Steel Towers - an Economic and Proven Overall Solution
Owners,engineers and contractors need a range of products for fast, efficient and durable erection of steel, concrete or hybrid towers.
Most large wind turbines are equipped with tubular steel towers which must be able to perform in some of the harshest working environments in the world over long periods of time. Due to their exposed locations they are subjected to a multitude of stresses.
Sika has therefore formulated corrosion protection coating systems for steel tower sections, which cover the full range of defined corrosive categories that protect both the interior and exterior of onshore steel towers.
Steel Towers - an economic and proven overall solution
Most large wind turbines are equipped with tubular steel towers which must be able to perform in some of the harshest working environments in the world over long periods of time. Due to their exposed locations they are subjected to a multitude of stresses. For example, they often operate in marine – or industrial environments experiencing extreme variations in temperature, strong UV-radiation or high humidity. Therefore, Sika has formulated corrosion protection coating systems for steel tower sections, which cover the full range of defined corrosive categories that protect both the interior and exterior of onshore steel towers.
SikaCor® and Sika® Permacor® high quality corrosion protection systems for interior and exterior surfaces of steel towers are based on high-strength, modern binder resins which enable very low solvent content formulations.
Due to the steel tower’s size and complexity, it is always delivered as elements and assembled onsite. As such, joints between the elements are weatherproofed once assembled. Due to the stresses experienced by our
towers including UV exposure, extreme weather conditions, and natural tower movement, the best performing sealing products have to be used. SikaHyflex® silicone weather sealants have a great reputation on glass and metal facades of high rise construction buildings worldwide, providing reliability and durability regardless of the environments they are exposed to. They have been designed to be applied easily due to
access challenges. Our SikaHyflex® product range comprises products for generic or dedicated applications.
SikaGrout® and Sikadur® series are cementitious and epoxy based engineering grouts, designed to completely fill voids and transfer load from the tower to the foundation. SikaGrout® series is specially formulated to fill vertical and horizontal joints.
Engineering grouts are designed to completely fill voids and transfer load.
Sika grouting technologies are ideal for:
- Filling of vertical and horizontal joints and small holes
- Levelling of interacting concrete surfaces
- Protecting post-tensioned wires from corrosion
One of the essential requirements for high performance grouts is the consistent production and workability of the grout under difficult conditions, onshore and offshore. Our grouts meet all of these demanding requirements.They have been developed and extensively tested to withstand all types of weathering and climatic conditions.
Steel tower coatings inside and outside
Primers with active pigments and thick-layer intermediate coatings ensure long-lasting corrosion protection, the top coats based on polyurethane technology meet the highest requirements for weather resistance and colour stability. In several decades of service, our corrosion protection systems have protected over 10,000 wind turbines.
Interior surface of tower
The minimum requirement for the coating system is mostly C4 high according to EN ISO 12944-2 for interior surfaces of steel towers and machine parts.
- Primer (EP): SikaCor-2440 MF or SikaCor Zinc R Rapid
- Top Coat (PUR): SikaCor EG-5
Exterior surface of tower
The minimum requirement for the coating system is mostly C5-M high according to EN ISO 12944-2 for steel tower exterior surfaces.
- Primer (zinc-rich): SikaCor Zinc R Rapid
- Intermediate Coat (EP): SikaCor-2440 MF
- Top Coat (PUR): SikaCor EG-5
Where is your construction most vulnerable to water ingress? At the joints!
The assembly of structures from building blocks such as concrete or steel elements requires the joints to be sealed to ensure water and air tightness. Joint sealants compensate and bridge the individual movement of the elements due to temperature changes, moisture, sound, wind and vibrations. Sikaflex® and SikaHyflex® stand for best-in-class and high quality envelope sealants. To achieve best performance for your application our assortment comprises of all major sealant technologies. Advanced polyurethane sealants for porous substrates and innovative silicones for non-porous substrates, or where a high adhesion is required, our unique silane-modified polymer range.
Elastic joint sealing
Engineering structures consist of individual elements which exhibit relative movements to each other. There are different kinds of such movements: Thermal movement originating from the thermal expansion, mechanical movements originating from stress on the structure like wind load or vibrations and structural movements as a consequence of permanent deformation of the structure. Movement within the joints is a reality and the long-term solution to compensate for movement is high-performance elastic joint sealants. These sealants retain their original functionality and good adhesion to the substrate throughout their whole life cycle.
Elastic sealants for movement joints
For porous substrates
- SikaHyflex®-250 Facade: Our low modulus PU sealant with the highest movement classification
- SikaHyflex®-160 Construction: Our high modulus PU sealant with good movement classification
For non-porous substrates
SikaHyflex®-905: This product has the highest movement classification. All our silicone range is low modulus
SikaHyflex®-605 or -305: Widely applied in the glass and metal facades all over the world this product convinces with unique application properties and good performance
SikaHyflex®-105: It can be used as weather sealant but is also often applied for generic applications
Sikaflex® PRO-3 and PRO-3 SL are ideal products for floor joints. Due to their mechanical properties (tough and elastic) they are highly recommend and the first choice for many.
Horizontal joints between tower and foundation
Cement and epoxy based grouting products are suitable for the wind towers thanks to their excellent load transfer capacity and extreme flowability. Sika Grout® –3000 series and Sikadur® range are specially designed to meet the most demanding requirements.
Horizontal joints between precast elments
Cement based grouting products are suitable for the wind towers thanks to their excellent fatigue resistance behavior and their excellent flowability. Sika Grout® –3000 series are especially designed to meet all demanding requirements. For adhering two concrete precast elements, check our structural bonding section.
Offshore Grouting
In offshore structures, the materials used are submitted to extreme conditions, typically carrying a high maintenance cost. Therefore, all the materials used, including the grouts used in connections, have to be high performing and durable.
SikaGrout® -3500 WP meets these demanding requirements for all types of foundations.
SikaGrout® -3500 WP has the following advantages:
- Outstanding flow properties
- Extremely long workability to avoid blockages in the pumping lines
- Annular gaps can be fully filled, free from voids, even under water
- Self compacting behavior
- Good consistence stability without sedimentation