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

info@mc-bauchemie.de

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

michal.lehky@mc-bauchemie.sk

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

michal.lehky@mc-bauchemie.sk

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

peter.schmidt@mc-bauchemie.de thomas.schneider@mc-bauchemie.de

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

mihail.todorov@mc-bauchemie.bg rafael.sass@mc-bauchemie.de

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

mihail.todorov@mc-bauchemie.bg rafael.sass@mc-bauchemie.de

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.

martin.vanlent@mc-bouchemie.com MariaLuisa.Perez@mc-bauchemie.de

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

eugen.kleen@mc-bauchemie.de

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.

nir@azmarketing.co.il wolfgang.litz@mc-bauchemie.de

eugen.kleen@mc-bauchemie.de

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

tim.hillringhaus@mc-bauchemie.de

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.

tim.hillringhaus@mc-bauchemie.de

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 %.

rafael.sass@mc-bauchemie.de

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

hubert.schiffbaenker@mc-bauchemie.at

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. bjoern.kracht@mc-bauchemie.de

Before and after comparison: Nafufill SF served to make the ceilings and walls extra smooth.

MC Personalia

15MC aktiv 3_2015 |

MC Personalia

15

hubert.schiffbaenker@mc-bauchemie.at

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.

IN@mc-bauchemie.de

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!