The Liquid-Shim® MM1018 economically secures the seal between the base rails and the reinforcement of roller and sliding contactors

In March 2022, as part of the renovation of a weir system on the Elbe and Havel rivers, the gaps between the base rails and the reinforcement of the roller and sliding gates of a 25-metre-wide contactor panel were fully grouted with MM1018 from DIAMANT to ensure a corrosion- and weather-resistant seal. The liquid lining sheet is the flexible, economical solution for force-fit tolerance compensation in hydraulic steel construction with very high compressive strength.

The Quitzöbel weir group (near Havelberg/Saxony-Anhalt) protects the Havel lowlands from Elbe floods, serves to cut off a flood crest of the Elbe, regulates the water level of the Lower Havel and enables the Elbe to be raised to low water levels.

In terms of its design principle, the renovated old arm weir is a system with underflow lift gates. The weir has a 25 m wide and 8.75 m high double-sweeping gate. This was designed as a four-belt roller protection with a retaining wall on the Havel side and was constructed using rivets. Weighing in at around 150 tons, the gate is moved by an open spur gear. A navigable bridge designed as a trough leads over the weir opening.

As part of the renovation of the old weir, which was built in 1935, the movable rolling and sliding gates of the sluice gate were replaced. The gaps between the base rails and the reinforcement of the contactors were sealed with MM1018 SEAL and MM1018 FL.

Pressure-tight joint sealing and 100% gap compensation

In preparation for the injection of the liquid gap compensation material MM1018 FL, the cavities between the base rails and the reinforcement of the contactors were sealed with MM1018 SEAL in the first step. The fast-curing (within two hours), corrosion- and weather-resistant metal polymer enables pressure-tight joint sealing.

Once the seal had fully cured, injection of the liquid lining sheet MM1018 FL could begin. The two-component reactive resin system is supplied in a double cartridge system with a static mixer. MM1018 FL must be pressed at least 10 mm deep into the gap to allow it to build up and ensure sufficient durability.

Injection of MM1018 FL starts at the lowest height position to push the material upwards. Before starting the injection, make sure that all valves are open. As soon as the injected lining sheet emerges at the first point, the corresponding valve is closed and injection continues until the material has reached the next highest point.

The major advantage of DIAMANT’s liquid lining sheet compared to conventional steel lining sheets is that MM1018 FL flexibly fills every gap 100 percent and does not need to be mechanically processed or adjusted. The two-component MM1018 reactive resin system can be used either as a paste or as a liquid and can be filled or injected, allowing even the smallest, non-specific gaps to be sealed securely.

The conventional solution for gap filling is the use of filling plates. However, unlike the MM1018 FL liquid lining sheet, these cannot guarantee the entire contact surface without manual adjustment, as this generally has a non-specific shape. Machining the shims to fill the gap 100% is associated with considerable costs for measuring, machining and assembly.

MM1018 liquid lining sheet saves time and costs

The use of MM1018 FL at the Quitzöbel weir system has saved the Federal Waterways and Shipping Administration (WSV), as the operator, time and costs during installation and enabled a smooth construction acceptance. The liquid lining sheet is perfectly suited for use in hydraulic steel structures subject to heavy loads and permanent moisture, as it achieves a compressive swelling strength of up to ten million load cycles and is both corrosion-resistant and weatherproof.

DIAMANT Managing Director Carsten Kunde emphasizes that “with the DIAMANT installation service, we offer our customers a full-service package. Our experienced fitters bring the necessary materials to the construction site and ensure efficient, smooth application. Excess material is taken back after completion of the work. The customer receives full documentation and a guarantee for full-surface gap filling on their building. Speed and quality are our top priorities. We want the customer to come back, not the product.”

Construction report PDF