High-strength, fast curing compound deemed suitable for offshore concrete structures

MasterFlow 9500 from Master Builders Solutions by BASF is the first product of its kind to receive a DNV GL (Det Norske Veritas Germanischer Lloyd) certificate for Offshore Concrete Structures. The Type Approval Certificate issued by the internationally acknowledged test and certification body, which specializes in oil, gas and maritime services as well as in energy and sustainability, officially confirms the quality of the offshore performance grout. “Being the first to receive this certificate feels like having received an award,” said Luc Westhof, global key account manager wind turbine grouts at BASF. “The certificate assures that MasterFlow 9500 has been developed, tested and produced to the highest standards applicable in the industry, and it also guarantees maximum reliability across the entire lifetime of the offshore wind farm.”

MasterFlow 9500 is an ultra-high strength high-performance offshore grout, a so-called exa-grout, with documented fatigue performance for time saving and durably secure grouting of offshore wind turbines foundations. The fast curing feature of the grout and its tolerance to very low temperatures speeds up the installation process and prolongs the timeframe for installation.

During the certification process, experts from BASF and DNV GL were working on testing and documenting material properties, assessing quality control of relevant aspects during the manufacturing process, product application and related installation guidelines as well as quality assurance documentation.

“BASF has successfully completed an extensive certification program for their material MasterFlow 9500,” DNV GL project manager Andreas Lervik said. “It is considered a suitable material for use in load carrying grouted connections when applied in accordance with the approved procedures and within the stated application limitations.”

The evaluation of MasterFlow 9500 was conducted in accordance with DNV-OS-C502 (Section 9E). DNV GL implemented the certification scheme for structural grouts in this standard for Offshore Concrete Structures in September 2012 to provide a uniform approach for documenting material properties and performance for relevant applications. A detailed summary of the material properties and conclusions from the certification process of MasterFlow 9500 is stated on the DNV Type Approval Certificate (No. K-5944, issued 2014-08-05).

Faster Installation, Protected Investment

In addition, MasterFlow 9500 also reduces the overall costs of offshore installations. The material develops a high strength very early on and can be applied at lower temperatures compared to conventional products. Considering the total cost of implementation, the time MasterFlow 9500 can save is a big factor in lowering the costs.

Also, provided the product is applied correctly, MasterFlow 9500 ensures a maintenance free connection between the tubular steel members for offshore wind turbine foundations.

“Achieving Type Approval Certification for MasterFlow 9500 provides both FoundOcean as installation specialist and its clients with increased reassurance of the performance of this material. This is extremely helpful and protects the investment in offshore wind energy”, says Andrew Venn, Marketing Director at FoundOcean, a globally active specialized supplier of offshore wind turbine installations.

MasterFlow 9500 was recently used on the West of Duddon Sands wind farm project in the UK, where 108 monopile foundations were installed in a record breaking period of just five months. In 2013, the performance grout was used, for instance, on the Gwynt-Y-Môr project with 160 monopiles in the Irish Sea as well as in the grouting of numerous test and demonstration turbines from several manufacturers, including the world’s currently most powerful offshore turbine with a rotor diameter of 164m and a capacity of 8 MW.