B&i2013 donderdag 14.15_zaal_d_sustainable metal innovations final

SlideTata Steel

Sustainable Metal Innovations

Bauke Hoekstra Bonnema

General Manager Tata Steel Construction Centre

Together we make the difference

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SlideTata Steel

Content Summary

Tata Steel

Sustainability

LCA + Innovations

Summary & Conclusions

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Trends Construction

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SlideTata Steel

Tata Group is one of the world’s fastest-growing and most reputable corporations

Tata businesses span 7 major industry sectors

India’s largest private sector employer, with over 456,000 employees worldwide

Operations in more than 80 countries

Total revenue in 2012-13: $100 billion

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Tata Steel is one of Tata’s largest companies

Tata Steel

Tata Motors

Tata Consultancy Services

Tata Power

Tata Chemicals

Tata Global Beverages

Tata Communications

Hotels

Titan

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Tata Steel Group is globally present

Steel making operations

Distribution and commercial centres including downstream assetsMining assets & projects

NML Canada(iron ore)NORTH AMERICA

WESTERN EUROPE

SCANDINAVIA

CIS

WESTERN AFRICA

Ivory coast(iron ore)

SOUTHAFRICA

LATIN AFRICA

Mozambique(coal)

TURKEY

CEE

CHINA

JAPAN

Australia(coal)

SE ASIAINDIA

Odessa

Oman(limestone)

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Tata Steel

Sustainability

LCA + Innovations

Summary & Conclusions

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Trends Construction

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Global mega-trends

Growing Population

Urbanization Climatechange

Accelerating technology

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Distribution of Urban Population

Source : FutureSteel Conference -Worldsteel

<0,5 mio <0,5 mio

>10 mio >10 mio 5-10 mio5-10 mio

1-5 mio

0,5-1 mio5-10 mio

1-5 mio

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Mega Cities (>10 mio)>50% population in urban areas

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Content Summary

Tata Steel

Sustainability

LCA + Innovations

Summary & Conclusions

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Trends Construction

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2011: 7000000000 2025: 8000000000

Danica May Camacho

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Challences Sustainable Development

World energy outlook 2010EIA, International Energy Statistics database

1950 – 2.5 billion2011 – 7 billion2050 – 9 billion

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Content Summary

Tata Steel

Sustainability

LCA + Innovations

Summary & Conclusions

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Trends Construction

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Steel and Sustainability

• Steel Production

• Construction/Building Process

• In Use Phase

• Re-use / Recycling

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Steelproduction : ULCOS -> Hisarna project

Iron ore

Coal

Cokes

Sinter and Pellet

Liquid iron

Blast Furnace

20% CO2 reduction

80% CO2 reduction in combination with CCS

HIsarna

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Steel and Sustainability

• Steel Production

• Construction/Building Process

• In Use Phase

• Re-use / Recycling

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High Strength Steel developments

Development High Strength Steel -> less steel -> CO2 reduction:

- Structure: max 30% CO2 reduction- Composite Floor Decks 20% reduction

Moreover: lighter material -> - Reduction transport CO2- Reduction foundation

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High Strength Steel

Steel strength development : S200 -> S355 -> S460

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Construction Phase: lightweight

Newbuild:

Weight conventional: 1200 kg/m2

(vs Residential loads : 70 kg/m2 !!)

Steel is lightweight -> Steelframe floor /

Quantum Floor

4x lighter vs conventional

-> Lower Transport

-> Lower Foundation

Renovation :

-> Option “upgrading” existing

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Construction Phase: lightweight

Renovation :

-> Option upgrade insulation

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Steel and Sustainability

• Steel Production

• Construction/Building Process

• In Use Phase

• Re-use / Recycling

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Energy collection : Steel cladding + PV

2020: EPBD: Zero Energy Buildings

Building Integrated PV:

Option energy-neutral Tata Steel AluPlusSolar

Tata Steel Prisma + Sollbond

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Energy collection : thermal collector

Colorcoat Renew SC® / SAB

zonnecollector

Micro-perforation

Max 50% energy reduction in use

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Energy reduction using Composite Floor Decking

Comflor Active® CFD

Low temp heating/cooling

Fast reaction time

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CoretiniumTM

Innovative honeycomb production by Tata Steel

Tata Steels renowned Colorcoat Prisma®

CoretiniumTM

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• High rigidity to weight

• Length up to 10 meters

• Flexible widths (900-1500)

• Surface flatness

• Class B fire rating

• Colorcoat Prisma® + Confidex® guarantee

• Hollow core structure

• High dent resistance

• Efficient material usage

• End of life return to basic steel making

• Fewer supports & longer span

• Unique aesthetics

• Design flexibility

• No bowing or buckling

• Covers most façade applications

• Durability

• Secret fixing

• Robustness

• Recycled content & low CO2 footprint

• Easy recycling (no separation)

Features Advantages

CoretiniumTM: Key panel features and advantages

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Only 1 fixing direction

No individual repair in case of damage

Conventional Fascades

Labyrint-joint Labyrint-joint

Individual fixing of panels

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Kalzip FC –Fascade

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Kalzip FC Fassadensysteem

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Reference Projects

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Reference Projects

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EcoClean™ : surface coating with titanium dioxide (TiO2),

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Self-cleaning effect

Smog (NOx) reduction effect

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Effect titanium dioxide TiO2

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Self Cleaning:

Titanium dioxide reacts with ultravioletlight, generates a photocatalytic reaction

significantly lower maintenance effort and a clean facade for many years

no ugly traces of dirt water from e.g. air vents

Smog (NOx) reduction results from the combustion of fossil fuels, e.g. from cars

purifies the air in immediate proximity to the building surface

Spandrel Areas

Exhaust Ports

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Smog results from the combustion of fossil fuels, e.g. from cars

1000 m² Eco-Clean façade surfaces

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Smog (NOx) reduction

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Reference projects

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Iceberg appartments , (Denmark)

Residential building, (Germany)

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Steel and Sustainability

• Steel Production

• Construction/Building Process

• In Use Phase

• Re-use / Recycling

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Circulaire Economy: Recycling , Downcycling , Upcycling

Keep materials in the cycle (EU: Roadmap Resource efficient EU)

Avoid Downcycling !!

Strive for Up-cycling !!

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End of life Construction (NL)

Building waste NL :

24 mio ton/year

90% concrete /stone

-> noise, dust

-> 2 mio truckloads

Source: eindrapport hoogwaardig hergebruik steenachtige materialen /Agentschap NL 2010

97%

1%

2%

Loss

Downcyling Low grade Fill for Road construction

Concrete Granulate (Downcycling)

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Recycling:LCA steel construction

- Re-cladding

- Flexible walling

- Upgrade Services

Loss:

<1%

Re-use

Steel

Re-use

Building

Same Quality

Beams : 50%

Cladding : 30%

Re-meltHigher Quality

“Upcycling”

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Sustainable Construction : future Offices

Empty offices: 7,1 + 6,1=13,2 mio m2

(27% of market)

No steel framed office empty : Steelstructures are flexible/adaptable ->

renovation or other function possible

Long functional life = low environmental footprint

Steel structure has high residual value (re-use/recycling), they are demontable so low demolishing costs

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Breeam Excellent projects

Lely Maasluis: office + production hall

Lidl Heerenveen: distribution centre

(top sustainability NL)

Nature’s Pride Maasdijk: distribution centre

(top EU )

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Sustainable materials in Infra

Source : Agenschap NL studie 2013

Agentschap NL + RWS: LCA study bridges (2013)

Steel most sustainable

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Content Summary

Tata Steel

Sustainability

LCA + Innovations

Summary & Conclusions

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Trends Construction

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Sustainability is becoming key factor in construction

Innovative Steel/Alu products provides excellent opportunities to improve the sustainability of buildings.

Process developments (Hisarna, etc.) and

Product developments (HSS) reduce “Embodied” environmental impacts

Innovative steel solutions provide energy reduction “in Use”

Steel in construction means : High flexibility /adaptability -> extended building life

Highest re-use of building materials

Closed loop of all steel building materials

No downcycling of building materials, the only material

with option for Up-cycling -> “cradle to cradle”

Steel is the material for a Sustainable future

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Do you have any Questions ?

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Together we make the difference

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