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  • Dear Readers,

    The term “shutdown” is really not the best choice of word for describing what our customers and we do during a major turnaround. The only thing that has been shut down is the facility itself – everything else around it is a hive of activity. In fact, work begins months before a shutdown is due to take place as everything has to be meticulously planned and organised and all possible parts produced in advance so that the plant can be up and running again in as short a time as possible.

    BUCHEN and XERVON took part in two major shutdowns earlier this year – both at the same time. All in all, the two companies deployed around 1,200 employees over this four-week period to carry out a whole range of different tasks. Very few companies in Germany are able to take on such a mammoth project. Read our feature article to find out how we succeeded in doing this.

    Brand-new technological developments

    Another thing that creates a hive of activity at our company is our desire to solve our customers’ problems and find bespoke solutions that meet their exact requirements. We are constantly working on further improving our services by developing technical innovations that make processes even more efficient. We have come up with a number of smart ideas for a range of different applications. From closed loop processes, to getting maintenance work fit for the future with condition monitoring, all the way through to creating our own complex technological developments such as the dense phase conveyor system and our very own industrial cleaning robot, the automated industrial cleaner (AIC).

    No matter what development we may be looking at, our focus is always on improving workplace safety. As a result, we have launched a variety of product innovations onto the market recently that makes working in boilers much safer. We have also been awarded a number of work safety prizes from our customers – demonstrating that this subject is just as important for them as well. And we are happy to admit that we are extremely proud to have been awarded these. They are proof that our ongoing efforts to improve work safety are bearing fruit. Whether it be RWE, EVONIK or Covestro – to name just a few – they have all commended us and thanked us for the hard work we carry out in this area. We, too, would like to say a big “thank you” to them: for giving us these awards and giving us the opportunity to work with them. We are also doubly proud because we operate in such a wide range of fields, all of which – such as tank cleaning work – have their own particular hazards and risks. Our experts are in high demand both for onshore and, in particular, offshore projects. From the North Sea to the easternmost region of Russia: our customers like to make the very most of our in-depth know-how and specialist technology.

    Outstanding scaffolding services

    What’s more, the latest scaffolding projects in Sweden and Austria clearly demonstrate just what a name XERVON has made for itself as one of the leading European scaffolding businesses. Both projects involve extremely complex requirements, whether it has to do with weather protection or special anchorage solutions. In fact, we are well-known for delivering specialty scaffolding solutions in all of the countries we operate in. Which was one of the reasons why we invested in our scaffolding business in the German town of Eisenhüttenstadt. With both the workforce and workload having expanded over the last few years, we decided to invest in our employees, in our customers and in the region as a whole.

    Have fun reading this first ever digital edition of our magazine – you’re bound to read about a service or product that could be of interest to your own business!

    • Hans-Dieter Behrens

      Olaf Karrass

      Jürgen Lennertz

    • Matthias Ebach

      Carsten Lange

      Klaus Thiele

A TÜV inspection every year

Once a year, XERVON’s surface technology experts travel to the German town of Bottrop-Kirchhellen to carry out one of their more unusual tasks: with all the rides at Movie Park Germany needing to be prepared for their annual TÜV inspection at the beginning of the winter season, the corrosion specialists are called in to service the rides’ steel supports and remove any corrosion that may have appeared over the previous twelve months.

Protecting the water ride against corrosion

“The environment is a bit more colourful than usual but the job we have to do is the same as anywhere else,” was the general opinion of the XERVON team responsible for the project at the Movie Park. Last year, the “Bermuda Triangle” water ride was at the top of the list of attractions needing to be serviced. Hardly a surprise really considering that the ride’s steel supports are permanently exposed to high humidity levels, making them more vulnerable to corrosion. A very careful eye is, therefore, kept on the steel beams and maintenance work is carried out as soon as any rust appears. This is essential work as they have to be able to support the weight of the tracks, the cars and the water. It doesn’t bear thinking about what might happen if a corroded steel beam failed: parts of the track that rise steeply through the inside of the volcano in the dark and surrounded by fog could then collapse.

  • As the name “splash” suggests, up to 800 guests an hour end up getting pretty wet when they travel through this part

Special coating for long-lasting protection

  • The surface technology experts from XERVON Oberflächentechnik carried out extensive maintenance work on two areas of the ride: the sides of the track in the “splash” section and three horizontal steel girders in the “exit lift” section. As the name “splash” suggests, up to 800 guests an hour end up getting pretty wet when they travel through this part. The final highlight of this really fast ride is when the car shoots out of the volcano and ends up in a pool filled with water. The first thing that had to be done before work could begin was to completely empty this pool. As soon as the water had been removed, the XERVON specialists carried out blasting work on the surface of both sides of the 15-metre track to determine the exact extent of the damage caused by corrosion. After the operator had completed some welding work in close consultation with the TÜV inspection agency, XERVON then blasted the surface again to ensure it was not only clean but also had the right degree of roughness. This is vital as the anti-corrosion coating can only provide long-lasting protection if the surface has been prepared properly.

The guests expect the rides to be safe – this is always the case here thanks to XERVON

Each coating manufacturer stipulates how and under what conditions their material should be used. XERVON’s corrosion protection experts not only have this specialist knowledge but also the know-how to analyse the environmental conditions and so determine which coating system will deliver the best results. Here in Movie Park Germany, for example, they chose a special damp-resistant coating that was applied in several layers.

The same method was then carried out on the three steel girders in the “exit lift” section – although an additional step was needed here: the horizontal steel beams had been so badly damaged as a result of being permanently exposed to water, that the operatives had to first remove the corroded steel by hand using hammers and chisels before the blasting work could begin. This was no problem for them at all, though, as such projects are always prepared meticulously beforehand so that they can deal with all eventualities and complete the task in hand efficiently and according to schedule.


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