Tata Steel

Bauke Hoekstra Bonnema
General Manager Tata Steel Construction Centre

Sustainable Metal Innovations

Together...
Tata Steel

Content Summary

1

Tata Steel

2

Trends Construction

3

Sustainability

4

LCA + Innovations

5

Summary & ...
Tata Steel

Slide

3

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

Slide

4

Tata Steel is one of Tata’s largest companies
 Tata Steel
 Tata Motors
 Tata Consultancy Services...
Tata Steel

Slide

5
5

Tata Steel Group is globally present

SCANDINAVIA
CIS

WESTERN
EUROPE
NORTH AMERICA

CEE

NML Cana...
Tata Steel

1

Tata Steel

2

Trends Construction

3

Sustainability

4

LCA + Innovations

5

Summary & Conclusions

Slid...
Tata Steel

Slide

7

Global mega-trends

Growing
Population

Urbanization

Climate
change

Accelerating
technology
Tata Steel

Slide

8

Distribution of Urban Population

>10 mio

>10 mio
5-10 mio

5-10 mio
1-5 mio
<0,5 mio

<0,5 mio

1-...
Tata Steel

Slide 9
Tata Steel

Content Summary

1

Tata Steel

2

Trends Construction

3

Sustainability

4

LCA + Innovations

5

Summary & ...
Tata Steel

Slide

Danica May Camacho
2011: 7000000000

2025: 8000000000

11
Tata Steel

Slide

12

Challences Sustainable Development
World energy outlook 2010
EIA, International Energy Statistics d...
Tata Steel

Content Summary

1

Tata Steel

2

Trends Construction

3

Sustainability

4

LCA + Innovations

5

Summary & ...
Tata Steel

Steel and Sustainability

•

Steel Production

•

Construction/Building Process

•

In Use Phase

•

Re-use / ...
Tata Steel

Slide

15

Steelproduction : ULCOS -> Hisarna project
Blast Furnace

Iron ore

Sinter and
Pellet
Cokes
HIsarna...
Tata Steel

Steel and Sustainability

•

Steel Production

•

Construction/Building Process

•

In Use Phase

•

Re-use / ...
Tata Steel

Slide

17

High Strength Steel developments

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

Slide

18

High Strength Steel
Steel strength development : S200 -> S355 -> S460

18
Tata Steel

Construction Phase: lightweight
 Newbuild:
Weight conventional: 1200 kg/m2
(vs Residential loads : 70 kg/m2 !...
Tata Steel

Slide

20

Construction Phase: lightweight
 Renovation :
-> Option upgrade insulation

20
Tata Steel

Steel and Sustainability

•

Steel Production

•

Construction/Building Process

•

In Use Phase

•

Re-use / ...
Tata Steel

Slide

23

Energy collection : Steel cladding + PV

2020: EPBD: Zero Energy Buildings
Building Integrated PV:
...
Tata Steel

Energy collection : thermal collector
Colorcoat Renew SC® / SAB
zonnecollector
 Micro-perforation
 Max 50% e...
Tata Steel

Slide

26

Energy reduction using Composite Floor Decking

Comflor Active®
 CFD
 Low temp heating/cooling
 ...
Slide 27

Tata Steel

CoretiniumTM
Innovative honeycomb
production by Tata Steel

Tata Steels renowned
Colorcoat Prisma®

...
Tata Steel

Slide

CoretiniumTM: Key panel features and advantages
Features
•
•
•
•
•
•
•
•
•
•

Advantages

High rigidity...
Tata Steel

Conventional Fascades

Labyrint-joint

Slide

Kalzip FC –Fascade

Labyrint-joint

Only 1 fixing direction
No i...
Tata Steel

Kalzip FC Fassadensysteem

Slide

30
Tata Steel

Reference Projects

Slide 31
Tata Steel

Reference Projects

Slide

32
Tata Steel

Slide

33

EcoClean™ : surface coating with titanium dioxide (TiO2),
 Self-cleaning effect

 Smog (NOx) redu...
Tata Steel

Slide

34

Effect titanium dioxide TiO2
Self Cleaning:
 Titanium dioxide reacts with ultraviolet
light, gener...
Tata Steel

Slide

35

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

1000 m² Eco-...
Tata Steel

Slide

36

Reference projects

Iceberg appartments ,
(Denmark)

Residential
building,
(Germany)

36
Tata Steel

Steel and Sustainability

•

Steel Production

•

Construction/Building Process

•

In Use Phase

•

Re-use / ...
Tata Steel

Circulaire Economy: Recycling , Downcycling , Upcycling
 Keep materials in the cycle (EU:
Roadmap Resource ef...
Tata Steel

Slide

39

End of life Construction (NL)
Building waste NL :


24 mio ton/year



90% concrete /stone

-> no...
Tata Steel

Slide

40

Recycling:LCA steel construction

Re-use
Building
Re-use
Steel

- Re-cladding
- Flexible walling
- ...
Tata Steel

Sustainable Construction : future Offices
Empty offices: 7,1 + 6,1=13,2 mio m2
(27% of market)

No steel frame...
Tata Steel

Breeam Excellent projects
Lely Maasluis: office + production hall

Lidl Heerenveen: distribution centre
(top s...
Tata Steel

Sustainable materials in Infra
 Agentschap NL + RWS: LCA
study bridges (2013)

 Steel most sustainable

Sour...
Tata Steel

Content Summary

1

Tata Steel

2

Trends Construction

3

Sustainability

4

LCA + Innovations

5

Summary & ...
Tata Steel



Sustainability is becoming key factor in construction



Slide 46

Innovative Steel/Alu products provides ...
Tata Steel

Do you have any Questions ?

Slide 47
Tata Steel

Together we make the difference

Slide 48
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B&i2013 donderdag 14.15_zaal_d_sustainable metal innovations final

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  • This is Danica , 7 th billion inhabitant of the earth
    Girl born in Philipines Manila 2 weeks ago
    Looks worried
  • There is a huge challenge
    the increasing population, puts enormous strain on the planets capabilities . In 2050 , 9 billion will be living on this planet.
  • Een belangrijke stap van de staalindustrie om de mondiale doelstelling van 50% CO2 reductie in 2050 te bewerkstellen is het ULCOS project.
    UCOS staat voor : Ultra Low Carbon Steelmaking. Een belangrijk project binnen ULCOS is het Hisarna project.
    In dit revolutionaire staalproces worden ijzererts en kolen, direct in een oven geinjecteerd, waardoor 2 processtappen worden overgeslagen en een CO2 reductie van 20% optreedt.
    In combinatie met opslag van CO2 (Carbon Capture en Storage) zijn CO2 reducties tot 80% mogelijk.
    Later in het programma wordt uitgebreid op dit Hisarna proces ingegaan.
  • The race to minimise embodied energy and associated CO2 emissions doesn’t necessarily mean switching to different materials, but it is often about using materials more intelligently. For example, the use of composite floor decking, combining steel structure, steel decking and concrete flooring, reduces the need for concrete in buildings and already reduces the embodied energy. On top of this, using the latest high strength steel can reduce the amount of steel used in the decking by up to 16% - and that means 16% lower embodied energy, 16% less use of precious raw materials and 16% lower CO2 emissions. And a lighter floor means even more savings can be made in the structural design as well, so total savings in embodied energy and CO2 can be even higher.
    [ the buildings shown are: LEFT - the Bur Khalifa Tower in Dubai, the world’s tallest building, which used Tata Steel Comflor 80 for the upper stories. The use of high-strength Galvatite S450GD+Z allowed increased spans and reduced structural steelwork in this region of the building; RIGHT – the Shard in London, the tallest building in Western Europe, which again uses our high strength steel in the floor decking, reducing the steel demand, reducing overall weight and increasing material efficiency]
  • Innovaties in Hoge Sterkte Stalen geven niet alleen in de automotive besparingen maar ook in de bouw:
    In 1890 had het staal dat gebruikt werd voor de bouw van de Eiffeltoren een sterkte van 200 Mpa.
    Door de ontwikkeling van hoge sterkte stalen zoals S460 en S690 zou dezelfde constructie thans ruim 40% lichter uitgevoerd kunnen worden, ofwel met dezelfde hoeveelheid staal kan ik nu 3 Eiffeltorens bouwen.
    Lichtere constructies geven een lagere CO2 footprint en milieukosten.
    Ook in de carrosserie van de nieuwe Landrover zijn hoge sterkte stalen verwerkt , dit leidt niet alleen tot materiaal besparing maar tevens milieu besparing door een lager brandstofverbruik.
    Gaarne nodig ik u uit de hoge sterkte aan den lijve te ondervinden tijdens de Landrover Experience die plaats vindt naast deze hal.
  • In de bouwfase betekent het lage gewicht van staal niet alleen lagere funderingskosten en CO2 footprint , maar eveneens een significante reductie van transport en dus verkeer op de weg.
    Het lage gewicht maakt het ook mogelijk om bestaande gebouwen te upgraden door het “optoppen” met een extra verdieping op bestaande bouw of toevoegen van extra balkons.
    Ook is het mogelijk om de gebouwschil thermisch te verbeteren door toevoeging van een stalen gevel.
  • In de bouwfase betekent het lage gewicht van staal niet alleen lagere funderingskosten en CO2 footprint , maar eveneens een significante reductie van transport en dus verkeer op de weg.
    Het lage gewicht maakt het ook mogelijk om bestaande gebouwen te upgraden door het “optoppen” met een extra verdieping op bestaande bouw of toevoegen van extra balkons.
    Ook is het mogelijk om de gebouwschil thermisch te verbeteren door toevoeging van een stalen gevel.
  • Naast windmolens en PV zijn er talrijke voorbeelden van staaltoepassingen die CO2 reduceren.
    Een recente studie van Boston Consulting Group laat zien dat door toepassing van staal,bv HSS in autos, efficientere motoren etc. reeds 1/3 van zijn klimaatdoelstellingen 2020 van Duitsland te halen is De 12mio ton CO2 nodig voor de productie van staal wordt ruimschoots gecompenseerd door de besparing in de gebruisfase van maar liefst 74 mio ton CO2
  • Steel roofing and facades can be used as carrier for PV cells generating electrical energy.
    PV foils can be laminated in steel facades and crystaline PV can be adhered cost effective to steel roofing.
  • If we look at Operational or “In use” energy consumption in buildings, steel cladding has excellent capabilities to provide significant energy reductions.
    The Colorcoat Renew Solar Collector, is a double skin facade, which is micro-perforated at the ouside.
    The thermal energy generated by the sun is used to heat the inside of a building , resulting in significant energy reductions.
  • Low temperature heating and cooling solutions are becoming the standard in low energy heating technology.
    Due to its large surface, Comflor Active steel composite floor decking provides, an excellent option to emit low temperature heat and cooling, again a solution to reduce energy “In use”.
  • Belangrijk is onderscheid te maken tussen
    Recycling : materiaal houdt zijn eigenschappen
    Upcycling : materiaal eigenschappen worden verbeterd
    Downcycling : materiaal eigenschappen verslechteren tijdens recycling.
    Om grondstiffen in de circulaire economie te behouden moet downcycling worden vermeden.
  • Hoe anders is de praktijk: in Ned ontstaat er jaarlijks maar liefst 24 mio ton Bouwafval .
    Dit bouwafval bestaat voor 90% uit beton en steen.
    Maarliefst 97% hiervan wordt gedowncycled naar een laagwaardige toepassing als vulmateriaal onder wegen. !!!!!
    Slechts 2 % wordt gebruikt als betongranulaat en ook dit is downcycling immers het hoogwaardige onderdeel van beton , het cement kan niet worden terug gewonnen. Dus hoogwaardig beton /steen wordt laagwaardig puin/grind.
    Daarnaast geeft de sloop van steenachtige materialen/beton een enorme overlast op gebied van stof en geluid. En zijn maar liefts 2 mio vrachtautoritten nodig om het sloopafval af te voeren.!
  • Op recycling gebied is staal bij uitstek een &quot;Cradle to Cradle &quot; materiaal :
    Doordat staalconstructies flexibel zijn is de aanpasbaarheid makkelijk, dus geen leegstand door incourante gebouwen.
    De constructie is demontabel dus staal elementen kunnen worden hergebruikt.
    Maar liefst 50% van de balken en 30% van de bekleding wordt al hergebruikt in Nederland.
    Hiermee heeft staal het hoogste hergebruik van alle bouwmaterialen, en realiseert hiermee een grote energiebesparing.
    Tot slot recycling.
    Niet alleen kan Staal 1:1 worden gerecycled, maar door een warmtebehandeling in de staalfabriek kan staal een hogere kwaliteit worden gegeven.
    Dit noemen we Upcyclen en ook dit is uniek voor staal.
  • De duurzaamheids eigenschappen van staal worden gedemonstreerd door recente Breeam Excellent projecten als het nieuwe kantoor en productiehal van Lely, uitgevoerd in Colorcoat Prisma
  • The Tatas were the first employers to introduce the 8-hour working day (1912), free medical aid (1915), workers’ provident fund scheme (1920) and many other welfare schemes even before they were introduced in the West.
    The “employee association with management” programme initiated in 1956 gave the workers a stronger voice in the affairs of the Company.
    The Social Welfare Scheme was formed in 1916 with the purpose of providing assistance to the surrounding areas in the field of education, vocational training, cultural programmes, self-employment and family welfare. The Joint Committee for Adivasi Affairs and the Tata Steel Rural Development Society jointly supported this multi-million project.
    Hence, the story that began in a zest of adventure expanded into an ever-evolving saga of continuous adventure and excitement. Having started out the hard way, at a time when India had no industrial base, self-reliance has become a way of life with Tatas. The humane dialogue initiated by Jamsetji Tata fostered an attitude of mutual trust and concern, which characterizes Tata relationships even today.
    The story of Tata’s achievements is a collective effort of people who sank differences of caste, creed, race and status to strive for a common goal- excellence. They offered their best as an expression of a sense of belonging, a sense of commitment to the family of which they were a part- the Tatas.
    Hoogovens IJmuiden :
    Huisvesting personeel jaren 60 etc
  • In conclusion :Sustainability is increasingly important and is here to stay.
    Steel provides excellent opportunities to increase the environmental footprint through the total life of a building:
    Breakthrough technologies like Hisarna and HSS reduce the embodied impact of steel.
    Furthermore Innovative steel concepts to collect solar energy and active CFD greatly reduce energy in use.
    The high flexibility and adaptability of steelstructures ensure a extended service life of a building , again reducing the environmental footprint.
    Demountability of steel components enables the highest re-use amongst all building materials.
    And finally steel is the only construction material which can be upcycled and therefor a excellent example of a true cradle to cradle material. So in our opinion steel is the material for a sustainable future .
  • B&i2013 donderdag 14.15_zaal_d_sustainable metal innovations final

    1. 1. Tata Steel Bauke Hoekstra Bonnema General Manager Tata Steel Construction Centre Sustainable Metal Innovations Together we make the difference Slide 1
    2. 2. Tata Steel Content Summary 1 Tata Steel 2 Trends Construction 3 Sustainability 4 LCA + Innovations 5 Summary & Conclusions Slide 2
    3. 3. Tata Steel Slide 3 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 3
    4. 4. Tata Steel Slide 4 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 4
    5. 5. Tata Steel Slide 5 5 Tata Steel Group is globally present SCANDINAVIA CIS WESTERN EUROPE NORTH AMERICA CEE NML Canada (iron ore) CHINA TURKEY Odessa WESTERN AFRICA LATIN AFRICA Ivory coast (iron ore) Oman INDIA (limestone) Mozambique (coal) SOUTH AFRICA Steel making operations Mining assets & projects Distribution and commercial centres including downstream assets JAPAN SE ASIA Australia (coal)
    6. 6. Tata Steel 1 Tata Steel 2 Trends Construction 3 Sustainability 4 LCA + Innovations 5 Summary & Conclusions Slide 6
    7. 7. Tata Steel Slide 7 Global mega-trends Growing Population Urbanization Climate change Accelerating technology
    8. 8. Tata Steel Slide 8 Distribution of Urban Population >10 mio >10 mio 5-10 mio 5-10 mio 1-5 mio <0,5 mio <0,5 mio 1-5 mio 0,5-1 mio 5-10 mio Mega Cities (>10 mio) >50% population in urban areas Source : FutureSteel Conference -Worldsteel
    9. 9. Tata Steel Slide 9
    10. 10. Tata Steel Content Summary 1 Tata Steel 2 Trends Construction 3 Sustainability 4 LCA + Innovations 5 Summary & Conclusions Slide 10
    11. 11. Tata Steel Slide Danica May Camacho 2011: 7000000000 2025: 8000000000 11
    12. 12. Tata Steel Slide 12 Challences Sustainable Development World energy outlook 2010 EIA, International Energy Statistics database 1950 – 2.5 billion 2011 – 7 billion 2050 – 9 billion 12
    13. 13. Tata Steel Content Summary 1 Tata Steel 2 Trends Construction 3 Sustainability 4 LCA + Innovations 5 Summary & Conclusions Slide 13
    14. 14. Tata Steel Steel and Sustainability • Steel Production • Construction/Building Process • In Use Phase • Re-use / Recycling Slide 14
    15. 15. Tata Steel Slide 15 Steelproduction : ULCOS -> Hisarna project Blast Furnace Iron ore Sinter and Pellet Cokes HIsarna Liquid iron Coal 20% CO2 reduction 80% CO2 reduction in combination with CCS 15
    16. 16. Tata Steel Steel and Sustainability • Steel Production • Construction/Building Process • In Use Phase • Re-use / Recycling Slide 16
    17. 17. Tata Steel Slide 17 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 17
    18. 18. Tata Steel Slide 18 High Strength Steel Steel strength development : S200 -> S355 -> S460 18
    19. 19. Tata Steel 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 Slide 19
    20. 20. Tata Steel Slide 20 Construction Phase: lightweight  Renovation : -> Option upgrade insulation 20
    21. 21. Tata Steel Steel and Sustainability • Steel Production • Construction/Building Process • In Use Phase • Re-use / Recycling Slide 21
    22. 22. Tata Steel Slide 23 Energy collection : Steel cladding + PV 2020: EPBD: Zero Energy Buildings Building Integrated PV: Option energy-neutral  Tata Steel AluPlusSolar  Tata Steel Prisma + Sollbond 23
    23. 23. Tata Steel Energy collection : thermal collector Colorcoat Renew SC® / SAB zonnecollector  Micro-perforation  Max 50% energy reduction in use Slide 24
    24. 24. Tata Steel Slide 26 Energy reduction using Composite Floor Decking Comflor Active®  CFD  Low temp heating/cooling  Fast reaction time 26
    25. 25. Slide 27 Tata Steel CoretiniumTM Innovative honeycomb production by Tata Steel Tata Steels renowned Colorcoat Prisma® CoretiniumTM 0.4mm coated steel Polypropylene honeycomb core 0.4mm coated steel
    26. 26. Tata Steel Slide CoretiniumTM: Key panel features and advantages Features • • • • • • • • • • Advantages 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 • • • • • • Fewer supports & longer span Unique aesthetics Design flexibility No bowing or buckling Covers most façade applications Durability • • • End of life return to basic steel making • Secret fixing Robustness Recycled content & low CO2 footprint Easy recycling (no separation) 28
    27. 27. Tata Steel Conventional Fascades Labyrint-joint Slide Kalzip FC –Fascade Labyrint-joint Only 1 fixing direction No individual repair in case of damage Individual fixing of panels 29
    28. 28. Tata Steel Kalzip FC Fassadensysteem Slide 30
    29. 29. Tata Steel Reference Projects Slide 31
    30. 30. Tata Steel Reference Projects Slide 32
    31. 31. Tata Steel Slide 33 EcoClean™ : surface coating with titanium dioxide (TiO2),  Self-cleaning effect  Smog (NOx) reduction effect 33
    32. 32. Tata Steel Slide 34 Effect titanium dioxide TiO2 Self Cleaning:  Titanium dioxide reacts with ultraviolet light, generates a photocatalytic reaction  significantly lower maintenance effort and a clean facade for many years Spandrel Areas  no ugly traces of dirt water from e.g. air vents Smog (NOx) reduction Exhaust Ports  results from the combustion of fossil fuels, e.g. from cars  purifies the air in immediate proximity to the building surface 34
    33. 33. Tata Steel Slide 35 Smog (NOx) reduction Smog results from the combustion of fossil fuels, e.g. from cars 1000 m² Eco-Clean façade surfaces 35
    34. 34. Tata Steel Slide 36 Reference projects Iceberg appartments , (Denmark) Residential building, (Germany) 36
    35. 35. Tata Steel Steel and Sustainability • Steel Production • Construction/Building Process • In Use Phase • Re-use / Recycling Slide 37
    36. 36. Tata Steel Circulaire Economy: Recycling , Downcycling , Upcycling  Keep materials in the cycle (EU: Roadmap Resource efficient EU)  Avoid Downcycling !!  Strive for Up-cycling !! Slide 38
    37. 37. Tata Steel Slide 39 End of life Construction (NL) Building waste NL :  24 mio ton/year  90% concrete /stone -> noise, dust -> 2 mio truckloads 97% Downcyling Low grade Fill for Road construction 2% Loss 1% Concrete Granulate (Downcycling) Source: eindrapport hoogwaardig hergebruik steenachtige materialen /Agentschap NL 2010
    38. 38. Tata Steel Slide 40 Recycling:LCA steel construction Re-use Building Re-use Steel - Re-cladding - Flexible walling - Upgrade Services Beams : 50% Cladding : 30% Loss: Same Quality <1% Re-melt Higher Quality “Upcycling”
    39. 39. Tata Steel 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 (reuse/recycling), they are demontable so low demolishing costs Slide 41
    40. 40. Tata Steel Breeam Excellent projects Lely Maasluis: office + production hall Lidl Heerenveen: distribution centre (top sustainability NL) Nature’s Pride Maasdijk: distribution centre (top EU ) Slide 42
    41. 41. Tata Steel Sustainable materials in Infra  Agentschap NL + RWS: LCA study bridges (2013)  Steel most sustainable Source : Agenschap NL studie 2013 Slide 43
    42. 42. Tata Steel Content Summary 1 Tata Steel 2 Trends Construction 3 Sustainability 4 LCA + Innovations 5 Summary & Conclusions Slide 45
    43. 43. Tata Steel  Sustainability is becoming key factor in construction  Slide 46 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
    44. 44. Tata Steel Do you have any Questions ? Slide 47
    45. 45. Tata Steel Together we make the difference Slide 48
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