also acts as with total success. not only on Poland’s energy indus-
a primer for other coatings (meaning try but also the country’s folklore.
that fewer coats are required) was The decision was made to use a pig-
daroslaw.demski@mc-bauchemie.pl
used as the concrete curing agent. mented surface protection system reinhard.martin@mc-bauchemie.de
MC-DUR 1277 WV delays evapora- from MC for this – now available with
tion of the water during the curing of a technically improved formula under
fresh concrete and so increases the the product name MC-Color Flair. It
mechanical and chemical resistance is characterised by very high resist-
of its surface. Then the highly acid-re- ance to fading, UV radiation and
sistant epoxy resin sealant MC DUR VS weathering, yet is open to water
NR 3 was applied in two coats over vapour diffusion and is also exten-
4 | MC aktiv 3_2019
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Sporting a sympathetic design and top-quality protection, the district heating complex in Assendelft serves as a fine example of how industrial buildings can be visually improved and
harmonised with their surroundings.
Industrial structure
aesthetically upgraded
Located in the middle of a The contractor VTG Beton from the preventive concrete protec- sion. Since the refurb there is noth-
residential area in Assendelft Velsen Noord started on the repair tion coating for outdoor surfaces ing left to remind onlookers of the
in North Holland, the façade and refurb work in October 2018. exposed to the elements. Offer- former grey concrete block. To the
of the district heating plant of The company, which specialises in ing outstanding surface protec- delight of the client, the commu-
local energy utility HVC Group concrete rehabilitation, had already tion, the pigmented coating was nity and, of course, local residents,
has now been not just repaired successfully implemented various applied in various shades of green a colourful, oversized work of art
but also aesthetically upgraded. projects with MC products – hence to provide an appealing back- has been created that provides for
Thanks to MC-Color Proof vision this further collaboration in Assen- ground for the artistic animal and a significant upgrading of the living
and MC-Color Flair pure, the delft. plant motifs subsequently painted environment.
once barren façade has been onto the façade. The ready-to-use,
marcel.boon@mc-bouwchemie.com
transformed into a minor work Façade repaired self-crosslinking copolymer disper-
of art. with Nafufill KM 220 sion is colour-stable as it is likewise
After expert substrate preparation, UV and weather resistant. Similarly,
In Assendelft, a town between Alk- the first step was to reprofile and it is open to water vapour diffusion
maar and Haarlem in the middle of level the entire outer façade of and carbonation-retarding as well
the Saendelft Ost residential area, the building using Nafufill KM 220 as being resistant to temperature,
there is a small natural gas-fired fibre-reinforced fine cement mor- frost and de-icing salts.
power station belonging to energy tar in a wet spraying process. This
utility HVC Group. While the adjoin- created the perfect surface for the Durable protection
ing administration building had further sealing and coating work In the final phase, the surfaces were
already been visually integrated required. Nafufill KM 220 is resistant provided with high-quality surface
into the surrounding area with to temperature, frost and de-icing protection in the form of MC-Color
an appealing façade design, this salts, offers high resistance to car- Proof vision. The two-component,
district heating plant itself was a bonation and impresses with its transparent high-performance
dreary concrete block that had excellent application properties, coating keeps the colour design
also been defaced by unsightly with possible layer thicknesses fresher for longer and offers per-
urban graffiti. In consultation with ranging from 2 to 30 mm. manent protection against graffiti,
the municipal administration, the dirt and grime. Roller-applied, it too
Take a look at the
operator decided to repair the Colourful coating is UV-stable, weather-resistant and
making-of video
building exterior and in so doing In the next step, the façade was carbonation-retarding while also https://bit.ly/344rTgo
to dramatically improve it visually. treated with MC-Color Flair pure, being open to water vapour diffu-
MC aktiv 3_2019 | 5
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Aktuell
Photo left: In the foreground the Strandkai (Beach Quay) construction site, in the background the completed Marco Polo Tower and the Hamburg Cruise Center.
Photo right: Futura Campus building (left) and the construction sites of the so-called Creative Blocks (right).
High-quality concrete surfaces
for Hamburg’s HafenCity
HafenCity in the proudly Hanse- The city of Hamburg is setting new the property developers responsi- fillers, will invariably provide the
atic City of Hamburg is currently standards with the development of ble for the individual projects are, solution required. All products are
seen as the largest inner-city this new municipal space along the they unanimously decided to rely polymer-modified and ready for use
urban development project in river Elbe: Over an area of 157 ha, a on MC’s know-how in concrete cos- immediately after mixing with water.
Europe. With around 140 differ- lively city-within-a-city with a maritime metics. In addition to reliable on-site The Emcefix-Spachtel G coarse filler, for
ent construction sites under- flair all of its own is being created, service and high product quality, the example, is suitable for concrete repairs
way, the volumes involved are combining work, home life, culture, extensive range of system products such as patching imperfections both
gigantic. In total, the building leisure, tourism and retail. By the end for a wide variety of applications has large and small, and the reprofiling
work will provide for more than of 2019, 68 individual construction also been a key factor in this blan- of deep flaws and spalled areas up
2.4 million m2 of gross floor “subprojects” will have been com- ket approval. In Hamburg’s Hafen- to 50 mm deep. Emcefix-Spachtel F
space. And wherever upgrad- pleted and a further 71 are already City, the challenges range from repair lang fine filler is available in seven
ing exposed concrete surfaces underway or in the planning stage. work such as closing anchor holes, different colours and is mainly used
becomes part of the project pores, cavities and joints in intricate for surface skimming and the preci-
remit, MC’s concrete cosmetics MC involved on numerous sites ceilings and complex walls, to the sion filling of standard and fair-faced
products are invariably the The concrete cosmetics of MC have visual upgrading of fair-faced con- concretes in layer thicknesses of up to
go-to first choice. been and are being used in numer- crete surfaces and further concrete 6 mm. And the superfine filler in the
ous of these construction projects, cosmetic work in demanding areas family, Emcefix-Spachtel F extra fein,
Here on the left you can see the construc- for example in SKAI HafenCity, the such as columns, balconies or under- is available in three colours and is
tion site of the Southern Überseequartier
“Southern Überseequartier”, Hafen- ground car parks. Different fillers and mainly used for the full-surface filling
with the finished Elbphilharmonie concert
hall, and on the right the Intelligent Quar- City University and the so-called colour shades were required for, in and skimming of standard concrete
ter and the HafenCity University. “Intelligent Quarter”. As different as particular, colour matching and the and fair-faced concrete with layer
removal of defects on exposed con- thicknesses of up to 3 mm.
crete surfaces.
Thus, MC’s concrete-cosmetic prod-
Superfine concrete ucts contribute to the high quality
cosmetics with Emcefix standards being regularly delivered
The products of the Emcefix family by the contractors involved in the
are therefore particularly in demand HafenCity project.
and constantly in use on the various
stephan.faelchle@mc-bauchemie.de
construction sites of HafenCity. As
the demands on concrete surfaces
increase, so too do the demands on
concrete cosmetics. If the surface
is to be truly flawless, the Emcefix
system of MC, consisting of a bond
coat and coarse, fine and superfine
6 | MC aktiv 3_2019
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© AAA Architects, Sofia
MC's high-performance superplasticisers are integral to the concrete used to build the foundation, core,
columns and ceilings of the Sky Fort Business Center.
MC know-how integrated in
Bulgaria’s highest skyscraper
The Sky Fort Business Center is an the building core, columns and ceil- after a short mixing time, delivering forces in the concrete, as well as a
office high-rise currently under ings. Due to seismic and structural good, sustained liquefaction as well reduction of the effort involved in
construction in Sofia. Measuring challenges, tests were required to as high early strength. MC-Power- placing, spreading and compacting
202 m, it is destined to be the determine the creep deformation of Flow 2695 can be used to produce the mix. Still on the up, this ambi-
highest building in Bulgaria. Due the concretes. Ultimately it was the concretes exhibiting low tack com- tious structure has yet to reach its
for completion in 2021, it will MC formulations which won through bined with very good workability and final height. The opening of what
boast 49 storeys and a floor space against all the competition. MC was pumpability as well as high-quality will then be the highest building in
of around 80,000 m2. Both the the only supplier able to develop the surfaces. Centrament Retard 370 set- Bulgaria is scheduled for June 2021.
planning engineers and the con- right recipes, the properties of which ting retardant was used to counter
nikolay.monev@mc-bauchemie.bg
structors involved in the project were confirmed by an independent the hot temperatures of the Bulgar-
have put their reliance in MC’s materials testing institute. “Having ian summer, enabling solidification
expertise. achieved the necessary test results, of the concrete to be delayed so as
we were duly selected as a supplier to extend its workability and ensure
The Sky Fort is located in the heart of for this project,” says lead engineer sustained pumpability. The superplas-
the Bulgarian capital and will provide Nikolay Monev, the man taking care ticiser Muraplast FK 19 and MC-Top
modern offices with a panoramic res- of the technical aspects of the work B, the surface-hardening dry mortar
taurant offering an incredible view on behalf of MC Bulgaria. for industrial floors, were used to lay
of the city and the surrounding area. the floor of the underground car park,
The building also has three under- High-specification concrete covering a total area of 30,000 m2. This
ground floors providing parking for Despite the large volume of the foun- resulted in good homogeneity and Lead engineer Nikolay Monev, MC Bulgaria,
around 850 vehicles. The skyscraper dation totalling 20,000 m3 with a depth a decrease in the internal frictional keeps a firm eye on the concreting work.
was designed by AAA Architects for of more than 3.5 m, the temperature
the investor Fort Noks (both of Sofia). in the core had to be kept to below
The company Structo was commis- 60 °C. MC therefore developed a
sioned with the planning work and concrete formulation that combines
is collaborating closely with the con- a special cement with the concrete
struction company Bulcarp. admixtures MC-PowerFlow 2695 and
Centrament Retard 370 to ensure a
Creep deformation test low hydration temperature. With this
successfully passed peaking at 51 °C, the specified value
Back in the planning phase in 2015/6, was never in danger. MC-PowerFlow
the parties involved consulted vari- 2695 is the primary admixture incor-
ous companies to find the right part- porated in the concrete used for the
ner for the required concretes, with skyscraper. The high-performance
strength class C 35/45 needed for the superplasticiser based on the latest
foundation and C 50/60 required for MC polymer technology takes effect
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© DB/Arnim Kilgus
Stuttgart 21 sets the future in train –
MC tunnelling expertise in great demand
The Stuttgart-Ulm project, also When Deutsche Bahn AG celebrated sections on the edge of Stuttgart's stieg (Swabia’s Jura uplands) were also
known as Stuttgart 21 (S21 the symbolic breakthroughs of the city centre are to be put to good on the list. Various MC technologies
for short), is one of the largest Filder Tunnel on 9 September and of use in the project, extending the and product systems were used in
infrastructure undertakings in the Albvorland Tunnel on 29 October downtown area by around 40 percent. all the tunnel construction projects,
the recent history of the Federal 2019 – with many of those involved The client and developer overseeing including special products for soil
Republic of Germany. In future, it in the five-year construction period this project is Deutsche Bahn. The conditioning, superplasticisers for
will add the metropolitan region as well as political representatives Federal Republic of Germany, the State lining segment production, injec-
in Swabia to the high-speed from the state administration, the of Baden-Württemberg, Stuttgart’s tion systems for waterproofing the
“Magistrale for Europe” rail link, federal government and the EU in integrated public transport authority tunnels and, last but not least, a
while also serving as an impor- attendance – the team of tunnel VRS, the state capital Stuttgart, the completely new, cement-free annular
tant hub within the North-South specialists from MC also had every airport company Flughafen Stuttgart gap backfill grout – an innovation
and East-West Trans-European reason to cheer. After all, MC was able GmbH and the European Union are successfully developed in harness
Transport Networks (TEN-T) to contribute a wealth of know-how also participating in the financing of with the special-purpose consortium
criss-crossing Central Europe. of its Tunnelling Field of Expertise and the project. Seen in its entirety, S21 ARGE ATCOST 21.
The breakthroughs of the Filder thus make a notable contribution is made up of the following subpro-
Tunnel in September and of the to the success of this mammoth jects: The lowering of Stuttgart main Due to the geological conditions, the
Albvorland Tunnel at the end of undertaking. station, construction of the Stuttgart machine-excavated Filder Tunnel is
October 2019 marked the suc- railway ring track and construction divided into an upper and a lower
cessful conclusion of an impor- A German megaproject of a new Stuttgart-Ulm line, which section with two tunnel tubes each
tant phase in this major project, With a spend of around 8 billion includes several tunnels. MC was with a diameter of 10.87 m passing
not just for Deutsche Bahn, but euros, the transformational Stuttgart significantly involved in the latter through an overburden of 20 to 220 m.
also for MC and its tunnel spe- 21 transport and urban development two measures in particular. With a total length of 9,468 m, it is the
cialists. project will greatly benefit the local longest tunnel of the S21 project and,
region through the creation in the MC’s expertise in mechanical tun- after completion, will be the longest
near future of a major hub in the nel excavation in high demand double-tube railway tunnel and the
national – and international – railway The heading operation with lining third longest tunnel in Germany.
network. More than 100 km of new, segment installation was conducted
fast railway track, three new stations using a full-thickness-cutting shield TBM A similar tunnel construction
and an intelligent traffic management featuring multi-mode earth pressure approach was also adopted in the
concept will set new standards in balance (EPB) for face support. The case of the Albvorland Tunnel. Here
domestic German and European rail Filder Tunnel was only one of several again, two tunnel tubes with a dia-
transport going forward. And there major tunnel projects involving MC meter of 10.87 m and an overbur-
will also be major benefits on the that were mechanically excavated – den of between 8 and 63 m were
urban planning side: About one square the Albvorland Tunnel and the Bossler excavated over a length of around
kilometre of current or former track Tunnel passing through the Albauf- 8,000 m. In the third major tunnel
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project, passing through the Albauf- backfill grout. The use of water in the solidification reaction. The grout to scientifically investigate the
stieg Jura uplands at Aichelberg, two the more sensitive contact zones also contains complex phosphates feasibility of the proposed solution.
tunnel tubes – each with a diameter was expressly prohibited. In the which influence the solution equi- The Institute for Building Research
of 10.87 m and up to 280 m of over- case of the shield shell and the librium of the anhydrite in such a at RWTH Aachen University (ibac)
burden – were excavated to create cutting tools, this was not a prob- way that swelling is inhibited. This was commissioned with the mine-
the Bossler Tunnel serving the new lem, but Deutsche Bahn demanded phenomenon can be described by ralogical petrographic investiga-
track section from Wendlingen to a specific solution for the grout that the law of mass action and has been tions to determine whether pos-
Ulm. With a length of 8,806 metres, it would reliably obviate the risk of proven in trials and suitability tests. sible reactions with the anhydrite
too will constitute one of the longest swelling and ground lift. MC and PORR Bau GmbH have since could occur in the annular gap.
railway tunnels in Germany. patented this globally unique techno-
Continued on page 10
The globally unique logy. This annular gap backfill system
Geological challenges solution developed for S21 solution has been given the name
An unleached gipskeuper, consis- The consortium ATCOST 21 responsible MC-Montan Grout AA 03; it exhibits
ting essentially of swellable anhy- for constructing the tunnel therefore optimum bedding properties with
drite, is located in the rock strata turned to MC, an approach that led high sulphate resistance to provide
surrounding the lower Filder Tun- to the joint development of a bes- the tunnel tube with true durability.
nel. Rock containing anhydrite poke geopolymer. Geopolymers are
can be found in several regions inorganic binders that do not contain Proven in practice
of the world, and one such is the cement and whose structure can In view of the high requirements
steep slope of the Filder plateau be traced back to the reaction of and the omnipresent media atten-
Photo above: View of the newly lined shell of
to the south of Stuttgart. If rock aluminosilicates in alkaline media, tion surrounding S21, renowned
the Albvorland Tunnel. Photo below: Internal
containing anhydrite comes into resulting in the formation of inorganic testing institutes were consulted view of the tunnel boring machine in the
contact with water, the volume polymers. The special feature of the together with ATCOST 21 in order Filder Tunnel.
increases by more than 60 %. This solution developed involves com-
results in enormous swelling pres- bining the advantages of a single-
sures which could lift the tunnel component (1C) grout with those of
and the surrounding terrain and a two-component (2C) grout through
subsequently lead to damage to the flexible use of an activator. The
buildings and structures located basis takes the form of a modified
above it. For the lower Filder Tun- 2C backfill grout containing a non-
nel, the TBM was operated with an reactive starting aggregate predo-
open shield, the main contact with minantly present in a grain structure.
the delicate gipskeuper strata thus Blast furnace slag and fly ash serve
©DB / Kilgus_Arnim
being with the shield shell, the as the binding agents to which an
cutting tools and the annular gap activator has to be added to initiate
MC
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High-performance
superplasticiser in lining
segment manufacture
MC products were also used for the concrete castings installed in the Bossler
Tunnel. SEMPER BETON GmbH & Co. KG produced the concrete for the lin-
ing segment factory of the consortium ARGE PTS Bosslertunnel, for which
purpose it used a high-performance superplasticiser of the MC-PowerFlow
series. It is based on the latest polycarboxylate ether technology from MC
and ensures both high early strengths and high-quality concrete surfaces
coupled with above-average water savings and economical dosing.
Continued from page 9
The engineering office Brameshu- grout proved so successful in the Tunnel soil conditioning was again a in EPB tunnelling as well as in rock
ber & Uebachs Ingenieure GmbH S21 megaproject that it has been major challenge as the TBM had to formations with a high clay content
subsequently prepared the envi- in great demand worldwide ever safely cross under the A8 motorway and a high likelihood of clogging.
ronmental analysis report. Together since. with an overburden of only 8 m of clay Economical in use, MC-Montan
with the Faculty of Building Materials and clay-marl stone. And in the case Drive FL 04 prevents deposition
Technology at the Ruhr University Optimised bedding properties of the Bossler Tunnel passing through and agglomeration and increases
Bochum, the material-specific tech- In addition, the experience gained the Jura slope of the Albaufstieg in the lubrication effect by dispersing
nological aspects of the grout were from the development of the modi- the third section of the Stuttgart-Ulm the clay minerals. By repelling spoil
investigated in order to ensure its fied 2C annular gap grout was also project, the rock encountered during and preventing accumulation at the
application suitability measured used to adapt a classic 1C annular heading operations was of very low cutter head, the agent also reduces
against state-of-the-art criteria. gap mortar at the Albvorland Tunnel strength in places and featured fault TBM power consumption and cutting
The special sensitivity of the issue between Wendlingen and Kirchheim zones with water ingress. A closed tool wear. Thus the soil condition-
is demonstrated by the fact that unter Teck. Because the rate of TBM shield machine was deployed on all ing solutions from MC were able to
the tests took more than two years advance had increased there, a faster three tunnel sections, with the exca- increase heading efficiency in all three
in total and were only successfully means of grouting of the tunnel tube vated soil being used to support the of the tunnel projects mentioned as
completed after large-scale trials under had become necessary, something working face as the TBM advanced. As well as satisfy strict cost-efficiency
practical conditions on the actual that was beyond the conventional 1C mentioned above, the tunnel boring requirements.
construction site. Subsequently, the mortar being used. For this purpose, method is based on EPB technology,
system solution was duly approved MC-Bauchemie developed the con- which is applied especially in difficult Summary
for use for S21 projects by Deutsche sistency modifier MC-Montan Grout geological formations and in inner- For the Stuttgart 21 megaproject, MC
Bahn and the consultant engineers. 05. As an additional component, it city areas. The MC-Montan Drive was able to contribute both its expertise
is added to the mortar via a mixing product series from MC was used and its bespoke product systems for
The tunnel-builders very quickly section during the injection phase, as the soil conditioning agent for all tunnel construction from its Tunnelling
recognised the enormous advanta- but prior to pilaster strip entry, ensur- the mechanically excavated tunnels Field of Expertise, all very much to the
ges accruing from this modified 2C ing optimum bedding properties. As of the new Stuttgart-Ulm line. And satisfaction of its clients. In cooper-
mortar compound once they began with S21, it also eliminates the risk of the MC-Montan Device CT (Cell Tube) ation with planning engineers and
to apply it in the grouting operations subsidence where heading performance foam generator was employed for the construction companies, the tunnel
for which it was designed. Despite the is accelerated. The modified grout was efficient production of a high-quality experts at MC also developed inno-
grain structure of the starter aggre- applied continuously in parallel to the and durable foam, enabling operations vative solutions optimally adapted to
gate, activator addition was made soil conditioning work over a length to continue with minimal interruption, the various requirement profiles and
possible before pilaster strip entry of 8 km at the Albvorland Tunnel. minimal maintenance and minimal challenges encountered on site, thus
through the provision of an addi- specific consumption values. further facilitating the smooth progress
tional mixing section, thus ensuring Efficient heading with soil of the tunnel projects.
effective backfilling of the annu- conditioners from MC Ideal lubrication
eugen.kleen@mc-bauchemie.de
lar gap as specified. The use of a Along the route of the upper Filder The most widely used soil conditioning
non-reactive starter aggregate has Tunnel, the tunnel boring machine agent was MC-Montan Drive FL 04
the advantage that the application mainly encountered Stuben sandstone, (Foam Liquid), an environmentally
open time is exceptionally long, which has a high proportion of sticky compatible and readily biodegradable
thus ensuring maximum operational clay and high-strength sandstone, with foam concentrate with a defined pro-
flexibility in such an environment. the concomitant danger of rapid tool portion of clay additive. The product
The new cementless annular gap wear. In the case of the Albvorland is ideally suited for soil conditioning
1010| MC
| MCaktiv
aktiv3_2019
3_2016MCMC
Personalia
MCAktuell
News
© AdobeStock/ALF_Ribeiro
Jaguaré Bridge, a section of which sank by around two metres in November 2018, was opened to road traffic again in April 2019 after a possibly record-breaking repair time of just five
months, thanks in part to MC's expertise.
Repair instead of demolition –
Jaguaré Bridge in São Paulo
On 15 November 2018, a section in Brazil. All the cracks requiring repair dinated, high-quality product sys- integration and interplay between
of Jaguaré Bridge along the were sealed with the special resin tems in the other areas of the bridge planning, execution and quality of
Marginal Pinheiros expressway MC-Injekt 1264 compact – both to requiring refurbishment. For example, the systems used. And it has become
in São Paulo sank about two prevent aggressive, damaging sub- the structurally enhancing special a model for further projects: As a pre-
metres. The structure therefore stances from penetrating the con- concrete replacement Nafufill KM caution after this incident, the author-
had to be closed and secured by crete structure again in the future, 250 and the special mortar Zentri- ities responsible put in place a com-
hydraulic supports. and to restore the static structure of fix CR were used for the reprofiling of prehensive inspection programme
the concrete. the concrete. Offering outstanding for all bridges – and have already
Given that the bridge is part of a main application properties and workabil- had another bridge repaired using
artery serving the metropolis of São Increased safety ity, both produced results well above the same methods and approaches
Paulo, the city administration decided In order to cope with future traffic the standards specified. employing MC’s proven systems.
– after a thorough investigation – loads, it was decided to install addi-
jaques.pinto@mc-bauchemie.com.br
against demolition and replacement. tional means of structural reinforce- A shining example of engineer- peter.schmidt@mc-bauchemie.de
Instead, the bridge was to be thor- ment. Since this was not possible ing excellence
oughly refurbished and structurally with conventional measures such After a possibly record-setting repair
reinforced. Right from the start, the as the provision of further beams time of only five months, Jaguaré
authority responsible was advised or supports, the highly effective Bridge was reopened to road traffic in
by MC as a company widely reputed MC-CarbonFiber system (formerly April 2019, providing a shining exam-
for its know-how and innovations in MC-DUR CFK) was used. This con- ple of engineering excellence and
bridge construction. sists of carbon fibre-reinforced straps also of how project success invariably
applied to the surface or glued in depends on ensuring the seamless
Major challenges slots as means of secondary bridge
The main challenges lay in lifting, reinforcement. In the case of Jaguaré
stabilising and reinforcing the sagging Bridge, surface-glued MC-Carbon-
bridge section in the shortest possible Fiber Lamella (formerly MC-DUR CFK
time. There were numerous cracks to Lamelle) reinforcing straps were pro-
rectify, structural repairs were required vided on both the upper face and the
at both the upper and lower faces, undersides of the bridge in accord-
and the roadway also needed to be ance with specifications drafted by
extensively refurbished. High-quality the structural engineers involved.
MC solutions and technologies were
applied in all phases of the work insti- Mutually complementary
tuted to tackle these problems. The systems
multifunctional concrete admixture Safety and durability are of para-
Muraplast FK 300 was used to restore mount importance in such under-
the pier foundations and the concrete takings. Hence, all parties involved
carriageways commonly encountered decided to use MC’s excellently coor-
MC aktiv 3_2015
3_2019 | 11MC News
Aktuell
Deceptively realistic: The Zollern colliery's coal drift, reproduced with MC-RockMortar sculpting and repair mortars from MC.
Replica drift built at Zollern colliery
On the premises of the Zollern Mining is integral to the heritage added another highlight within just a MC-RockMortar was also the product
Colliery Museum in Dortmund, of the Ruhr region. The fact that few days: a deceptively realistic coal of first choice for the Zollern colliery
a “walk-in, hands-on mine” was coal is no longer being extracted drift recreated with MC-RockMortar. project. Offering excellent applica-
opened to visitors in 2018. At from the area has changed nothing Projections and light give the impres- tion properties and resistance, these
the beginning of 2019, this exhi- in that respect, with the era being sion of a long, deep tunnel – even special single-component mortars
bition, steeped in history, was kept alive by museums such as that though the actual training mine can be applied both by hand and
expanded by the construction of of the Zollern colliery. The anthra- is located above ground. The idea by wet spraying. The mortars are
a replica coal drift to make the vis- cite coal mine in the northwest of is to give visitors an impression of ideal for the delicate sculpting and
itor experience even more realis- Dortmund, which was closed down what it was like to work in such dark, modelling of lifelike rock, stone or
tic. The surface of the drift tunnel in 1967, consisted of two pits that narrow drifts. Original sounds from wooden surfaces. They are therefore
was stabilised and modelled with joined together underground. In a the mining industry and a vibratory often used for the artificial depic-
products of the MC-RockMortar project that was completed in the plate imitating the vibrations of coal tion of natural worlds, e.g. in zoos
(formerly Oxal RM) family, the summer of 2019, the former training mining further enhance the museum or amusement parks.
sculpting and repair mortars mine of Westerholt colliery in Herten experience.
of MC. was rebuilt here in order to provide Deceptively realistic
a particularly authentic insight into Versatile high performer At the Zollern colliery, too, the high-
the everyday life of the miners. The project, supervised by Andreas est demands were placed not only
Hoppenrath of the LWL Industriemu- on the creativity of the sculptors and
A hands-on mining experience seum organisation, was carried out craftsmen but also on the material.
courtesy of MC-RockMortar by BETON.ROCKS from Halle/Saale. Initially, creating the black, shiny coal
In addition to the usual information The BETON.ROCKS team led by Giorgi surface of the simulated drift was the
boards, there are also many “hands-on Gugunava consists of sculptors, biggest challenge. Thanks to MC-Rock-
View of the drift tunnel prior to com- stations” in the training mine. In the designers, classically trained crafts- Mortar, the end result was decep-
mencement of the sculpting work. middle of January 2019, the museum men and machine technicians. It has tively realistic to the delight of the
created numerous artificial worlds in museum operators and visitors alike.
the past, ranging from simple rocky
andreas.zahn@mc-bauchemie.de
landscapes to detailed reproductions jonas.hallmann@mc-bauchemie.de
of old cultural sites and witnesses
of days gone by.
The team has often worked with MC’s
microsilica-modified MC-RockMortar
sculpting and repair mortars, which
include the fine-grained MC-Rock-
Mortar L (formerly Oxal RM-L) for
particularly intricate designs and the
coarser-grained, higher compressive
strength MC-RockMortar H (formerly
Oxal RM-H) and MC-RockMortar
HS (formerly Oxal RM-H HS) mortars.
12 | MC aktiv 3_2019MC Innovation
The photo illustrates how MC-Injekt 2133 is applied and how it stops water ingress into structures and components.
MC-Injekt 2133 stops water fast
MC-Bauchemie has launched the It was more than 30 years ago that Immediately stops MC-Injekt 2300 top / 2300 rapid
single-component, fast-foaming MC-Bauchemie introduced onto the pressurised water reacts reliably in the protection of
injection resin MC-Injekt 2133 market its two-component injection MC-Injekt 2133 is immediately ready the foam structure to provide a per-
for waterproofing applications. resin MC-Injekt 2033, a product spe- for use, serving as a single-compo- manent seal.
Among other things, it is suitable cifically created to fill cavities and nent plug in water-bearing cracks.
markus.treinen@mc-bauchemie.de
for stopping water flows in both stop water ingress into buildings. The injection resin reacts quickly to holger.graeve@mc-bauchemie.de
buildings and construction pits. water contact, foams and increases
With the new single-component its volume by a factor of 60 within
injection resin MC-Injekt 2133, seconds, quickly stopping the flow of
MC-Bauchemie has now developed even pressurised water. Its pot life is
a reliable product that requires no unlimited, thus ensuring maximum
mixing or extensive preparation, time and consumption efficiency.
enabling it to be used both eas- In order to achieve a durable seal,
ily and instantly. MC-Injekt 2133 post-injection with MC-Injekt 2300
is also phthalate-free, i.e. contains top / 2300 rapid is recommended Take a look at
our product video:
none of these potentially harmful after application of MC-Injekt 2133.
https://youtu.be/G7WPwaA0VBY
plasticisers. With this 2-step injection method,
Geopolymer concrete – concrete without cement
The use of alkaline-activated binder phases formed are mainly of the cal- mer concretes in various applica- system made from granulated blast
systems is becoming increasingly cium silicate hydrate kind, whereas tions. For example, in the construc- furnace slag, fly ash and activators
important in concrete technology. in geopolymer systems the forma- tion of Toowoomba Wellamp Airport and concrete admixtures from MC
Aside from ecological aspects such tion mechanism tends primarily to (see photo), Earth Friendly Concrete especially adapted to the application.
as the reduction of CO2 emissions produce inorganic, three-dimension- (EFC) from the company Wagners
in binder production, the improve- ally cross-linked aluminium silicate was used to the greatest possible
eugen.kleen@mc-bauchemie.de
ment achieved in respect of certain networks. extent. It was produced with a binder
concrete properties is also gaining in
significance. Alkaline-activated binder Geopolymer concretes are particularly
© Wagners, Toowoomba
systems with comparatively low cal- suitable for (steel-reinforced) concrete
cium contents are often referred to components likely to be exposed
as “geopolymers”. The reactions of to high levels of acid or sulphate
geopolymer binder systems required attack, such as sewerage pipes or
to achieve sufficient strength dif- components in sulphate-containing
fer significantly from those of nor- (ground) water. In Australia, exten-
mal Portland cement (PC) binder sive experience has already been
systems. In PC-based systems, the gained with the use of geopoly-
MC aktiv 3_2019 | 13MC News
Aktuell
©Dreßler Bau, Eibe Sönnecken
Modern car park building
at Zollverein colliery
Between August 2017 and The building is a car “park” in two GmbH from Aachen opted for pre- coating and for all other in-situ con-
December 2018, new parking senses of the word – first there is its fabricated concrete elements with crete measures in the floor, wall and
spaces for around 360 vehicles pure functionality as a repository for multiple bends, which were assem- ceiling areas. As a protection against
were provided on the site of the temporarily vacated vehicles, and then bled to form a peripheral roof edge. evaporation, it ensures a good barrier
Zollverein coking plant, part of there is its innovatively greened roof effect, facilitates optimum hydration
the Zollverein colliery, a world slab, which serves as a small park with Reliable demoulding progress in the near-surface concrete
cultural heritage site in Essen paths and seats, allowing people a The contract for the construction work layer and minimises the formation
in Germany’s Ruhr region. The place to stroll and relax. A rising rein- was awarded to Dressler Bau GmbH, of early shrinkage cracks. In order
ambitious new structure in the forced concrete structure consisting Essen, with which MC has an excellent to meet the planners’ demands for
form of an open parking deck of columns and wall sections sup- long-standing relationship. The proven exceptionally high surface quality,
covered with a landscaped roof ports the approximately 190 x 47 m concrete release agent Ortolan Basic some areas were also repaired and
was built using concrete release reinforced concrete slab. The parking 761 from MC was used in the manu- colour-matched with the concrete
agents, curing agents and con- level itself was also designed with facture of the precast elements for the cosmetics of MC’s Emcefix product
crete cosmetics from MC. high aesthetics in mind. The sin- wall and ceiling areas as well as for the system.
gle-storey deck was slightly lowered columns. Solvent-free, low in odour
and blended with embankments to and quickly biodegradable, it offers And with very good results: The huge,
give the impression that the almost excellent environmental credentials. almost floating landscape roof was
Another real eye-catcher is the new 9,000 m2 roof slab was floating above It is easy to use, weather-resistant opened in spring 2019 after 15 months
single-storey car park on the Zollverein
ground level. In order to reinforce this and ensures clean demoulding, with of construction and is another real
colliery world heritage site, another con-
struction project in which MC products impression, the architectural and plan- a correspondingly high quality of eye-catcher on the former coking
were used. ning team of Kadawittfeldarchitektur concrete surface resulting. For the site, a location that already has more
roof edge, the planning team chose a than its fair share of amazing visual
black-dyed concrete with a fine grain attractions.
containing mica in order to achieve
rainer.staendler@mc-bauchemie.de
an appearance reminiscent of the
anthracite coal mined at Zollverein
from 1847 to 1986.
Effective colour-matched
protection
In addition to Ortolan, the architectural
team also opted for Emcoril Protect M
Lite from MC for curing the cleanable
1414| MC aktiv 3_2019
3_2015MC
MC Personalia
Personnel
Long-service awards
Following an old and established custom, the first Thursday in the month yalty and commitment to the company evidenced by their long service.
of December always sees the MC Group’s latest long-service awardees Each was also given a gift in keeping with the time they have been an
honoured by MC’s Management Board at a ceremony, followed by a tra- MC employee. Both honoured and gratified, the awardees were visibly
ditional banquet at the Gasthof Berger restaurant in Bottrop. Taking place pleased to receive both the kind words and the gifts. After the ceremony,
this year on 5 December 2019, the ceremony was attended by MC em- the rest of the evening was given over to a delicious three-course dinner
ployees from various countries who were celebrating their 10th, 25th and enjoyed in an informal atmosphere. In addition to the award ceremony
40th anniversaries. MC’s three Management Board members shook hands in Bottrop, other MC locations around the world also held long-service
with each attendee, expressing their appreciation and thanks for the lo- anniversary celebrations.
10-year anniversary Sven Steppa (D) Katarina Genyiova (SK) Wolfgang Hienert (D) Sylwia Apanowicz (IN & UAE)
Johann Schuh (AT) Christoph Werab (D) Loret Erum (UAE) Ulrike Hippler (D) Daroslaw Demski (PL)
Nikoley Monev (BG) Marcel Boon (NL) Dang Thi Bon (VN) Thorsten Ingenhaag (D) Tadeusz Wasąg (PL)
Daniel Medina (CH) Manuela Kwint (NL) Lars Jankowski (D) Cosmina Dobre (RO)
Isabel Meili (CH) Krzysztof Tobolski (PL) 25-year anniversary Jens Kleinau (D) Daniel Sandu (RO)
Stefan Scheck (CH) Pawel Wszeborowski (PL) Peter Kiermayr (AT) Mathias Lehnigk (D)
Daniel Stirnimann (CH) Ivan Vlaskovic (SRB) Frank Albitz (D) Hartmut Leye (D) 40-year anniversary
Stephan Abel (D) Aibek Amanbaev (RU) René Barth (D) Reinhard Martin (D) Waldemar Franke (D)
Martin Buschlinger (D) Nikolay Boyko (RU) Werner Clauß (D) Holger Riebeling (D) Barbara Petersen (D)
Stephan Fälchle (D) Alexandr Gorykov (RU) Roman Czaja (D) Daniela Wnendt (D) Silvana Schäkermann (D)
Sven Heinrich (D) Vitaliy Khachatryan (RU) Josef Frauenkron (D) Koltai Csaba (HU) Wolfgang Vogel (D)
Mieczyslaw Pacanowski (D) Ivan Mahlaev (RU) Jerome Gamon (D) Béla Rapp (HU) Günter Warkowski (D)
Katharina Ruland (D) Dmitriy Popov (RU) Stefan Gebhardt (D) Balogh Tibor (HU)
Andreas Sewald (D) Igor Savin (RU) Bernd Hahmann (D) Tibor Tóth (HU)
Congrats to the
long-service
awardees of
MC Russia
On 19 November 2019, Evgeniy
Sokolov, Managing Director of MC
Russia, congratulated seven employees
on reaching their 10th anniversary
at the company. From left to right:
Vitaliy Khachatryan, Alexandr Gorykov,
Ivan Mahlaev, Nikolay Boyko, Evgeniy
Sokolov, Aibek Amanbaev, Igor Savin
und Dmitriy Popov.
MC aktiv 3_2015
3_2019 | 15OS 10
WITH HIGH-SPEED
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K Moisture-tolerant during application
K Rapid curing
K UV-stable
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K Excellent crack-bridging properties
Floor-coating system for car parks
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MC-Floor TopSpeed
Binding layer:
MC-Floor TopSpeed +
Waterproofing layer:
MC-Floor TopSpeed flex plus,
dry-shake quartz sand two coats
solution consists entirely of TopSpeed components based
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on KineticBoost-Technology®. The result is a certified OS 10 MC-Floor TopSpeed SC
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MC-Floor TopSpeed SC
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MC-Bauchemie · Infrastructure, Industry & Buildings · IN@mc-bauchemie.deYou can also read
