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| Surface Protective Systems
Masonry
The history of Steuler Industries began almost a century ago with the development of the world's first acid-resistant cement. Such materials made it possible to construct large-volume tanks and equipment for the chemical industry. Since that time, Steuler has created a portfolio of innovative products for liquid-tight membranes, cements and brick materials that meet all the requirements of modern industrial masonry. Steuler is therefore your experienced partner in masonry for, among other things, pickling plants, regeneration plants, tanks, flue gas piping, reactors, Venturi scrubbers, autoclaves and absorption towers.
- Membranes on a polyurethane, epoxy resin, unsaturated polyester resin, vinyl ester resin, furan resin, rubber lining and thermoplastic base
- Resin cements on a furan, phenol, unsaturated polyester and vinyl ester resin and various potassium cement bases
- Normal brick, shaped brick and special formats in a variety of brick grades (acid-resistant ceramic/graphite and carbon brick/refractory materials)
Our practical experience and the know-how of our innovative construction department enable us to advise you on the selection of a masonry system for each process. Our enormous selection of reliable materials means that a systematic solution can be found for any application. As a masonry specialist, Steuler can provide acid-resistant and refractory grades of brick and cement from its own production for high temperatures and other specialty applications, e.g. for autoclaves or pressurised tanks, and even carry out the entire installation.
Linings for tanks and equipment
Our goal in both new structures and the renovation of existing plants is to create permanent protection for storage and process tanks, drinking water tanks, piping, scrubbers, flue gas channels, basins and connected equipment to minimise production downtimes and repair work.
A large number of tested and innovative lining systems are available that can stand up to the greatest chemical, mechanical and thermal stresses:
- High-performance trowel-applied linings with fillers that determine their properties to resist great chemical and mechanical loads on a vinyl ester resin, epoxy resin or furane resin base.
- Spray-applied linings on a polyurethane, vinyl ester, unsaturated polyester resin and epoxy resin base with special flake fillers to achieve high diffusion resistance. Special vinyl ester resin lining materials with high temperature resistance as well as epoxy resin linings approved for use in contact with drinking water.
- Laminate linings with glassfibre and synthetic fibre reinforcement on a furane resin, vinyl ester resin, unsaturated polyester resin and epoxy resin base offering high solidity and excellent chemical resistance for the protection of steel and concrete structures.
In plants with process technology, linings are exposed to a variety of corrosive stresses they have to cope with on every level. To achieve reliable and long-lasting protection from corrosion, Steuler also develops customised solutions for specific requirements and process technologies in cooperation with its clients. Rapid application and short curing times ensure that as little production time as possible is lost. Our own specialist applicators and supervisors also use innovative application technologies to ensure that the solution is implemented quickly, cost effectively and with the highest level of quality.
Floor and ceramic brick and tile toppings
Temperature fluctuations, moisture, chemicals, heavy traffic, scratching during production or repair work – industrial flooring from Steuler can safely stand up to any load. Such special surface properties as levelling and walking safety improve work operations and occupational safety. In many industries, such supplementary properties as electric conductivity, tightness to liquids, colourful design, physiological safeness, ability to bridge cracks, resistance to weathering and aging or water vapour permeability are also prescribed. If required, linings with specially coated surfaces are also available. Steuler develops, produces, delivers and installs
- a variety of artificial resins on a polyurethane, epoxy resin, vinyl ester resin, unsaturated polyester resin and furane resin base processed into trowel-applied, pourable, sprinkle-applied and laminate toppings
- coordinated system composition (primer, adhesive and self-levelling coats, intermediate coats, top and abrasion coats, sealants) with a variety of fillers and reinforcements are available and
- high-quality floor toppings created by using acid-resistant ceramic brick and tile as well as carbon materials in standard and special sizes together with bedding and jointing cements on a potassium or artificial resin base
An exact analysis of the substrate, operational loads and the required economic aspects determine which individual components are used and how they are structured into a system for a floor topping or floor covering. Floor toppings and acid-resistant ceramic brick and tile from Steuler protect the concrete substrate from corrosive destruction, prevent ingression by chemicals and damaging materials into the substrate and preserve the value of the plant. Field-proven solutions for expansion joints, trench connections and designs as well as sealing details for foundation pedestals and hall structures round out our variety of flooring systems.
Many of our floor toppings can be created in a variety of RAL shades and optically upgraded by sprinkling them with chips or coloured sands. Special grades for the food processing and pharmaceutical industries are also available as well as electrically conductive systems for the electronics and other industries.
Acid-resistant ceramic brick or tile offers a high level of safety for use with highly concentrated chemicals or constant moisture.
Lining systems in accordance with Sec. 19 of the German Water Management Act
Proof to official authorities of special protection for surfaces and equipment in production and storage is more the rule than the exception in many industries. We can offer the most technically and economically sensible solutions from a number of approved lining systems. We can also support you throughout your project from planning, approval and material selection right down to final inspection.
- Resin systems on a polyurethane, epoxy resin, vinyl ester resin and furane resin base
- Systems for all test groups based on the approval principles in the DIBt and in other chemical tests
- Tested chemical resistance, crack bridging, machine traffic and electric conductivity
Many of our lining systems with general building permits also meet other requirements. Our portfolio of water-safe linings has been developed for a wide variety of different practical applications. Various systems can also resist higher chemical concentrations over longer periods or meet the rules in many occupational safety regulations.
As a recognised specialist operation according to Sec 19 l of the German Water Management Act, we are also aware of our responsibility for proper installation by our trained specialist installators.
Thermoplastic linings
With its mechanically anchored thermoplastic lining systems, Steuler has greatly expanded the selection of materials used in industrial corrosion protection. Combining a thermoplastic lining featuring high corrosion and chemical resistance with a statically highly durable material like concrete creates the ideal combination of stability, safety and durability.
The Bekaplast™ lining system developed and patented by Steuler safely suppresses the expansion differentials of the two materials. It has proven its value in use in the chemical industry and in municipal sewage systems over the past 30 years. Based on this, Steuler has created a number of different lining systems for specified fields of application.
- Bekaplast™ for sewage, reaction and processing tanks, absorption towers, entire sewage systems, electrolysis cells, flue gas scrubbers
- Bekaplast DWS™ Double Wall System
- Bekaplast™ catchment basins with the official DIBt Building Permit
- Lining 400™ for municipal sewage systems, shafts and tanks
- Ankerplast™ for Tübbing structures in municipal sewers and other structures made of prefabricated concrete components
- Bolted Lining™: a bolted-on thermoplastic system for retrofit linings and the relining of steel and concrete structures
- MFA and PFA linings
Thermoplastics are highly chemical resistant, stand up to mechanical loads and are also resistant to biogenic corrosion. Welded to be gas and water-tight, the smooth, anti-adhesive surface offers low friction and prevents incrustations. These lining systems are easy to install, can be repeatedly tested and are also easy to repair if ever damaged.
The available materials, polyethylene (PE-HD), polypropylene (PP), polyvinylide fluoride (PVDF) and polyvinylchloride (PVC), can be delivered in a variety of thicknesses and in various material grades to be electrically conductive, UV-stabilised or even with anti-skid properties. Ladders, pump swamps, pipe connections, trench constructions and detailed system solutions round out the portfolio of systems.
Bekaplast™ PE-HD has a general DIBt Building Permit for use in sealing catchment basins for the storage of liquids hazardous to water.
Rubber linings
Rubber linings from Steuler have a particularly wide range of possible uses. The selection criteria in this are chemical, temperature and abrasion resistance, size and geometry of the structure to be protected. Additional requirements such as vacuum resistance, decontamination ability, high diffusion resistance and crack bridging in concrete structures can be met as well as special chemical resistance.
- Rubber grades for steel and concrete structures on a rubber base butyl (IIR), brombutyl (BIIR), chlorbutyl (CIIR), chloroprene (CR), hypalon (CSM), natural rubber (NR) and special grades
- Steuler rubber linings are self-vulcanising, pre-vulcanised or can be vulcanised on site using hot water or vapour
- Autoclave rubber linings with the inclusion of steel components are also delivered by Steuler
Steuler rubber linings have a wide variety of uses in a number of sectors, such as concrete trenches, concrete tanks, pressurised and vacuum equipment, pickling tanks, Venturi scrubbers, processing and storage tanks. Besides a variety of soft rubber linings, we also offer hard rubber linings with special resistance properties. Our rubber linings are frequently used as protective membranes under brick and tile masonry. Steuler delivers the material and carries out the work.
Refractory systems
Innovative material developments and grades also make Steuler a competent provider of refractory linings. Our products and know-how are used around the world by top-line companies in virtually every industrial sector. Our production programme includes both shaped and monolithic products. The range of raw materials extends from dry-pressed fireclay for inlet zones and permanent linings to corundum materials with up to 99% Al2O3. A wide selection of zirconium, silicone carbide and andalusite materials provides our clients with the exact material for their particular needs. Depending on the requirements profile, we also use such additives as chromium oxide and zirconium-based materials. Steuler has also developed a special impregnation system for environments with extreme alkaline loads. Materials for permanent linings, such as lightweight refractory bricks and insulation materials, ceramic fibres, refractory castables and compounds round out our delivery portfolio.
For the ceramic industry, in powder metallurgy and in ferrite manufacturing, Steuler also offers kiln furniture on a cordierite, mullite, andalusite and corundum basis.
Engineering, execution of refractory construction and complete assembly also form part of the services we offer. Demanding refractory solutions require our own research and development departments. Our laboratories develop new materials and test them in conformity with internationally recognised norms. To assure the development of reliable refractory materials, we carry out all the necessary tests in advance, such as comprehensive raw material selection as well as wear and slagging analyses. Using the steel construction drawings and process data provided by the client as a basis, Steuler also designs the complete refractory layout for each individual aggregate. Assembly drawings, but also heat-transfer calculations and heat-up recommendations, are included in our performance package. Specially trained supervisors control the entire sequence of work at the construction site as well as the actual building work. This ensures proper implementation of our refractory systems .
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Click to enlarge!
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Double-layer rubber lining and double-layer carbon brick lining of a stainless steel pickling tank.
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Gas inlet duct and above a self-supporting Steuler-dame constructed of acid-resistant ceramic material.
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Coated reactor tank with baffles and an additional ceramic lining to protect against abraison.
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Spray applied polyurethane coating in a process tank.
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Protection of the total hall construction against aggressive fumes with a spray applied coating.
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Polyurethane coating of a reactor vessel with fabric reinfarcement on the tank bottom.
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Coated floor surfaces and plinths with brick-lined channel construction.
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In the course of the large-scale refurbishment of a chemical plant, vinyl ester floor coatings were apllied to ensure the long-lasting protection of areas subjected to extreme loads.
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Thermoplastic channels mechanically anchored into the foundation, with special details for connection to the tiled industrial floor are pre-fabricated in our workshops.
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Self-levelling flooring system in the foof industry. Without pores, easy to clean, also resistant to aggressive cleaning solutions, outstanding mechanical resistance.
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Production area coated in accordance with the German Water Resources Act. Steuler also supplies pipework made of duroplastics and thermoplastics.
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Coated collection basin with additional tile lining.
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Large-surface sealing system and tile lining in a flue gas desulphurisation plant.
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Owing to the defined number and form of the Bekaplast™ ancor stubs anchored in the concrete, stresses inducted by the different thermal expansion properties of concrete and plastic are safely and reliably contained.
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Bekaplast™ – Double Wall System with defined leakage gap.
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Strorage tank retrofitted with a bolted-on thermoplastic lining – Bolted Lining™ System.
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Sewage pipe system completely lined with mechanically anchored thermoplastic materials. Steuler also offers special design solitions to integrate coatings and brick linings.
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Repair of pipe systems or subsequent lining of concrete structures. Compression distribution is carried out with special polyethylene foam.
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Rubber-lined storage tank ichemical production facility.
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Rubber-lining faeture; the additional lining using carbon bricks is applied subsequently.
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Rubber-lined agitator tank in a chemical production facility. The overflow channels and the entire supporting structure were also rubber-lined.
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In order to safely the reliability of our refractory materials , abrasion and slagging tests are conducted in advance.
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Steuler production utilises state-of-the-art firing technology, espacially in the high-temperature range.
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Field testes conducted on our customers`premises promate the continued development of refractory qualities manufactured by Steuler.
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Microscopic photo of the reaction zone slag/brick.acke/Stein.
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Specially trained Steuler installation personnel ensure the proper realisation of the refractory solutions.
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