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ReferencesPower Generation Industry


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Long-term protection of reinforced concrete structures

in power plants poses the highest demands on rehabilitation

and coating systems. Reliability of the structures long-term pro-

tection is a vital factor that ensures operational reliability of the

entire power plant.

Ongoing dialogue with planners and power plant opera-

tors and MCs own research and development has made the

company a reliable partner of the energy industry for more than

40 years when it comes to the protection of their concrete struc-

tures. Worldwide MC employees are developing project-specic

solutions, be it for the new construction or repair of cooling

towers, chimneys and reactor buildings.

In addition to the vastly differing demands from a struc-

tural point of view for each and every one of these structures,

impact from weather conditions which have to be assesseddifferently depending on the respective climate zone, demand

bespoke system solutions that are tailored to the respective

overall conditions of the project.

Complementary to the technical demands of such reha-

bilitation and surface protection systems, the aesthetic nish

of the power plants has become another important aspect.

Here, highly UV-resistant coating systems from MC make it pos-

sible to achieve complex colour designs.

This brochure gives you an overview of international

examples for the use of our system solutions for a diverse range

of power plant structures.

Investments of such signicance demand solutions that last!

Anja SpirresHead of Division Holger SchwarzeProtection Technologies


4/754

Product: Zentricryl RBSYear: 2007

Projectinformation: Already in 1993 until 1994 one of

the cooling towers at the nuclear

power plant Doel was repaired

on the inside and outside surfaces

with the tried-and-tested surface

protection system. Based on years

of good experiences with the com-

pany, MC-Bauchemie was again

called upon in 2006 when the

reactor building 1 needed to be

sealed. The particular challenge

in this case was finding a system

design with which the negative

pressure required for operations

could be achieved in the shortest

possible time and which could

maintain this pressure with the

available aggregates. In this

instance the system Zentricryl RBS

was applied.

Good cooperation resulted in

further building elements being

repaired, such as the cooling towersupports, for which Nafufill KM 250

was used.

BELGIUM, DOEL

Nuclear Power PlantDoel


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BELGIUM, RUIEN

Coal-fired Power PlantRuienProduct: Nafufill KM 250,

EmceColor-flex

Year: 2008

Projectinformation: In 2008 the Nafufill KM 250 system

was successfully used to repair

damage to the chimneys.

The surface protection used in

this instance was EmceColor-flex.

Systems from MC-Bauchemie were

used in repairs of cooling towers

here as early as the 1990s.


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Product: Nafufill KM 250,Zentricryl RBS

Year: 2008

Projectinformation: Crack-bridging surface protection

was required to repair the dam-

aged exterior shells of this power

plants cooling towers. Following

the concrete repair works with

Nafufill KM 250 the surface protec-

tion system Zentricryl RBS with its

high crack-bridging properties was

therefore used in this case.

BELGIUM, VILVOORDE

Cogeneration PlantVilvoorde


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Product: Zentrifix F 82 XX,MC-DUR 1277 WV,

MC-DUR VS NR3,

MC-Schutzberzug 702

Year: 2008 / 2009

Projectinformation: In the construction of the new

cooling tower great emphasis

was placed on the surface protec-

tion of the concrete both inside

and outside right from the start.

Based on the analysis of the

expected operational loads an

important aspect here was the

feeding of flue gasses into the

cooling tower for the inside the

MC-DUR VS NR3 surface protec-

tion system was chosen, while

MC-Schutzberzug 702 protected

the outside shell.

BULGARIA, GALABOVO

Coal-fired Power PlantAES-3C Maritsa East 1


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Product: MC-DUR 1800 TX,MC-DUR 1200 VK,

Zentrifix EC 6,

MC-DUR VS-PUR,

MC-DUR 1277 WV,

EmceColor-flex,

MC-702 SX

Year: 1992-1996 / 2007

Projectinformation: After two cooling towers were

successfully repaired on the inside

and outside using systems from

MC during 1992 to 1996, in 2007

it was the chimney that was refur-

bished with systems from MC.

CZECH REPUBLIC, CHVALETICE

Power Plant Chvaletice


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Product: MC-Schutzberzug 702 SX,EmceColor-flex,

MC-DUR 1277 WV,

MC-DUR VS NR3,

MC-DUR VS-PUR

Year: 2002-2003

Projectinformation: During 2002 and 2003 a new chim-

ney was built. In its construction

MC after-treatment and long-term

protection systems were applied.

For more than a decade the cooling

towers of this plant have been main-tained and repaired with products

from MC, both inside and outside.

CZECH REPUBLIC, DETMAROVICE

Hard-Coal-fired Power PlantDetmarovice


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Product: MC-DUR 1277 WV,MC-DUR VS NR3,

MC-Schutzberzug 702 SX,

EmceColor-flex

Year: 1997-1999 / 2005

Projectinformation: After all four cooling towers were

successfully protected inside and

two of them outside using MC pro-

ducts during 1997 to 1999, the same

systems were again used in 2005

for the surface protection of the

exterior shell of the two remaining

cooling towers.

CZECH REPUBLIC, TEMELIN

Nuclear Power PlantTemelin


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MC-DUR VS NR3

Year: 2009

Projectinformation: For the cooling tower with flue

gas inlet for the new block of

this power plant near Beijing the

planner specified systems from

MC-Bauchemie based on previous

good cooperation with the com-

pany. The exterior surface protec-

tion was also carried out with MC

products.

PR CHINA, TIANJIN

Coal-fired Power PlantJulian Cheng


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Product: Zentrifix F 82 XX,MC-DUR VS NR3,

MC-RIM F

Year: 2009

Projectinformation: For the two cooling towers of the

new power plant powered with

seawater the client stressed his

desire for lasting functionality of

the surface protection as the long

service life of the plant is para-

mount. Based on MC-Bauchemies

experience with similar projects

(Power Plant Rostock, SAFCO 4,

Shuaiba 2 and SHARQ3) planners

and principal opted for MC. This

also applies to the concrete protec-

tion for the outer shell. Another

reason for the successful coopera-

tion between everyone involved

was the regular support by MC

staff onsite.

PR CHINA, HANGU

Coal-fired Power PlantBeijiang


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MC-DUR VS NR3,

MC-Schutzberzug 702

Year: 2006

Projectinformation: One of the largest cooling technol-

ogy service providers in Germany

recommended systems from MC

for this project. After intensive

consultations and the drafting of

an individual concept MC was

awarded the contract to supply

the surface protection systems

for the inside and the outside of

the towers.

The client was not only impressed

by MCs application technology but

also by excellent onsite support.

PR CHINA, BEIJING

Coal-fired Power PlantHuaneng


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Product: Zentricryl RBS,EmceColor-flex S

MC-DUR 1277 WV

Year: 2003

Projectinformation: During the hot summer of 2003 the

repair of the hybrid cooling tower

posed a particular challenge. The

proven system MC-DUR 1277 WV

was used on the inside. Since high

loading by vibration caused by

ventilators is to be expected in this

cooling tower the highly crack-

bridging system Zentricryl RBS

was selected for the outside sur-

face protection. And due to the

great heat during that summer the

intended mineral levelling mortar

was not used, instead the applica-

tors were able to fall back on the

acrylate system Zentrifix CR finish,

which does not require any after-

treatment.

GERMANY, ALTBACH

Hard-Coal-fired Power PlantAltbach


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GERMANY, BERGKAMEN

Coal-fired Power PlantBergkamenProduct: MC-DUR VS-EW,

MC-DUR 2103 M,

MC-FLEX 2098

Year: 2005

Projectinformation: The cooling tower had been

successfully restored inside and

outside with MC products in the

1990s, but also needed to be

toughened up at the chimneys

opening in 2005.

Of particular importance in this

case was to apply a crack-bridging

surface protection system at the

mouth of the chimney to comple-

ment extensive concrete repair

measures.


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GERMANY, BEXBACH

Coal-fired Power PlantBexbachProduct: Zentricryl RBS,

EmceColor-flex S

Year: 2004

Projectinformation: For the outer shell repair works

of this cooling tower particular

emphasis was put on the high

crack-bridging properties of the

surface protection system. For this

reason a combination of Zentricryl

RBS/EmceColor-flex S was used.


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GERMANY, BIBLIS

Nuclear Power PlantBiblisProduct: Nafufill KM 124,

Zentrifix F 92,

EmceColor-flex

Year: 1995

Projectinformation: For the outer repair of the cooling

towers a crack-bridging system

was required that was also used at

the reactor domes. Further building

components such as the cooling

tower basin, the office buildings

and the concrete fence were subse-

quently repaired with systems from

MC as well.


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GERMANY, BOXBERG

Coal-fired Power PlantBoxbergProduct: Zentrifix F 82 XX,

MC-DUR 1277 WV,

MC-DUR VS NR3

Year: 1998

Projectinformation: After several older cooling towers

had already successfully been

repaired with systems from MC,

it naturally followed that in the

construction of the new cooling

tower Q at the Boxberg power

plant, a surface protection was

preventatively applied inside using

the tried-and-tested systems from

MC because of the flue gas inlet.


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GERMANY, BRAUNSCHWEIG

Cogeneration PlantBraunschweigProduct: Nafufill KM 250,

MC-DUR 1200 VK,

MC-DUR VS EW,

MC-DUR 2103 M,

MC-FLEX 2099

Year: 2006

Projectinformation: After many years of operation the

top end including the so called

"down wash area" was partially

damaged and had to be repaired

and protected for coming decades

of maintenance free operation.

As this building is a landmark for

its surrounding the colouration of

the top coating was required in

best possible quality. In addition

the top coat MC-DUR 2103 M fulfils

moderate crack bridging for near

surface cracks.


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GERMANY, CHEMNITZ

Hard-Coal Power PlantChemnitzProduct: Nafufill GTS-HS,

Zentricryl RBS,

EmceColor-flex,

MC-DUR 1277 WV,

MC-DUR VS NR3

Year: 2008

Projectinformation: Preliminary tests found high sul-

phate content in the concrete of

the cooler to be repaired, which

prompted the use of Nafufill

GTS-HS as concrete replacement

system. Because of the risk of

crack formation Zentricryl RBS

and EnceColor-flex were used on

the outside. Inside the traditional

structure with MC-DUR 1277 WV

and MC-DUR VS NR3 was used.


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GERMANY, ESSEN

Waste-to-Energy PlantEssen-KarnapProduct: Zentrifix F 82 XX,

MC-DUR VS,

MC-DUR VS-PUR,

Betonflair

Year: 1990

Projectinformation: This chimney, a landmark for the

Ruhr region, was protected with

systems from MC-Bauchemie when

it was newly built.


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Product: Nafufill GTS,Zentricryl GS 2000,

EmceColor-flex

Year: 2005

Projectinformation: In the case of this chimney it was

especially important to ensure an

economical and reliable application

of the products. By way of consist-

ently using a levelling mortar on

acrylate basis that did not require

any after-treatment the works could

be completed within the scheduled

timeframe. In the following year a

further cooling tower was success-

fully repaired on the outside based

on the same system.

GERMANY, GELSENKIRCHEN

Coal-fired Power PlantGelsenkirchen-Scholven


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GERMANY, GRAFENRHEINFELD

Nuclear Power PlantGrafenrheinfeldProduct: Zentricryl RBS,

EmceColor-flex

Year: 1999 / 2000

Projectinformation: Following extensive tests and

sample productions during the

planning stage in 1998 the reactor

dome was repaired successfully.

At a later date the cooling tower

basin was also sealed.


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GERMANY, HEILBRONN

Cogeneration PlantHeilbronnProduct: Nafufill KM 250,

Betonflair Uniprimer,

EmceColor-flex

Year: 2009

ProjectInformation: The tried-and-tested, crack-bridging

and vapour-diffusion open system

EmceColor-flex was used for the

surface protection of the exterior of

this cooling tower.

Due to the condition of the sub-

strate and based on its good work-

ability Betonflair Uniprimer was

applied first.


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MC-DUR VS NR3,

MC-Schutzberzug 702

Year: 1996 / 1997

Projectinformation: The chimney was repaired using

proven systems after having been

inspected thoroughly. Particularly

challenging was here the existing

epoxy resin paint at the opening,

which could not be removed

completely. The application was

adapted jointly with owner,

planer and applicator to suit the

local conditions.

GERMANY, IBBENBREN

Hard-Coal-fired PowerPlant Ibbenbren


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GERMANY, LIPPENDORF

Lignite-fired Power PlantLippendorfProduct: Zentrifix F82 XX,

MC-DUR 1277 WV,

MC-DUR VS NR3

Year: 2001

Projectinformation: Preventative surface protection

for both cooling towers had been

applied before they were put into

operation. The interior of the shells

had been protected against opera-

tional load impact, in this case a

mixture of cooling tower plume

and flue gas condensation. The

shell exterior was protected against

the impacts from the atmosphere.

Each side of the tower shell has a

surface of approximately 45,000 m.

After 7 years of more or less unin-

terrupted operation the coating

system on the inside of one of the

two cooling towers was inspected

by an expert. The inspection report

certified that under continuous

operation the service life of the

surface protection is expected to

be at least 20 years.


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Product: Zentricryl RBS,EmceColor-flex

Year: 2004 / 2008-2009

Projectinformation: After the cooling tower had been

successfully repaired with the use

of MC systems, the restoration of

the reactor building 2 was realised

in 2008 and 2009.

GERMANY, NECKARWESTHEIM

Nuclear Power PlantNeckarwestheim


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GERMANY, NEURATH

Lignite-fired Power PlantNeurathProduct: Nafufill GTS,

Zentrifix F 82 XX,

MC-DUR VS NR3,

MC-DUR 2203

Year: 2007-2009

Projectinformation: During 2007 to 2009 several cool-

ing towers with flue gas inlets

were again toughened up using

new and more effective concepts.

In this instance, besides the con-

crete repair particular emphasis

was placed on a functioning

interior shell surface protection

system with sealed off pores,

which would protect the interior

effectively until the end of its life-

span. Of particular importance was

UV protection above the waistline.


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Product: Nafufill GTS,Zentrifix F 82 XX,

MC-DUR VS NR3,

MC-DUR 2203

Year: 2007-2009

Projectinformation: Based on the technical prepara-

tions and experiences in the power

plants Weisweiler and Neurath

newer, more efficient toughening

concepts were developed for the

repair of the interior shell. After the

cooling towers of this power plant

had during the 1990s already been

protected against the aggressive

impact of the flue gases fed in, MC

systems were again applied in this

repair measure.

GERMANY, NIEDERAUSSEM

Lignite-fired Power PlantNiederauem


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GERMANY, ROSTOCK

Hard-Coal-fired Power PlantRostockProduct: Zentrifix F 82 XX,

MC-DUR VS NR3,

MC-Schutzberzug 702

Year: 1992

Projectinformation: This power plant was the first

new-built power plant in the new

federal states after reunification.

It is also the first power plant in

Germany where the cooling tower

is operated by sea-water (other

power plants with this technology

started operations in Saudi Arabia

and in Kuwait between 2002 and

2008). Another important consider-

ation is the fact that the operation

uses flue gas inlets here as well.

Due to the heavy load impact that

this entails surface protection with

systems from MC-Bauchemie

became necessary.


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GERMANY, SPREMBERG

Lignite-fired Power PlantSchwarze PumpeProduct: Zentrifix F 82 XX,

MC-DUR VS NR3,

MC-Schutzberzug 702

Year: 1994-1995

Projectinformation: In the new construction of blocks

A and B of the brown-coal-fired

power plant Schwarze Pumpe

effective concrete protection for

the interior shell was included in

the planning right from the start

because of flue gas inlets; this was

performed using the MC systems

MC-Schutzberzug 702 (outside)

and MC-DUR VS NR3 (inside).

An overhaul of the interior surfaces

above the waistline was carried out

in 2009 for one of the towers, the

second cooling tower is planned

to also receive a cover coat with

UV-resistant polyurethane in 2010.


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Product: Nafufill GTS,Zentrifix F 82 XX,

MC-DUR VS NR3,

MC-DUR 2203

Year: 2007-2009

Projectinformation: Because of intensive operational

loading of the cooling towers with

flue gas inlets damages occurred

despite several surface protection

measures having been carried out

during the 80s and 90s. A com-

pletely new concept of repair and

surface protection including partial

static strengthening was therefore

developed by a team of experts,

with instrumental support from

MC-Bauchemie. As a result all

cooling towers of the power plant

(amongst them block G) are being

toughened with systems from MC.

GERMANY, WEISWEILER

Lignite-fired Power PlantWeisweiler


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Product: MC-DUR 1277 WV,MC-FLEX 2099,

MC-DUR VS NR3,

MC Schutzberzug 702

Year: 2008-2009

Projectinformation: After several cooling towers and

chimneys of the existing power

plant were already repaired suc-

cessfully with MC products during

the 1990s, MC products were again

used in the new construction of

another cooling tower.

Additionally, special colours were

required for the design of the exte-

rior shell.

POLAND, BELCHATOW

Lignite-fired Power PlantBelchatow


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POLAND, KATOWICE

Power Plant Laziska

Product: Zentrifix KMH,Nafufill KM 250,

MC-DUR 1277 WV,

MC-DUR VS NR3,

MC-DUR VS-PUR

Year: 2008

Projectinformation: For this cooling tower it was par-

ticularly important to repair the shor-

ing in the water distribution level

and the cooling tower basin. First of

all the concrete was repaired using

the tried-and-tested Nafufill KM 250

system, followed by the surface

protection system MC-DUR VS NR3

combined with MC-DUR VS-PUR.

Both chimneys were also repaired

in this power plant, for which MCs

surface protection systems matched

to the respective load scenarios

were used.


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Product: Zentrifix KMH,Zentrifix GM2,

MC-DUR 1277 WV,

MC-DUR VS

MC-Schutzberzug 702 SX,

Betonflair W

Year: 1998

Projectinformation: In this plant the cooling tower was

successfully repaired with MC

products on the inside and outside.

Whats worth mentioning here is

that the colour design for the outer

surface was done by the children

from the primary school in Opole.

POLAND, OPOLE

Power Plant Opole


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Product: Nafufill KM 250,Betonflair Uniprimer,

EmceColor-flex,

MC-DUR 1277 WV,

MC-DUR VS NR3,

MC-CFK Sheets

Year: 2007-2009

Projectinformation: Following extensive inspections

that identified a rather thin con-

crete cover it was decided to repair

one cooling tower of this power

plant with the PCC mortar Nafufill

KM 250, which is statically creditable.

Surface protection was then applied

with the EmceColor-flex system.

The inside surface was also repaired

and was protected with the proven

system MC-DUR VS NR3. Of great

importance in this case was the

static strengthening of the cooling

towers with MC-CFK sheets.

Another special feature was the col-

our design, luminous rings painted

with RAL 3000.

ROMANIA, IERNUT

Power Plant Iernut


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Product: MC-Schutzberzug 702,MC-DUR VS,

MC-DUR VS-PUR

Year: 2007

Projectinformation: In this project during new con-

struction the proven products

from MC-Bauchemie were also

being used. The deciding factor

here was the possibility of concrete

after-treatment in slip form con-

struction with integrated long-term

protection.

RUSSIA, RYAZAN

Power Plant Ryazan


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Product: MC-Schutzberzug 702Year: 2008

Projectinformation: Recoating of the smoke band to

provide protection from chemical

attack and to create an aesthetically

pleasing finish. MC-Schutzberzug

702 was selected as this product

provides very short drying times

between coats a requirement

in order to minimise moving the

access platforms.

UNITED KINGDOM, FAWLEY

Petrochemical ManufacturingPlant ExxonMobil


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