High standards - coatings for corrosion protection

In everyday life, we encounter large and visible steel structures, especially in infrastructure. Motorway, road and railway bridges are particularly eye-catching. They cross rivers, gorges, roads or railway tracks, connect us with each other and help to shorten routes. There are around 140,000 bridges in Germany, each of which is individually designed – tailor-made engineering for local conditions. Whereas bridges were mainly made of wood and stone in earlier centuries, steel dominated as a primary building material well into the 20th century. Most of these bridges are still in use today. However, reinforced concrete is now often used in the construction of new bridges – in combination with numerous steel elements, such as struts, wire ropes, beams or hollow bodies and orthotropic road surfaces.

AREAS OF APPLICATION - INTERNATIONAL ACC. TO ISO 12944

Korrosionsschutz, Verkehrsbau, Industrial Coatings

COATING SYSTEM

for trowel application

1. PRIMER (optional)
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. TOP COAT
SikaCor® Elastomastic TFN

(2-component, solvent-free, thick-layer epoxy-polyurethane hybrid liquid plastic)

FILLER/SPRINKLING AGENT
Quartz sand
(0.4 – 0.7 mm)

The diagram shows an example of a coating system.

COATING SYSTEM

for airless application

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER (optional)
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. TOP COAT
SikaCor® Elastomastic Airless

(2-component, solvent-free, thick-layer polyurethane liquid plastics can be applied using airless systems)

 

The diagram shows an example of a coating system. 

Korrosionsschutz, Verkehrsbau, Industrial Coatings

COATING MATERIAL

for friction surfaces

SUBSTRATE: Steel Sa 2 1/2

1. COATING MATERIAL
SikaCor® Zinc ZS

(1-component solvent-based ethyl silicate zinc dust primer (Zn-ESI))

 

 

The illustration shows an application example. 

 

Coating system for closed ropes made of galvanized steel

COATING SYSTEM

for closed ropes made of galvanized steel

SUBSTRATE: Sweep-blasted

1. PRIMER
Sika® Cable Primer Plus

(2-component, low-solvent primer containing zinc phosphate and based on epoxy resin)

2. INTERMEDIATE COATINGS
2 - 3x Sika® Cable Top-1
(2-component, low-solvent intermediate coating containing micaceous iron oxide and based on polyurethane, with high elasticity, impact resistance and wear resistance)

3. TOP COAT
Sika® Cable Top-2

(2-component, low-solvent elastic polyurethane top coat in DB and RAL shades)

  • ADDITIONAL PRODUCTS
    Sika® Cable Flex-1
    (2-component, solvent-free, elastic sealant based on polyurethane for joints and crevices)
  • Sika® Cable Flex-2
    (2-component, solvent-free, highly penetrating, low-viscosity polyurethane-based injection resin for filling cavities)

 


The diagram shows an example of a coating system. 

COATING SYSTEM

for blasted surfaces

SUBSTRATE: Steel Sa 2 1/2

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

2. TOP COATS
2x Sika Poxicolor® SW NEW
(2-component, low-solvent, epoxy resin/plastic combination coating in RAL and DB shades)

3. OPTIONAL
In case of increased demands on colour stability, additionally use top coats (e.g. SikaCor® EG-5)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

for partial and limited surface preparation

SUBSTRATE: Steel PSt 2/3

1. PRIMER
Sika Poxicolor® Primer HE NEU

(2-component, low-solvent, surface-tolerant epoxy resin-based primer)

2. INTERMEDIATE COAT
SikaCor® EG-1 VHS

(2-component, very low-solvent, epoxy resin-based intermediate coating containing micaceous iron oxide)

3. TOP COAT
SikaCor® EG-4/ SikaCor® EG-5/ Sika® Permacor®-2330/ Sika® Permacor®-2230 VHS 

(2-component, acrylic polyurethane coating material in DB or RAL shades)

 

The diagram shows an example of a coating system. 

HIGH QUALITY C5 HIGH COATING SYSTEM:

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® EG Phosphat Plus

(2-component, low solvent, epoxy resin-based coating material conatining zinc phosphate)

2. INTERMEDIATE COAT
SikaCor® EG-1 Plus

(2-component, low-solvent, epoxy resin-based coating material containing micaceous iron oxide)

3. TOP COAT
SikaCor® EG-4/ SikaCor® EG-5/ Sika® Permacor®-2330/ Sika® Permacor®-2230 VHS

(2-component, acrylic polyurethane coating material in DB or RAL shades)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

Primer and intermediate coat in the factory,
top coat on the building site

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® Zinc R

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

2. INTERMEDIATE COAT
SikaCor® EG-1

(2-component, low solvent, epoxy resin-based coating material containing micaceous iron oxide)

3. INTERMEDIATE COAT
SikaCor® ZP-1

(2-component, low solvent, polyurethane-based coating material containing micaceous iron oxide)

4. TOP COAT
SikaCor® EG-4/ SikaCor® EG-5/ Sika® Permacor®-2330/ Sika® Permacor®-2230 VHS

(2-component, acrylic polyurethane coating material in DB or RAL shades)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

Road surface sealing system

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. TOP COAT
SikaCor® Elastomastic TFN

(2-component, solvent-free, thick-layer epoxy-polyurethane hybrid liquid plastic)

FILLER/SPRINKLING AGENT
Durop
(2 - 3 mm, 1:1)

 

The diagram shows an example of a coating system. 

 

COATING SYSTEM

Sealing system for footpaths and bicycle tracks

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

 

2. TOP COAT
SikaCor® Elastomastic TFN

(2-component, solvent-free, thick-layer epoxy-polyurethane hybrid liquid plastic)

FILLER/SPRINKLING AGENT
Quartz sand (0.7 – 1.2 mm, 1:1)

3. SEALING (optional)
Sikafloor®-359 N

(2-component, yellowing-free, pigmented polyurethane sealing)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

Steel bridge sealing by adhesive layer

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® HM Primer

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. UNDERCOATING
SikaCor® HM Mastic

2-component, solvent-free epoxy resin coating)

3. ADHESIVE LAYER
Sikalastic®-827 HT

(Modified hot melt adhesive granules for scattering)

4. MASTIC ASPHALT

 

The diagram shows an example of a coating system. 

 

INTERNATIONAL

According to ISO 12944

High quality corrosion protection according to ISO 12944

APPLICATION AREAS     

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

APPLICATION AREAS

  • Complete refurbishment on the construction site
  • Repair or partial renewal of old coatings
  • Coating of weld joints
  • Partial and limited surface preparation
Surfaces in contact with soil, water or concrete

APPLICATION AREAS

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

Friction surfaces of threaded and of riveted connections 

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

ADVANTAGES   

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

APPLICATION AREAS

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

CHARACTERISTICS

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

Coatings for full locked coil ropes and cables

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

APPLICATION AREAS

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

 

CHARACTERISTICS

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

Protection of pavements and road cover plates

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

APPLICATION AREAS

Roadway:

  • Lifting bridges
  • Bascule bridges
  • Movable bridges
     

 

Footpaths and bicycle tracks:

  • Pedestrian walkways
  • Stairways
  • Pedestrian and cycle bridges
     
CHARACTERISTICS
  • Corrosion protection for the steel plate
  • Weight reduction compared to mastic asphalt
  • High abrasion resistance on pavement and roadway
  • Slip resistance on pavements and cycle paths
     
Waterproofing system under mastic asphalt

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

SEALING WITH INNOVATIVE ADHESIVE LAYER

The melt adhesive granulate Sikalastic®-827 HT is scattered into the undercoating as an adhesive layer. When asphalting, the adhesive layer is subjected to temperatures of around 180 °C. As a result, the adhesive granulate melts and expands and a damping system with excellent adhesion to the mastic asphalt is created.

YOUR ADVANTAGES

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

AREAS OF APPLICATION - GERMANY ACC TO ZTV-ING

Korrosionsschutz, Verkehrsbau, Industrial Coatings

COATING SYSTEM

for trowel application

1. PRIMER (optional)
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. TOP COAT
SikaCor® Elastomastic TFN

(2-component, solvent-free, thick-layer epoxy-polyurethane hybrid liquid plastic)

FILLER/SPRINKLING AGENT
Quartz sand
(0.4 – 0.7 mm)

The diagram shows an example of a coating system.

COATING SYSTEM

for airless application

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER (optional)
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. TOP COAT
SikaCor® Elastomastic Airless

(2-component, solvent-free, thick-layer polyurethane liquid plastics can be applied using airless systems)

 

The diagram shows an example of a coating system. 

Korrosionsschutz, Verkehrsbau, Industrial Coatings

COATING MATERIAL

for friction surfaces

SUBSTRATE: Steel Sa 2 1/2

1. COATING MATERIAL
SikaCor® Zinc ZS

(1-component solvent-based ethyl silicate zinc dust primer (Zn-ESI))

 

 

The illustration shows an application example. 

 

Coating system for closed ropes made of galvanized steel

COATING SYSTEM

for closed ropes made of galvanized steel

SUBSTRATE: Sweep-blasted

1. PRIMER
Sika® Cable Primer Plus

(2-component, low-solvent primer containing zinc phosphate and based on epoxy resin)

2. INTERMEDIATE COATINGS
2 - 3x Sika® Cable Top-1
(2-component, low-solvent intermediate coating containing micaceous iron oxide and based on polyurethane, with high elasticity, impact resistance and wear resistance)

3. TOP COAT
Sika® Cable Top-2

(2-component, low-solvent elastic polyurethane top coat in DB and RAL shades)

  • ADDITIONAL PRODUCTS
    Sika® Cable Flex-1
    (2-component, solvent-free, elastic sealant based on polyurethane for joints and crevices)
  • Sika® Cable Flex-2
    (2-component, solvent-free, highly penetrating, low-viscosity polyurethane-based injection resin for filling cavities)

 


The diagram shows an example of a coating system. 

COATING SYSTEM

for blasted surfaces

SUBSTRATE: Steel Sa 2 1/2

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

2. TOP COATS
2x Sika Poxicolor®
(2-component, low-solvent, epoxy resin/plastic combination coating in RAL and DB shades)

3. OPTIONAL
In case of increased demands on colour stability, additionally use top coats according to sheet 87

 

The diagram shows an example of a coating system. 

COATING SYSTEM

for hot-dip galvanized surfaces

SUBSTRATE: hot-dip galvanized steel; sweep-blasted

1. TOP COATS
2x Sika Poxicolor®
(2-component, low-solvent, epoxy resin/plastic combination coating in RAL and DB shades)

2. OPTIONAL
In case of increased demands on hue speciality, additionally use top coats according to sheet 87

 

The diagram shows an example of a coating system.

HIGH QUALITY C5 HIGH COATING SYSTEM:

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® EG Phosphat Plus

(2-component, low solvent, epoxy resin-based coating material conatining zinc phosphate)

2. INTERMEDIATE COAT
SikaCor® EG-1 Plus

(2-component, low-solvent, epoxy resin-based coating material containing micaceous iron oxide)

3. TOP COAT
SikaCor® EG-4/ SikaCor® EG-5/ Sika® Permacor®-2330/ Sika® Permacor®-2230 VHS

(2-component, acrylic polyurethane coating material in DB or RAL shades)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

for partial and limited surface preparation

SUBSTRATE: Steel PSt 2/3

1. PRIMER
Sika Poxicolor® Primer HE NEU

(2-component, low-solvent, surface-tolerant epoxy resin-based primer)

2. INTERMEDIATE COAT
SikaCor® EG-1 VHS

(2-component, very low-solvent, epoxy resin-based intermediate coating containing micaceous iron oxide)

3. TOP COAT
SikaCor® EG-4/ SikaCor® EG-5/ Sika® Permacor®-2330/ Sika® Permacor®-2230 VHS 

(2-component, acrylic polyurethane coating material in DB or RAL shades)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

Primer and intermediate coat in the factory,
top coat on the building site

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® Zinc R

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

2. INTERMEDIATE COAT
SikaCor® EG-1

(2-component, low solvent, epoxy resin-based coating material containing micaceous iron oxide)

3. INTERMEDIATE COAT
SikaCor® ZP-1

(2-component, low solvent, polyurethane-based coating material containing micaceous iron oxide)

4. TOP COAT
SikaCor® EG-4/ SikaCor® EG-5/ Sika® Permacor®-2330/ Sika® Permacor®-2230 VHS

(2-component, acrylic polyurethane coating material in DB or RAL shades)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

Road surface sealing system

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. TOP COAT
SikaCor® Elastomastic TFN

(2-component, solvent-free, thick-layer epoxy-polyurethane hybrid liquid plastic)

FILLER/SPRINKLING AGENT
Durop
(2 - 3 mm, 1:1)

 

The diagram shows an example of a coating system. 

 

COATING SYSTEM

Sealing system for footpaths and bicycle tracks

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® HM Primer Plus

(2-component epoxy resin-based primer containing micaceous iron oxide)

 

2. TOP COAT
SikaCor® Elastomastic TFN

(2-component, solvent-free, thick-layer epoxy-polyurethane hybrid liquid plastic)

FILLER/SPRINKLING AGENT
Quartz sand (0.7 – 1.2 mm, 1:1)

3. SEALING (optional)
Sikafloor®-359 N

(2-component, yellowing-free, pigmented polyurethane sealing)

 

The diagram shows an example of a coating system. 

COATING SYSTEM

Steel bridge sealing by adhesive layer

SUBSTRATE: Steel Sa 2 1/2

1. PRIMER
SikaCor® HM Primer

(2-component epoxy resin-based primer containing micaceous iron oxide)

2. UNDERCOATING
SikaCor® HM Mastic

2-component, solvent-free epoxy resin coating)

3. ADHESIVE LAYER
Sikalastic®-827 HT

(Modified hot melt adhesive granules for scattering)

4. MASTIC ASPHALT

 

The diagram shows an example of a coating system. 

 

Corrosion protection for civil engineering structures

Infrastructure in Germany

FEDERAL HIGHWAY RESEARCH INSTITUTE (BAST)

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

www.bast.de
 

SUPPLEMENTARY RULES OF THE BAST

ZTV-ING

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

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

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

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

TL/TP-KOR STEEL STRUCTURES

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

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

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

RI-ERH-KOR

Guidelines for the maintenance of corrosion protection of steel structures

 

DBS 918084

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

 

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

TL-sheets according to TL/TP-KOR STEEL STRUCTURES

Infrastructure in Germany

Sheet 81 - Surfaces in soil or in contact with water

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

APPLICATION AREAS

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

CHARACTERISTICS

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

Sheet 86 - Friction connections

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

APPLICATION AREAS

- Single-layer corrosion protection for:

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

 

CHARACTERISTICS
  • 1-component system
  • Sliding surface class A according to EN 1090-2
  • Very good corrosion protection even under water and moisture loads
  • Fast drying, dries even at humidity < 50%
  • Can be versatilely reworked with 1-component and 2-component coating materials
     
Sheet 87 - Steel Structures

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

APPLICATION AREAS

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

 

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

CHARACTERISTICS

  • Very high corrosion protection for all atmospherically stressed surfaces
  • Long reworking intervals of intermediate and top coat
  • Top coat with high weather and light resistance
     
Sheet 89 - 1-pack moisture curing coating system

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

APPLICATION AREAS

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

 

CHARACTERISTICS

  • 1-component system
  • Very short overcoating intervals
  • Can be applied in difficult weather conditions
  • High durability > 25 years
     
Sheet 94 - High solid coatings and maintenance

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

APPLICATION AREAS

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

CHARACTERISTICS

  • Surface tolerant
  • Low-solvent coating system
  • Highly efficient due to few work steps (3-layer system)
     
Sheet 97 - Fast curing even at low temperatures

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

APPLICATION AREAS

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

 

Compatible with sheet 87

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

 

CHARACTERISTICS

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

ZTV-ING

Ballast trough according to DBS 918084

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

APPLICATION AREAS

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

CHARACTERISTICS

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

Cables and ropes according to ZTV-ING Part 4, chapter 5

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

APPLICATION AREAS

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

 

CHARACTERISTICS

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

Waterproofing system underneath mastic asphalt according to ZTV-ING Part 7, chapter 4

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

SEALING WITH INNOVATIVE ADHESIVE LAYER

The melt adhesive granulate Sikalastic®-827 HT is scattered into the undercoating as an adhesive layer. When asphalting, the adhesive layer is subjected to temperatures of around 180 °C. As a result, the adhesive granulate melts and expands and a damping system with excellent adhesion to the mastic asphalt is created.

YOUR ADVANTAGES

  • Few weather-dependent operations
  • Fast applications
  • Extremely strong layer bond
  • Excellent shear resistance
     
Pavements, bicycle tracks and roads according to ZTV-ING Part 7, chapter 5

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

APPLICATION AREAS

Roadway:

  • Lifting bridges
  • Bascule bridges
  • Movable bridges
     

 

Footpaths and bicycle tracks:

  • Pedestrian walkways
  • Stairways
  • Pedestrian and cycle bridges
     
CHARACTERISTICS
  • Corrosion protection for the steel plate
  • Weight reduction compared to mastic asphalt
  • High abrasion resistance on pavement and roadway
  • Slip resistance on pavements and cycle paths
     

Infrastructure in Austria

Coating systems according to RVS 15.05.11 and RVS 08.09.02

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

 

The FSV (Forschungsgesellschaft Straße - Schiene – Verkehr [Road - Rail – Transport Research Association])
THE FSV

The counterpart to the BASt

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

www.fsv.at
 

ESSENTIAL DIFFERENCES

In the coating system to ZTV-ING

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

COATING SYSTEM

Standard system for steel structures

SUBSTRATE: Steel Sa 2 1/2

1. PRIMING COAT
SikaCor® Zinc R

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

2. INTERMEDIATE COAT
SikaCor® EG-1 VHS NEW

(2-component, very high solid, epoxy resin-based coating material containing micaceous iron oxide)

3. TOP COAT
2x SikaCor® EG-4 VHS

(2-component, very high solid, polyurethane based coating material containing micaceous iron oxide)

OPTIONALLY AS A DESIGN COAT
SikaCor® EG-5

(2-component, acrylic polyurethane coating material in RAL shades)

 

The illustration shows an example of a coating system. 

  • Sika systems according to RVS
    -S1   Steel constructions
    -S4   Composite components, Concrete-contact surfaces
    -S9A, S9B   Ballast trough coatings
    -S9C   Pavements and cycling tracks, curb protection (thin coatings on steel)
    -S11   Repair, railing and lightweight constructions
    -S13   Bearings and road crossing constructions
    -S14   Steel constructions
    -S15, S16   Atmospheric steel constructions
  • Material-number overview - RVS-listings
  • Additionally - Sika systems according to ZTV-ING

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