Research & Development

New solutions to the customer’s benefit
In rapidly changing markets the ability to innovate is a key to success. Sika constantly keeps a finger on the pulse of it’s customers. In 2005 the company succeeded again in raising the number of it’s new products and patents notably. It’s development work concentrates on solutions that serve to conserve the resources of Man and his environment, enhance safety and at the same time provide customers greater value. It is a challenge gladly accepted by our teams.

For five years we have successfully pursued a two-pronged, reciprocally rewarding R&D (research and development) strategy. One, directed by central research, performs long-term tasks, analytical services and manages R&D for the entire Sika Group. Since 2002 Sika Technology AG, a subsidiary, has been assuming this responsibility. Objectives of it’s research programs, which often take years to accomplish, are, for instance, to investigate, explain and optimize interactions between components of concrete and Sika admixtures. The findings guide our progress in production of admixtures and improvements of product properties. We proceed similarly with sealing and bonding materials with the aim to develop new binders and innovative additives.

The other R&D effort is directed at improving products, solutions and applications. The work is performed decentrally in eight technology centers, scattered strategically around the globe. In cooperation with regional technology support centers, the regional units also adjust products to local conditions and to the diverse, individual needs of customers. Take Sika® ViscoCrete®, for example: Technology support centers, thanks to their regional proximity, make adjustments better and faster to climatic conditions or to specific types of local aggregates like gravel and sand.

R&D Management
As in the prior year, research and development expenditures amounted to about 1.6% of net sales. The pattern of research fund allocations also was not changed. About three-fourths of the R&D budget was again allocated to product development and maintenance, one-fourth to long-term research projects. The technology center, opened in Denmark during the previous year and fully integrated into Sika’s R&D structure in 2005, is responsible for twocomponent polyurethane adhesives applied to panels in industrial and construction applications.Sika’s Board of Directors elected Dr. Urs Mäder to head research and development and serve as a member of Group Management as of September 2005. Dr. Mäder holds a doctorate degree in chemistry from the University of Freiburg in Switzerland. He joined Sika in 1989 and was named Product Technology Director for Construction Chemicals and Mortar in 2000. Under his leadership he pressed ahead with numerous developments, especially the Sika® Visco- Crete® technology.

Product development and market introduction process
PCP)
Prior to marketing, new developments have to conform to strict internal and external economic viability, environmental, health and safety standards. The «Product Creation Process» (PCP) lessens risks, minimizes costs, shortens the time required for product market introduction (TTM) and assures continuous improvements in quality. PCP therefore defines the conditions for the development process and the market introduction requirements for Sika products and solutions. We value having products introduced simultaneously in all targeted regional markets. Most of the admixtures sold bear the quality seal of EFCA, the European Federation of Concrete Admixture Producers. In the year under review Sika Technology AG again conducted PCP training for the staffs responsible for such work in national companies. Since its introduction in 2003 the interactive PCP training program has been used extensively. An added benefit: It helps to sensitize all participants to Sika’s high standards. The technology support centers are responsible for conformance with PCP in their region and monitor the quality of the processes on hand of regular local PCP audits, thus assuring that all participating employees are on the same track in putting Sika standards into practice. In the year under report such audits were again performed in Asia/Pacific, Latin America and Southern Europe. Most of these check-ups indicated the need for action in respect to economic aspects involving new products. In the coming year emphasis will be placed on the global introduction of a revised PCP version. It applies stricter criteria to selecting projects and their prioritization in order to achieve greater efficiencies and accelerated market introductions.

Patent portfolio and market introductions
In 2005 we applied for 41 (30) new patents. To protect Sika’s innovations even more successfully and, if possible, to have all inventions included, all departments are being subjected in 2006 to qualitative goals in submitting invention reports. Moreover, we intensified intellectual property (IP) training. Thanks to these measures the number of invention reports rose sharply to 59 (32). By optimizing internal processes we succeeded in 2005 to shorten the time required from the conception of a new invention to patent filing. All sectors of our operations again launched a very promising number of innovative products during the year under report.

Innovations for the Construction Division
Sika® ViscoCrete® AT 307: By varying Sika’s well-known ViscoCrete® production process, it is possible to manufacture tailor-made products based on a basic polymer. With Sika® ViscoCrete® AT 307 we furnished AlpTransit, a customer, an admixture that combines the processing time for a ready-mix concrete product with the curing period required for precast products. It has excellent workability properties and improved features for the cured concrete.

Sika® ViscoCrete® 112 EB: Sika’s ViscoCrete® polymers and the corresponding powder technology, combined with a selected production process, permit the production of a special PowerPack. This PowerPack, Sika® ViscoCrete® 112 EB Powder, refines the cement into a directly usable self-compacting concrete binder with constant performance characteristics. It features a distinct improvement in curing and allows the use of Flextremo 4R for concrete work in cold temperatures as well as in precast plants.

Sikaflex®-AT Connection and Sikaflex®-AT Universal: AT stands for advanced technology or one technology for all substrates, meaning that these products, unlike conventional adhesives and sealants, exhibit excellent adhesion on porous as well as non-porous substrates. Thus Sikaflex®-AT Connection seals joints, for instance, between PVC windows and concrete without the installer having to spend much time preparing the substrates. Sikaflex®-AT Universal is an all-purpose adhesive, performs like its Connection counterpart but achieves greater adhesive strength. It meets various adhesion requirements in construction.

SikaBond® T52 FC and SikaBond® T54 FC: Introduced in the year under review, these elastic adhesives, designed for installing wood flooring, meet highest ecological standards; they are ideal for use in interior rooms. Another advantage: Due to the fast curing adhesive the floor can be sanded a few hours following installation. The products are jewels in the crown of our flooring adhesives range. Introduced concurrently the new Sikabond® Dispenser-5400 equipped with several dispensing channels simplifies adhesive applications and saves time.

Sikaplan® universal: A weather-resistant soft PVC roofing membrane that is installed mechanically with or without gravel or can be bonded in place. These membranes are sold through dealers and/or do-it-yourself markets both for new construction and repairs.

Mipoplast® Biodiesel: Mipoplast® Biodiesel is a new membrane – the first suitable for sealing biodiesel tanks. This PVC membrane is resistant to alcoholysis and microbes present in biodiesel fuels.

Sikaplan® GWPO: This polyolefin membrane, resistant to weather and most chemicals, is used to line drydocks and catch-basins for chemical tanks, but also irrigation or snowmaking installations.

Innovations for the Industry Division:
Sikaflex®-250 DM-3: The product, a benchmark in direct automotive glazing, was introduced by DaimlerChrysler in 2005. It combines the advantages of high torsion-resistance, direct adhesion as well as adhesion to glass without the use of black primer. The system saves process steps for customers, while still maintaining the highest technical performance standard. Introduction of this product confirmed again the success of the Sika-developed technology of bonding glass without the use of black primer.

SikaPower®-496/3: Thanks to Sika’s new nanotechnology it is possible to produce more impact-resistant epoxy-polyurethaneadhesives. SikaPower®-496/3 opens Sika automotive customers the opportunity for the first time to enhance the stiffness and durability of automotive bodies and to improve their crash resistance at the same time.

SikaMelt® 9635: This is the first product of a new generation of reactive hot melt adhesives developed especially for the automobile’s laminating processes. It allows for coating decorative laminates (for instance, for dashboards and interior door panels), which in turn are press-laminated to a variety of materials.

SikaForce®-7550 L05: This fast-curing two-component polyurethane adhesive, developed in particular for industrial applications, bonds different materials – EC coated metals, ceramic, glass and lacquered metals etc. – elastically, yet with high adhesive strength.

SikaForce®-7550 L15 is suitable for structural bonds that are subjected to dynamic stress and demand quick load-bearing capacity and fast curing. SikaForce®-7550 L15, ideal for bonding large building and assembly components, can be used for bonding many different materials, including plastics, metals, wood and ceramic. It was developed especially for applications in commercial vehicles.

SikaMelt®-9181 is a reactive hot melt adhesive designed in particular to bond polypropylene without pretreatment. SikaMelt®-9181 is free of isocyanates and was developed, above all, for laminating and bonding construction assemblies. It adheres well on homopolar materials.

SikaColl® 4300 FD, a solvent-free adhesive primarily used by the commercial vehicle industry, stands out for long periods of workability, early adhesion, broad adhesion spectrum, simplicity in application and extremely good ageing.

SikaColl®-4486, a water-based adhesive for the production of special adhesive tapes for fastening roofing membranes, incorporates strong initial adhesive tenacity, is waterproof and resistant to ageing even when exposed to very low temperatures. It also has good wetting properties in use with homopolar materials.

SikaMelt® 9211: In cooperation with a well-known European producer of coated wood flooring we developed SikaMelt® 9211, a new solvent-free, hot melt, one-component adhesive. The product also dampens noise.

Outlook for 2006
In 2006 we will strive for our goal to be No. 1 or 2 in our target markets and to come up with a package of easy-to-produce, patented innovations.We will succeed in our mission only if we are cost leaders. The largest potential for innovation is open to us in the cement, concrete, adhesives and sealants, flooring and automotive sectors. Another major focal point lies in the development of environmental-friendly, water-based as well as products low or free of solvents in order to be prepared for stricter environmental, health and safety regulations to come in the future.