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Renewable energy

Be it wind farms or solar parks, the market for clean energy from the wind and sun is growing rapidly. So that the complex technical systems remain in long-term operating condition, the components and fasteners being used need to be efficiently protected from corrosion damage. This is especially so in climatically challenging environments. High-performance coating solutions help here to extend the systems’ maintenance cycles and service life and to increase efficiency. Tailored to the respective areas of use, Dörken MKS offers a comprehensive portfolio of chromium(VI)-free corrosion products for all sorts of system components, globally available in top quality.

Your contact
Klaus Gradtke
Tel: +49 2330 9134065
Contact
Your contact
Klaus Gradtke
Tel: +49 2330 9134065
Contact

Application segments

Long-lasting, proven protection

Components in onshore wind turbine constructions are subjected to tough climatic conditions and to mechanical stress caused by wind loading and the operation of the turbine itself. In order to fulfil the demanding requirements of ISO 12944 and the specifications of the wind turbine manufacturers, each individual component has to be protected against corrosion in a manner appropriate to the surrounding conditions – sometimes calling for corrosion classes up to C5-M. For this Dörken MKS offers a long-lasting coating solution, through the use of its high-quality zinc flake systems.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Colouring black, silver, blue, green
  • Coefficients of friction

Solutions

Dörken MKS zinc flake systems have been proven in practice for many years and have group approval from many leading wind power equipment manufacturers. The coatings for components in the onshore sector consist of a zinc flake basecoat and an organic or inorganic topcoat. The topcoat fully seals off the basecoat against any outside influences. Even with extremely thin layer thicknesses, it is possible in this way to produce a high level of cathodic corrosion protection of up to 1,000 hours against red rust (as per DIN EN ISO 9227). The application process takes place without creating any hydrogen. There is thus no danger of high-strength steel components suffering any brittle fracture failure. The very thin layer thicknesses ensure excellent thread-fastening properties, thus enabling maintenance and installation jobs to be carried out in an easier and more time-efficient way. Another advantage of Dörken systems is their global availability in consistently high quality.

Example components

Rotor blade thread-fastenings

For wind turbines, threaded pins with double ends are mainly made in sizes M12-M64. These high-strength components (strength classes: 8.8-10.9) need to be reliably protected against corrosion. To assist easy installation they must at the same time have good thread-fastening qualities.

HV sets

The HV sets used in wind turbine construction consist of a screw, nut and 2 washers – in each case made of steel of grade 8.8-10.9 – and are used in sizes M12–M36.

Anchor bolts

Anchor bolt is the term used for different kinds of bolts that are countersunk into the turbine base. It is on these components – up to 8 metres long and also known as foundation bolts – that, for example, the turbine tower is fixed.

Armed for extreme conditions

Through constant contact with salt water and salty sea air, the components fitted in offshore wind turbines are exposed to extreme climatic and thus very corrosive influences. Therefore the coating systems used need to provide highly effective, long-lasting corrosion protection and guarantee protective effects of 1,000-3,000 hours in salt spray testing (SST) as per ISO 9227. That is the only way that costly maintenance work can be reduced and turbine service life increased. Last but not least, when selecting the optimum component coating for simpler installation the thread-fastening qualities should also be taken into account.

Requirements

  • Corrosion resistance 1000-3000h (e.g. ISO 9227)
  • Colouring black or silver
  • Coefficients of friction

Solutions

In the offshore sector where components are exposed to extreme conditions highly effective chromium(VI)-free zinc flake systems have proved themselves both in tests and in practice. These systems usually consist of a basecoat and an organic or inorganic topcoat matched to the respective component. Using the zinc flake technology, the very thin coatings enable the achievement of a permanently watertight seal, which also has very good thread-fastening qualities. As no hydrogen is introduced during the coating process, any hydrogen embrittlement can be ruled out. The low annealing temperatures of c. 200°C avoid any pre-damaging of the rigid steel component through exposure to excessive heat.

Example components

Rotor blade thread-fastenings

For wind turbines, threaded pins with double ends are mainly made in sizes M12-M64. These high-strength components (strength classes: 8.8-10.9) need to be reliably protected against corrosion. To assist easy installation they must at the same time have good thread-fastening qualities.

Threaded sleeves

The threaded sleeves – also called root bushings – are the counterpart to threaded/stud bolts and get built firmly fixed into the rotor blade. As the maintenance jobs are extremely labour-intensive, lasting protection against corrosive influences is especially important here.

HV sets

The HV sets used in wind turbine construction consist of a screw, nut and 2 washers – in each case made of steel of grade 8.8-10.9 – and are used in sizes M12–M36.

Corrosion protection for securing systems

Both in the sub-structure of rooftop solar panels and in the supporting constructions of large-scale solar installations on open ground various different securing systems are used. Be it supporting profiles, clamps or fasteners, all components are continually exposed to the effects of the weather and to mechanical strain caused by wind load. In order to ensure that the entire systems keep working for a long time, the components used need to be given a long-lasting corrosion protection coating. At the same time the optimum corrosion protection solution also has a positive effect on thread-fastening and installation qualities.

Requirements

  • C5 M as per DIN ISO 12944
  • Strict requirements to corrosion resistance (1440 h as per DIN EN ISO 9227)

Solutions

Based on the component to be coated, Dörken offers a range of chromium(VI)-free microlayer corrosion protection systems for solar power equipment. Every system provides effective cathodic protection from corrosion. Our zinc flake technology, for instance, consists of a basecoat and an organic or inorganic topcoat and in the field of solar power construction has general building authority approval from the German Institute of Civil Engineering (DIBt) for corrosion protection class C5-M. At the same time, zinc flake systems fulfil all requirements of DIN EN ISO 12944 for coatings in steel construction and are thus suitable as an economic alternative to A2 stainless steel. The very modest coating thicknesses ensure that fasteners have good thread-fastening properties, including against different materials.

Example components

Mounting rails

Mounting rails or also supporting profiles form the frame and sub-structure for solar panel systems. They can be up to 14 metres long. Telescopic pieces enable perfectly fitting brackets to be produced without any cutting to size.

Clamping systems

Adjustable clamps ensure a high degree of flexibility in the installation process and make it possible to use standardised fixings for different applications. The very thin zinc flake coating facilitates good thread-fastening qualities and is thus very low maintenance.

Fasteners

Screws, nuts and hooks are used to fasten the individual components. In addition to simple installation, optimum form and force locking is essential– here too the zinc flake technology with its very modest layer thicknesses contributes to making the thread fastening easier and to ensuring that the system keeps working for a long time.

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