Page 77 - Dockside Magazine Muskoka, Summer/Fall 2018

Steel docks are legendary surface rust or imperfections grandchildren, it needs to be the electrodes work well when But, even the best dock
for their strength and durability, but the process of building the
best docks begins long before the workers are anywhere near the water.
Muskoka’s own Man of
Steel – Philipp Spoerndli of Nordcap Steel Docks – says sand-blasting, painting, epoxy coating applications, welding and even some pre-assembly are best when done well away from the lake. Doing the work inland is much more efficient, convenient for the client, and creates a product that can be guaranteed, he says.
“By knowing exactly where each part of your dock comes from and getting them ready in-house, we are better able to provide the quality our docks are known for,” says Philipp.
Because it takes less time to
do the prep work at a proper facility, labour costs are reduced. Completing these tasks while barges are on site is not ideal.
Philipp invites his clients to visit his company’s prep yard in Gravenhurst, so they can see the quality craftmanship taking place. There, they might see workers sand-blasting new steel, removing any millscale,
that have built up since the material left the mill. “Sand- blasting the steel to a near-white finish takes a lot of time and effort,” says Philipp. “It would be a major inconvenience and pollute the water for us to do it on-site. It also allows us to take 100 per cent responsibility over our product.”
Epoxy coating
For over 27 years, Philipp has been refining the way
he builds steel docks. This experience provides him with an exceptional knowledge of how to create products that last. It’s why Philipp insists on using an epoxy coating
on every one of his steel docks: like the costume on a superhero, epoxy gives an important measure of added protection.
Without an epoxy coating, steel will develop rust a lot faster. Although it’s a more expensive process, it’s worth it because
it results in a dock that will
last 70 years or longer. The epoxy coating is designed and manufactured to perform in submersion when applied to a 10 mil dry thickness.
“If you want something to hand down to your
epoxy coated,” says Philipp. “Bare metal docks are rusting out within 25 to 30 years and I-beam docks installed in the ‘90s are deteriorated to the point where a full replacement is necessary.”
Meticulous welding
The process of prepping
the docks in their own yard before moving them to their customer’s property is just one of the ways Nordcap maintains quality control as
a dock builder. They have
a welding engineer on staff who inspects the weld quality on docks as they are being assembled on site.
“It’s another way we adhere
to and go above the industry standards,” says Philipp. “The welds are key for a dock of superior strength and we refuse to compromise on the weld quality. Having them regularly checked helps maintain our high standards.”
Even the welding materials are hand-picked for effectiveness in Muskoka’s lakes. Nordcap uses a welding rod which is developed for mining: with
a flux that does not absorb moisture,
used directly over the water.
“A standard welding rod
is easily contaminated by moisture,” he explains. “That doesn’t happen with the specially-coated rod we use.”
Material matters
Attention to details like the welding rod is a standard part of Nordcap Steel Docks’ process to build super-strong docks. The actual frame materials and construction are the next step.
Nordcap begins with high- strength piles, five inches in diameter with 5/8-inch thick walls. After they’re coated with epoxy and ready to be installed, the round piles are driven to or pinned to bedrock, and filled with concrete to displace water and oxygen, thus preventing rust from forming inside.
To combat Muskoka’s
spring flooding conditions, Philipp chooses stainless steel fasteners. Stainless steel won’t rust and is more pliant than carbon steel – a major advantage when battling the forces of water and ice.
structures can suffer from ice damage. To better protect your dock, use a bubbler system with combined thermostat/ timer settings to make sure
it doesn’t run more than necessary. Also, have someone do regular checks to make sure it’s working correctly.
“You don’t need a lot of open water, but a good four-to-six- foot buffer zone on a large lake is ideal,” says Philipp.
Having been in the steel
dock business since 1991, Philipp proudly brings the craftsmanship and pride to Muskoka from his native Switzerland. He notes the Swiss build things to last centuries, not just for a few years.
“We have a responsibility to the customer to sell them a long-term dock and long-term support for their boathouse,” he says. “I take that mentality into every dock I build.” DS
BY CHRIS OCCHIUZZI
705-637-0555 • philipp@nordcap.ca • www.MuskokaDocks.com