A clear path for stable noise protection: frictional connection between the pillars and the steel bridge thanks to the Liquid-Shim® MM1018

As part of the expansion of the Berlin S-Bahn line Dresdner Bahn, great attention was paid to noise protection. Due to the inner-city location of the construction site and the associated proximity to residential buildings, the noise barriers, which were up to five meters high, had to meet particularly high requirements.
proximity to residential buildings. In order to ensure the frictional connection of 15 noise barrier posts on a
steel bridge permanently, with high precision and form-fit, the gap compensation was achieved withThe Liquid-Shim®
MM1018 from DIAMANT Polymer GmbH. MM1018 is a highly filled metal polymer for full-surface and non-positive
filling of inaccuracies and unevenness between metal elements.

Noise barriers on railroad tracks that run over a steel bridge are exposed to exceptionally high loads. They not only have to absorb the noise of rail traffic, which is made up of noise from wheels and rails. The bridge body is also a source of noise and vibration. This is why particularly efficient measures are required here to ensure long-term noise protection for the surrounding residential areas.

Special technical challenge for force-fit gap compensation

This poses particular technical challenges for the flange connections between the noise barrier posts and the steel bridge. To ensure that these bolts do not come loose even under permanently high loads – a problem that is often associated with considerable repair costs and downtimes – the connecting flanges must be flat and tight to the millimetre so that no excessive stresses can build up and the components meet the high requirements of a long service life in rail traffic.

In order to ensure the best possible frictional connection between the 15 support posts and the steel bridge in Berlin, with a base plate of 460mm x 380mm and a wedge of 0 to 5mm to be filled, DIAMANT Polymer GmbH was commissioned to have the gap compensation on the flange connections carried out by a team of experienced specialists.

“We are delighted to have made a contribution with our products to ensuring the population-friendly noise protection of a highly frequented railroad line in the German capital,” summarizes Carsten Kunde, Managing Director of DIAMANT Polymer GmbH.

Form-fit injection of the MM1018 liquid lining sheet

Two perfectly matched variants of the high-performance polymer were used on the Berlin steel bridge. MM1018 SEAL is a fast-curing metal polymer for pressure-tight joint sealing. It is used in conjunction with the injection of the low-viscosity gap filling material MM1018 FL to seal cavities to be injected and prepare them for application with MM1018 FL.

The application of the corrosion and weather-resistant MM1018 SEAL is facilitated by cartridges with a forced action mixer. MM1018 FL is the liquid version of the highly filled metal polymer for casting or injection. The product is currently the only one of its kind to have general building authority approval for use between steel components.

Construction report PDF