Icopal and Esha Infra Solutions BV.

This time, the reception will be from one o'clock in the afternoon, as in preparing for this activity it was decided to be able to view some of the company's processes while they are still operating in the factory. Moreover, our hosts offered a lunch beforehand.

This company visit came about for KIVI Noord's own regional members, as it had previously been decided to plan a visit to Esha Infra Solutions BV in 2018 in the international cooperation between KIVI Noord and the Vereinigung der Straßenbau- und Verkehrsingenieure, VSVI - Bezirksgruppe Ostfriesland. As part of a day-long programme, together with a visit to the then-in-progress Ring Groningen and lectures focusing on innovative projects in road construction.

Our group of 12 participants was welcomed by Frits Zandvoort, R&D manager at Icopal and Ralph Venema, business development manager at Esha Infra Solutions.

Frits Zandvoort started around 13:30 with his presentation on Icopal. Here we are explained, that this company originally started as Smid & Hollander (1927) and very recently became part of GAF (2016), the largest producer of roofing materials in North America. Some overviews underline, that Icopal is the leading -, largest -, pan-European producer of roofing materials and sealing products.

As bitumen is the main raw material for the end products, this natural raw material is first discussed in more detail. It is also explained, that nowadays natural bitumen is equivalently replaced by a by-product of distilled petroleum. Natural bitumen is scarce and therefore expensive worldwide, while the alternative is also sustainable and cheaper.

An interesting interactive discussion ensues about this.

A special feature of Icopal is that the company has its own bitumen tanker. This can come ashore at the company and, by sailing up and down to refineries in Rotterdam and Antwerp several times a week, the shiploads of 850 tonnes of bitumen are stored at the plant site for further processing. There is also supply by axle.

Icopal's multitude of different roofing products is then presented.

Newer developments are also discussed. Like, for example, the increase in white roofs (cool roofs!), which have been proven worldwide to be much better for energy use and climate control in buildings. This is particularly inspired by experiences in the Middle East and North America, where it can get very hot in certain regions.

Green roofs are also fairly common in Icopal's production sphere. This too is a sustainable development within the company. Here, the challenge is the structural side and moisture control in the construction.

Icopal likes to invest in sustainable roof systems. Everym2 of roof surface provides an additional function. Through air purification and with cool roof roofs, this roofing makes a positive contribution to environmental and climate issues.

Next, a second presentation on Esha Infra Solutions will be given by Ralph Venema.

This will cover various innovative developments on life-extending maintenance of asphalt structures, joint transitions at viaducts, paving structures on bridge decks, etc.

Bitumen is a petroleum product. And petroleum will become scarcer in the near future. Therefore, they developed the bitumen recycling process This process is explained in this presentation. In principle, bitumen can be infinitely recycled into new bituminous products. Retaining all its good properties. And; with great benefit to the environment. To further spare the environment, some of Esha Infra Solutions' products also have rapeseed oil as a bitumen substitute.
In the various countries where the company operates, regulations and types of construction differ considerably. As a result, the company faces challenges.

In the Netherlands, for example, steel bridge decks are used almost exclusively. As a result, the Dutch market is very specific: the waterproofing of railway and road bridge decks is almost exclusively done by a waterproof membrane with cast asphalt.

By using a bitumen developed specifically for this purpose, 50% old porous asphalt can be used in new porous asphalt overlays. The environmental gain is unprecedented. Combined with the lower cost price and longer life expectancy compared to other porous asphalt mixtures, this asphalt mixture based on recycled porous asphalt offers the solution for porous asphalt in the future.

Quality control of applied asphalt mixtures remains one of the most important prerequisites. In addition, the necessary innovations help make asphalt construction much more efficient.

With one or more so-called PenTack treatments (suitable for all types of asphalt), the service life of the road surface is doubled, at minimum cost and with a positive contribution to the environment. Less frequent major maintenance. And then, if it comes to that: reduction of the execution time (again due to innovations), so the road needs to be blocked to traffic for less time.

When asked why new road surfaces always have traffic signs warning of initial roughness problems for a relatively long time, the answer is that the traffic itself has to create a roughening effect by wearing off the bitumen film around the crushed stone. By itself, this could also be done by working the new road surface, but that increases the risk of damage resulting in the release of crushed stone material. The latter is also a risk for the road manager, as damage claims by road users can be expected.

In 2014, Esha Infra Solutions BV. also introduced bitumen emulsion for adhesion of white, slightly reflective crushed stone. Besides additional road safety through increased contrast and opportunities for energy savings on public lighting, the white crushed stone benefits the life of the road surface. The asphalt will absorb less heat, resulting in less rutting and a longer life of the road surface. This also benefits the environment (urban heat effect).

At 15:15, the tour of the factory site begins. First, we look at a site where the various rolls of roofing materials are manufactured. Because there is a very large number of different products plus "a lot of customisation" towards customers, speed of production is less important to Icopal, than high quality of the final product. This is easy to observe. The tour then goes to a pumping plant, where bitumen is mixed into bitumen emulsion. The capacity here is about 40 tonnes per hour. This is impressive, given the small size of this pumping plant, which is unique to the Netherlands.

Walking around the plant site, in response to questions we are given an explanation of the in-house company fire brigade. There are several reasons for such a facility on the 8.7-hectare site. In the past, on a number of occasions, fires have had to be fought. Given the relative sensitivity due to flammable materials and products, they remain extremely keen on (fire) safety.

After a look in the central control room, we finally visit the plant where the SBS (elastomeric bitumen), Styrene (vinylbenzene) - Butadiene - Styrene is made.

Elastomers improve the elastic behaviour of bitumen. SBS modified roofing is therefore highly elastic. SBS modified bitumen has very good low-temperature flexibility and high fatigue resistance. As a result, these roofing materials can sustainably resist deformation even at low temperatures.

In road construction, SBS modified bitumen is successfully used in situations where rutting is a problem.

At around 16:15 this afternoon ended with a joint drink. After this, the participants went home enthusiastic and a lot wiser about roofing materials and asphalt technology.

Including the conclusion, that upon returning in 2018 together with colleagues from the Vereinigung der Straßenbau- und Verkehrsingenieure, VSVI - Bezirksgruppe Ostfriesland, another highly informative - and fascinating (sub)activity is in store!

Description

Esha Infra Solutions is part of Icopal, Europe's leading manufacturer of products for the protection and sealing of building structures. In road construction, Esha Infra Solutions (founded as Smid and Hollander) has been active for more than 80 years. From its production site in Groningen, Esha Infra Solutions supplies products, mainly bitumen-based, for the construction and maintenance of asphalt pavements to many countries in Europe.
Esha Infra Solutions works with various parties in the market to realise the right technical and functional solution for infra projects. In doing so, Esha concentrates on:
- Asphalt production and processing
- Asphalt maintenance
- Sealing, reinforcing and protecting structures and the environment -
Its own R&D department is continuously developing new products and improving existing ones. For example, Esha was the first party to supply bitumen products that save CO2. Through its own R&D laboratory, Esha can add value to (alternative solutions for) maintenance issues and sustainable procurement.

Esha has sustainable solutions for asphalt:
- ECO bitumen: saving CO2 and raw materials.
In the production of ECO bitumen, part of the bitumen is replaced by vegetable raw materials. ECO bitumen is polymer-modified, the asphalt has high quality and a demonstrably longer service life.
- Bitumen for sustainable asphalt overlays. asphalt can be processed at lower temperatures. Some bitumen is replaced by the vegetable, renewable raw material rapeseed oil.
- New life for old porous asphalt. The environmental gain is unprecedented. Combined with the lower cost price and longer life expectancy, this asphalt mixture based on recycled porous asphalt (R-ZOAB) offers the solution for porous asphalt in the future.
- Lifetime-extending maintenance. One or more PenTack treatments (suitable for all types of asphalt) can double the service life of the road surface, at minimal cost and with a positive contribution to the environment.

Besides solutions for infrastructure, there are very many products for roofing.
- Icopal Universal is a rock-solid durable single-ply roofing system
- Sustainable roofing systems from the Eco-Activ line: through air purification and with cool roofs, this roofing material makes a positive contribution to environmental and climate issues.
- High-quality self-adhesive roofing membranes, faster weathering coatings (Syntan coating), safer overlaps and various types of adhesives.
- Green roofing with root-resistant roofing membranes.
- Seal-a-Leak is a repair kit even if there is a layer of water on the roof.
- Fastlock Roofing. A (semi-)transparent roof for carports, conservatories, terraces, pergolas, home entrances, greenhouses, etc.
- White roofing. Energy-saving, better indoor comfort, longer lifespan, environmentally conscious.
- POCB roofing. Reinforced roof roll with polyester and glass

Speaker(s)

Herman Schutte, Managing Director.
Ludo van Duuren, Sales Director.
Lars Dahlstrand, Production Director

Location

Hoendiep 316, 9744 TC Groningen.

Organiser

Region North

Name and contact details for information

Piet Dijkshoorn, tel: 06-41438072. noord@kivi.nl

Esha Infra Solutions BV