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Boniface Towers in Mainz: Successful concrete repairs

Sick giants are once again healthy

In the immediate vicinity of Mainz main railway station there they stand, the two office towers, simply known as Tower A and Tower B. Each tower has 24 floors and is exactly 82.60 metres high. Both were built at the end of the 1970s as column/rail constructions from reinforced concrete and were up to 90 percent clad with washed concrete elements. Severe damage due to concrete corrosion demanded a thorough repair of the complete exterior concrete surfaces.

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The concrete repairs on the two Boniface Towers in Mainz were carried out by the Wiesbaden company, Fritz Wiedemann + Sohn GmbH. All the facade areas were first of all treated as required with high pressure jets and then defects and damaged areas were identified and recorded. There were about 3,800 meters of damaged area of different depths to deal with, including approximately 460 metres of broken edges. In the course of the work about 1860 meters of reinforcing steel was exposed and treated. In addition fifteen kilometres of joints had to be renewed.

After chiselling out the damaged areas with an electric hammer, the exposed reinforcement was derusted using the moist sandblasting method according to DIN. The derusted steel was then coated twice with Disbocret 501 anti-rusting treatment based on epoxy resin. Then the exposed areas were filled with Disbocret 507 Multitec Mortar up to about one centimetre below the surface. Stone chippings were added to the same mortar and the exposed areas were then finally reprofiled such that they matched the surface of the washed concrete with regard to texture.

In order to obtain a surface which was as homogeneous as possible and to cover the finest hairline cracks, all surfaces were coated twice with Disbocret 510 filler coating. This filling layer was sprayed on with the airless equipment and rolled immediately afterwards with a lambskin roller to obtain the most uniform application possible. The final coat was realised with Disbocolor 493 methacrylic resin protection, again applied twice using the spray method.

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