Since March 2024: BAW approval according to Im1
Steel constructions of all kinds must be protected against corrosion in order to maintain static safety and fatigue strength.
The new and innovative powder coating system ENVfunctional Powder of ENVIRAL® Oberflächenveredelung GmbH is based on an intelligent and highly effective corrosion protection (SmartCorr®) as well as an excellent antifouling protection against the permanent formation of microorganisms and the adhesion of e.g. mussels.
> Powder Coating for Hydraulic Steel Construction (Download Flyer)
Scientific support incorporating testing institutes as part of the transformation into practice:
The SmartCorr® product developed by ENVIRAL® Oberflächenveredelung GmbH is based on the basic research of the Max Planck Institute of Colloids and Interfaces in the field of nanotechnology. It is patented and exclusively licensed to ENVIRAL® by Max Planck Innovation GmbH.
On this basis, Prof. Dr.-Ing. Bernd Bachert is working on the further development of an innovative and sustainable powder coating system for hydraulic steel construction as part of an R&D project in cooperation with ENVIRAL®. In March 2024, the BAW (Federal Institute for Hydraulic Engeineering), a higher federal authority subordinate to the Ministry of Transport, has approval according to Im1, following tests in its own testing laboratory, confirming suitability for use in freshwater and in the area of the federal waterways (WSV). The Institute for Antifouling and Biocorrosion Dr. Brill an Partner is also integrated.
How was the application under high mechanical load tested?
“The coating system was tested in the BAW laboratory in accordance with the guidelines for testing coating systems for corrosion protection in hydraulic steel construction and is suitable for use under heavy mechanical loads. We are very pleased having achieved the certificate of approval of the BAW", states Prof. Dr.-Ing. Bernd Bachert, who is highly satisfied with the results.
In addition, a fatigue test simulating 35 years of fatigue strength stress was successfully completed in the laboratory at Iproconsult. The colour samples were tested for their insulating property before and after the test by “poro_scan porosity decetion”.
Under what extreme conditions was the corrosion protection tested?
"The innovative SmartCorr® corrosion protection has already been successful proven in real life in recent years. We are all the more pleased to be able to use and further develop the high requirements as a basis for hydraulic steel construction," says Ing. Rainer Rogovits, Managing Director of ENVIRAL®.
After more than four years of exposure in an extremely corrosive environment, the SmartCorr® coating shows excellent behaviour under real-life conditions.
o Picture in the middle: Corrosion attack is minimal even on artificially created damage.
o Picture on the right: Classically coated comparison samples tend to be close to failure.
How we take responsibility for the environment?
The new powder coating system is free from bisphenols, VOC's (volatile organic compounds) and halogens. It does not contain PVC, phthalates or other plasticizers; solvent-free.
2003 + 2014
ENVIRAL® DE:
DIN EN ISO 9001 + 14001 Certification
2021
ENVIRAL® AT und DE:
GSB Master certifications for aluminium, steel and galvanized steel
2023
Successful antifouling tests according to ASTM D 3623-78a (2020) and ASTM 6990-20
2024
BAW approval according to Im1
suitable for use in fresh water and in the area of federal waterways (Federal Institute for Hydraulic Engineering)
2024
Project Beacon Wustrow: red and white striped tubular mast with 8 m height and 50 cm diameter
2025
Project Weir Eisenhammer: Two sill weirs with about 4.6 m x 1.4 m each; together with steel construction for gearbox support
2026
Project BAS.I.S:
ENVfunctional POWDER robust; Further development for durability against high abrasion