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Construction machines

Whether it is cranes, forklifts and conveying vehicles, road buildings or mining machines: construction machines and tools used in the construction area are exposed to constantly changing environmental conditions and need to withstand often extreme chemical and mechanical stresses. The requirements for the optimal coating system for the parts and components are correspondingly high. A high-performance corrosion protection solution ensures enduring functionality and helps preserve the optical appearance of the valuable capital goods.

Your contact
Tobias Schmitz
Tel: +49 2330 9134056
Contact
Your contact
Tobias Schmitz
Tel: +49 2330 9134056
Contact

Application segments

Making high-tensile steel resistant

Cranes contain numerous fastening elements and construction parts, which are subjected to constant climatic and therefore highly-corrosive influences. Effective corrosion protection prevents the formation of red rust on valuable crane components. In addition, a coating system can help to prevent sudden material failure in the often high-tensile materials used as a consequence of hydrogen-induced stress corrosion cracking, thus ensuring the ongoing operational readiness of the crane.

Requirements

  • Corrosion resistance C5 (e.g. ISO 12944)
  • Resistance to stone chip
  • Resistance to chemicals
  • Colouring
  • Coefficients of friction

Solutions

With its zinc flake technology Dörken MKS offers a high-performance, chromium(VI)-free corrosion protection system that extends the lifetime of the steel parts installed in the crane and helps preserve value. With comparatively extremely thin coats comprising base coat and top coat a long-lasting cathodic corrosion protection can be provided. The low annealing temperature means that deformation of thin-walled components does not occur during application. This saves the need for often expensive post-processing. A further advantage: no hydrogen is involved in the coating process. Particularly with regard to high-tensile steels of up to > 1,000 N/mm² this means that hydrogen embrittlement is prevented and the long-term function of the coated components is ensured.

Example components

Fasteners

The typically high-tensile steel fasteners used in cranes are fitted in a range of different designs and geometries. The coating must have high corrosion protection of 480–1440 hours (salt spray test) and good coefficients of friction.

Steel components on the assembly platform

The steel components mounted on the assembly platform need to be coated with a highly-effective corrosion protection system (1440 hours as per salt spray test). It is also important that the components do not deform in the application process – zinc flake technology is a good option here due to the low annealing temperatures.

Steps

Steps are used to access the crane operator’s cabin and are a safety-relevant component that requires coating with long-lasting corrosion protection (1440 hours as per salt spray test). Here too, the avoidance of material deformation in the annealing process is significant.

Retaining functionality, extending life time

Forklift and conveying vehicles contain countless fasteners and construction parts, which require effective protection against corrosion, depending on area of application. Whilst vehicles used for intra logistics require low corrosion protection performance, vehicles intended for outdoor use require considerably higher protection. In hygiene-related areas the selected surface coating must also display characteristics such as chemical resistance due to the continuous cleaning processes. Lastly, the choice of component coating also needs to take account of criteria such as mechanical resistance, the long-term preservation of appearance and options for adding colour.

Requirements

  • Strict requirements to corrosion resistance (1440 h as per DIN EN ISO 9227)
  • Resistance to stone chip
  • Colouring
  • Coefficients of friction

Solutions

One alternative to galvanisation or the use of KTL coatings or powder coatings for steel components is chromium(VI)-free zinc flake technology. This consists of a zinc flake base coat and an organic or inorganic top coat tailored to the application. Very thin coats (from 8 µm) enable cathodic corrosion resistance to be established and premature, rust-related loss of components prevented. During the application no hydrogen is involved – with the result that no hydrogen embrittlement occurs. The enduringly high chemical resistance of the high-performance systems means that they are also suitable replacements for the use of stainless steel solutions – in particular for components that are exposed to cleaning agents. Choice of colour is also possible via the selection of the top coat.

Example components

Fasteners

In addition to long-term corrosion protection (480-1440 hours as per salt spray test ) ease of assembly is also important for fasteners used in forklift and conveying vehicles. Zinc flake coatings guarantee excellent fastening properties with individually adjustable coefficients of friction.

Springs

Springs are fitted in many different sizes and types and comprise mainly high-tensile steel – making the avoidance of hydrogen brittling enormously important in the application of the coating solution. Moreover, in addition to the high requirements of corrosion protection, a high degree of resistance to chemical cleaning agents must also be provided.

Guard plates/undercarriage

Guard plates and components in the vehicle undercarriage must withstand constant stresses such as stone impact, splashing or chemical cleaning agents and therefore require a long-term, high-performance corrosion protection. Chromium(VI)-free zinc flake technology offers all options here – both economic and ecological.

Ensuring functional ability over many years

Fasteners, stud bolts, hydraulic elements: road construction machines contain numerous construction parts that are required to withstand daily weather influences and sometimes continuous stresses such as stone impact. In order to protect the components against red rust, secure long-lasting appearance and functionality and preserve the value of expensive capital goods over a long period of time a high-performance corrosion protection of the parts is required. In addition to the corrosion protection effect, resistance to cleaning agents and – especially for fasteners – coefficients of friction play a significant role in coating.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Resistance to stone chip
  • Resistance to chemicals
  • Colouring
  • Coefficients of friction

Solutions

A long-lasting, high-performance solution for the coating of construction components for road construction machines is provided in the form of the zinc flake technology developed by Dörken MKS. The chromium(VI)-free system consists of a base coat and a top coat and is applied in very thin coats from 8 µm at extremely low annealing temperatures. The process occurs without hydrogen embrittlement, with the result that no hydrogen-induced stress corrosion cracking can occur in high-tensile steel components. This extends the lifetime of the machine and retains long-term value. In addition, the zinc flake systems also display high resistance to stone impact. The formation of red rust is also successfully prevented for a long period in the event of damage.

Example components

Fasteners

As an alternative to stainless steel, fasteners can be manufactured from steel and coated with a chromium(VI)-free zinc flake coating. This ensures high corrosion protection and excellent fastening properties (coefficient of friction) as well as avoiding the risk of hydrogen embrittlement during application.

Stud bolts

Stud bolts are used in special vehicles primarily to secure large and heavy components. In addition to long-term corrosion protection the coating must ensure key functional properties such as high trueness of fastenings to facilitate assembly.

Hydraulic components

The components fitted in hydraulic machines require corrosion protection that is effective against corrosive influences. Galvanic surface coatings from Dörken are well-suited to this. These are free from chromium(VI), cobalt and nickel and ensure high-performance corrosion protection (720 hours as per salt spray test). In addition, they also ensure the ongoing resistance of the components to recurring cleaning intervals.

Highly-effective corrosion protection required

Mining machines are often in use around the clock and need to function reliably for many years under the most demanding conditions. To protect the construction components and parts against stone impact and contact with acid and alkaline media a high-performance corrosion protection of up to 1440 hours as per salt spray test (pursuant to ISO 9227) is required. The coating makes a decisive contribution to securing the functionality of highly stressed components in the long term and subsequently preventing expensive breakdowns of machinery due to corrosion damage.

Requirements

  • Strict requirements to corrosion resistance (1440 h as per DIN EN ISO 9227)
  • Resistance to stone chip
  • Resistance to chemicals
  • Coefficients of friction

Solutions

Dörken MKS zinc flake systems are an economical alternative to standard stainless steel solutions. These have specification entries with well-known construction equipment companies and ensure the long-term retention of value and function of the coated parts. Consisting of a zinc flake base coat and a top coat, the systems offer very good corrosion protection with extremely thin coats. No hydrogen is involved in the application process, which is of particular significance for high-tensile steels. Because this enables hydrogen-induced stress corrosion cracking to be avoided, which is often responsible for the sudden fracturing of components and downtime of machines. Functional requirements such as stone impact resistance and chemical resistance can also be satisfied with zinc flake technology.

Example components

Fasteners

Fasteners installed in mining machines require effective protection against corrosive influences (480-1440 hours as per salt spray test). In addition, the coating must enable good fastening properties for ease of assembly, such as individually-adjustable coefficients of friction for threaded parts.

Springs

In addition to excellent corrosion protection, the mostly high-tensile steel springs utilised also need to be protected against hydrogen-induced stress corrosion cracking, thus ensuring enduring function. High-performance chromium(VI)-free zinc flake systems are a good choice for this.

Hydraulic components

Hydraulic components need to be coated with an effective corrosion protection. Galvanic surface coatings from Dörken MKS are an option for this. These are free from chromium(VI), cobalt and nickel and ensure high-performance corrosion protection (720 hours as per salt spray test). In addition, they also offer the high-performance components long-lasting protection against acid and alkaline media.

A wide range of corrosion protection requirements

Whether it is breakdown recovery vehicles, snowcats or aircraft towers: each of these special vehicles contains countless steel parts and components. To give these long-term, effective protection against environmental influences and stresses such as stone impact as well as providing long-term function, high-performance coating is required against corrosion – in some cases the corrosion protection category C5 as per DIN EN ISO 12944. At the same time, the coating system employed must also ensure functional characteristics such as fastening properties and chemical resistance.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Resistance to stone chip
  • Resistance to chemicals
  • Colouring
  • Coefficients of friction
  • Compability to micro-encapsulation

Solutions

An economically and ecologically practical solution for components in the field of special vehicles is that of Dörken micro layer corrosion protection systems such as the chromium(VI)-free zinc flake technology. Good protective effects of up to 1,000 hours against base metal corrosion according to DIN EN ISO 9227 can be achieved using only extremely thin coats. No hydrogen is involved in the coating process. This means that there is no danger of hydrogen-induced stress corrosion cracking. For this reason, the zinc flakes are also particularly well-suited for high-tensile steels of the classes 10.9 and 12.9 or from 1,000 MPa. Finally, zinc flake systems also offer high resistance to stone impact. The formation of red rust is also successfully prevented for a long period in the event of damage.

Example components

Fasteners

As an alternative to stainless steel, fasteners can be manufactured from steel and coated with a chromium(VI)-free zinc flake coating. This ensures high corrosion protection and excellent fastening properties (coefficient of friction) as well as avoiding the risk of
hydrogen embrittlement during application.

Stud bolts

Stud bolts are used in special vehicles primarily to secure large and heavy components. In addition to long-term corrosion protection the coating must ensure key functional properties such as high trueness of fastenings to facilitate assembly.

Hydraulic components

Hydraulic components require effective corrosion protection. Galvanic surface coatings from Dörken are well-suited to this. These are free from chromium(VI), cobalt and nickel and ensure high-performance corrosion protection (720 hours as per salt spray test). In addition, they also ensure the ongoing resistance of the components to recurring cleaning intervals.

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