z in c… essen tial for life global market & technology trends
TRANSCRIPT
Zin
c…es
sent
ial f
or li
fe
IZA International Galvanizing Conference and Exhibition
Delhi, India July 10-11, 2014
Global Market & Technology Trends: General Galvanizing
Frank E. Goodwin Sc.D.
Zin
c…es
sent
ial f
or li
fe Market and Technology
Trends 1. Market Trends • Global Scene • Selected Regions
REGION / YEAR 2012 2013 2014 12/11 13/12 14/13 2014 as % of 2007
World 1.412,6 1.453,9 1.500,3 1,2 2,9 3,2 123,0
European Union (27) 140,1 139,5 144,1 -‐9,3 -‐0,5 3,3 71,8
Other Europe 34,7 36,9 38,4 4,1 6,1 4,1 122,0
CIS 56,5 57,6 59,8 3,3 2,0 3,8 106,2
NAFTA 131,2 135,0 139,0 7,8 2,9 3,0 98,1
Central & South America 46,9 49,8 52,0 2,6 6,2 4,3 126,8
Brazil 25,2 26,2 27,2 0,8 4,0 3,8 123,1
Africa 26,6 28,8 31,0 6,8 8,3 7,6 136,8
Middle East 48,9 49,3 52,3 -‐1,2 0,8 6,1 127,7
Asia & Oceania 927,6 957,1 983,8 1,8 3,2 2,8 143,8
Japan 64,0 62,6 62,2 -‐0,2 -‐2,2 -‐0,6 79,8
China 646,2 668,8 685,5 1,9 3,5 2,5 153,4
India 71.6 74.0 78.2 2.6 3.4 5.6 151.8
The basis for growth in the galvanized steel sector is growth of steel consumption
Worldsteel Finished steel apparent consumption, million tonnes
Zinc consumption per capita 2013 Zinc Usage 2013 Population Zinc Usage
1000 tonnes millions annual kg/person
Korea 559 50 11.18 Taiwan 201 23 8.74 Australia 176 23 7.65 China 5748 1365 4.21 EU 28 2000 505 3.96 Japan 498 127 3.92 Turkey 234 76 3.08 USA 935 318 2.94 Thailand 137 64 2.14 Mexico 210 119 1.76 Russia 250 143 1.75 Brazil 276 202 1.37 India 655 1245 0.53 Indonesia 119 247 0.48 Africa 164 1000 0.16 World 12982 7170 1.81
ILZSG, Dept. of Economic and Social Affairs of the United Nations
Zin
c…es
sent
ial f
or li
fe Global Hot Dip Galvanizing
Market Sizes, USD millions
North America $1300
South America $500
Europe, Middle East, Africa $2500
Asia Pacific $2250
R. Cornish, 2014 Intl Zn Conf
Zin
c…es
sent
ial f
or li
fe
North American Trends
Continued economic recovery – public sector economic stimulus for infrastructure LCC part of highway/bridge decisions Competition from paint/powder coatings Growth in parking garage, short span bridge projects
Zin
c…es
sent
ial f
or li
fe Trends in European Markets
Construction sector is now driving growth HDG remains with less than 5% of steel produced The need for HDG is no self-fulfilling promise; patterns of use are changing • More high-strength and special quality steels are being used • Innovation is driving the markets (strength against weight) HDG needs to move with growing segments • Existing clients are looking for complex solutions including
but not limited to logistics not just a corrosion protection; • Automotive and offshore (new) are looking for better
systems
V. Van Alsenoy, GalvaPower
Zin
c…es
sent
ial f
or li
fe
Location of 770 general galvanizing plants showing alignment with
economic zones
85
Bohai
Yangtze
Pearl River
449
236
Zin
c…es
sent
ial f
or li
fe
China Trends • Ultra-High Voltage Transmission Lines – 70 million
tonnes of HDG required for 1000 KV network • High Speed Trains and freight line development – HDG
used for track furniture • Continued urbanization and development of
infrastructure • Steel structures for wind energy
Source: Votorantim Metais analysis.
Die Casting
General Galvanizing
Continuous Galvanizing
Brass / ZnO / Others
Zinc demand per sector:
Growth in Brazilian Zinc Market Sectors
Zin
c…es
sent
ial f
or li
fe
Brazilian Market Trends
Missed opportunities for World Cup/Olympic applications Oil & Gas – work in progress New projects in coastal environments using galvanized rebar, structural steel Conversion of concrete light poles to galvanized
Photo gallery of Brazilian projects
Rio de Janeiro Museum of Art Ibere Camargo Museum, Porto Alegre
Sugar Warehouse, Santos 220 tons steel, 18 tons Zn
India Galvanizing Market Segments
Galvanised Structures 78,500 MT
ConstrucQon – 26%
Infrastructure-‐ 13%
AutomoQve -‐9%
White Goods -‐9%
Packaging -‐4%
Exports – 35%
DistribuQon – 27%
Galvanized Zinc Demand Approx. 4,83,560 MT
Galvanised Sheet 3,14,000 MT
Others – 5%
GI Pipes 55,264MT
Plumbing – 29%
Infra & Constn – 23%
Others – 18%
IrrigaQon – 30%
Galvanized Wires 13,188 MT
Constn & infra – 70%
Exports – 10%
Agriculture – 5%
General Engg. – 15%
Galvalume 11,304MT
ConstrucQon – 90%
Others – 10%
1.8%
Component 11,304 MT
Misc Galvanizing – 100%
Power T&D – 43%
Others – 13%
Exports – 17%
12.5 %
1.8%
2.1%
50 %
8.8%
Zin
c…es
sent
ial f
or li
fe Jawaharlal Nehru National Solar
Mission
Phase 1 goal: 150MW of Solar PV and 500MW of Solar Thermal from base of zero operational thermal solar and 10MW solar PV
Zin
c…es
sent
ial f
or li
fe Market and Technology
Trends 2. Technology Trends
• New Steels for Galvanizing – Lighter, Higher Strength Structures
• K-Joint project results • Galvanized Rebar • Zinc quality (old zinc)
Zin
c…es
sent
ial f
or li
fe
Tem
pera
ture
Ms
Time
A=Ferrite + Pearlite B=Ferrite+Bainite C=Ferrite+Bainite+Martensite
Time-Temperature Transformation (TTT) Diagram for low-alloy strip steels showing results of different cooling rates (A=slowest, C=fastest)
Zin
c…es
sent
ial f
or li
fe
Steel Alloying Domain for 355 MPa Grade using the Controlled Rolling Process
Steel Alloying Domain for 355 MPa Grade using the QST Process
Zin
c…es
sent
ial f
or li
fe
Contrast of Strip, Long and Flat Plate Products and Processes
• Non-Uniformity of Section Thickness for Section Products e.g. Beams
• Heavier Section Thicknesses Require More Intensive Cooling -> Non-Uniformity of Cooling Through the Section – Distortion, Microstructure Issues
• Higher Strengths Require Higher Rolling Forces: Limited Availability
• Holding Times after Quenching for Self-Tempering may be More Significant than Lean Alloy Savings
• Thermomechanical processing alone may not be sufficient to produce sections with strengths above S355 grade
Zin
c…es
sent
ial f
or li
fe Implications for General
Galvanizing
Higher Strength Long Products and Plates can be made by: Alloying (conventional normalized steel grades) Thermo-Mechanical Rolling Quench and Self-Tempering IZA/EGGA Project: There is no evidence that galvanizers will encounter problems processing future steels in the main applications for which general galvanizing is used
Zin
c…es
sent
ial f
or li
fe Developing design recommendations
for K—joints
Vents and position of holes for analysis
Zin
c…es
sent
ial f
or li
fe Buckling in
specimen without vent hole
Buckling in specimen with vent
hole (black and HDG)
Effect of galvanizing on fatigue
In Germany, hot dip galvanized structurals could not be used in bridges until recently because standards only covered non-galvanized details
Simonsen, EGGA 2013
Zin
c…es
sent
ial f
or li
fe Conclusion – HDG now included
in bridge structure specifications
Simonsen, EGGA 2013
Zin
c…es
sent
ial f
or li
fe
• No difference is detected in test results for geometries with and without vent holes. This lack of influence was also observed in the finite element simulation. The welds with the chord are close to the holes, acting as reinforcement. Therefore, the local buckling in the brace does not occur at the location of the hole. • The most common failure mode in the tested joints was local buckling of the brace member that is far enough from the hole to avoid any influence of it. • It is possible to develop design guidance on the size and location of galvanizing holes for tubular lattice girders and similar structures.
Conclusions 1/2
Conclusions
Zin
c…es
sent
ial f
or li
fe
Galvanized Reinforcing Bar For Concrete
Galvanized reinforcing bar (rebar) for concrete structures is increasing in use in Australia, China, Japan and North America
Continuous rebar galvanizing
Deepwater Ocean Outfall, Sydney, Australia
Two products:
Traditional general galvanizing
Zin
c…es
sent
ial f
or li
fe Galvanized rebar used for more than
40 years to give long lives to marine structures
ANDOC North Sea Oil Platform • Caissons are 104 m
x 104 m x 32 m high and consist of 81 cells each 11 m x 11m.
• Cost of galvanizing was only 0.12% of the total project cost.
Zin
c…es
sent
ial f
or li
fe Other galvanized rebar projects
Singapore sewage outfall system, 5 km long into the Straits of Singapore. Each pipe section is 3m in diameter and 8.0m in length and contains 7-8mt of galvanized reinforcing bar.
Boca Chica bridge, Florida Keys, in service since 1972. Cl- levels now 2.5 times higher than required for Fe corrosion
Zin
c…es
sent
ial f
or li
fe
Old vs New Zinc • Oxidation and soil adherence are
superficial phenomena on zinc ingots, affecting ppm levels of gross zinc weight
• Many millions of tonnes of zinc have been recovered from warehouses, ie New Orleans LME warehouse flooded during Hurricane Katrina (2005)
• Superficial washing and drying sufficient to allow full metallic value to be realized
Zin
c…es
sent
ial f
or li
fe International Case Studies
USA Award Winner: Marshall Islands Military Fuel Pier
• Severe tropical marine environment with fuel exposure; 75 year service life required
• 15 ton load capacity – Superstructure, just above water 100% galvanized
• Entire structure pre-assembled on mainland to check fits, then disassembled and transported to island
• Concrete deck with galvanized rebar
Zin
c…es
sent
ial f
or li
fe International Case Studies
USA Award Winner: Gulfstream Park Horse Stalls, Florida
• Open air building <8km from ocean, 380 stalls • Coating required to withstand abrasive horse activities and
various types of equipment hung on it • Able to meet project timeline with no weather delays • Metallic finish blends in well and is aesthetically pleasing. • Galvanizing uses natural, healthy zinc to coat steel, which is
already in the animals’ diets – no chip or flake problems coming from paint
Zin
c…es
sent
ial f
or li
fe International Case Studies
France: Rebuilding of Route A63
• 105 km long toll roadway under a concession contract with a duration of 40 years
• Guard rail and other furniture required to have life time of at least 40 years
• Required 7,500 tons (safety devices, modular construction elements), including 370 km galvanized guard rail
Zin
c…es
sent
ial f
or li
fe International Case Studies
Germany:Handelsleben Bus Station
• Transformed an unorganized space into a transportation hub
• Lightweight, low-cost overhead ring allows light in during day, diffuses light through expanded metal mesh by night
• Prefabricated and assembled only with screws on site • Variety of seating venues also provided • Galvanized to give a long life and attractive appearance
Zin
c…es
sent
ial f
or li
fe International Case Studies
Spain: Small football stadium
• Required to place a stadium within a limited footprint, between the football pitch and the track
• 3.8m wide space accommodates 5 rows of seats • Terrace floor, walls, roof and supports made of galvanized
steel with 240 bolted connections
Zin
c…es
sent
ial f
or li
fe
International Case Studies
UK 2014 Award Winner for Engineering Structure: Biomass Fuel Storage Building • 150m from Irish Sea • 34m high • 1200 tonnes galvanized steel • Holds 65,000 tonnes of wood pellets
• 39° roof pitch simulates angle of repose of biomass piles, creating efficient storage
• Entire frame clad in PVC
Zin
c…es
sent
ial f
or li
fe Improving the competitive
position of HDG
• Closer working with customers (quality, logistics, expertise/design)
• Use of high quality steel – plan for the higher strength grades that are coming
• Development of advantageous national and industrial standards
• Ecopolicies (Life Cycle Policies, Environmental Product Declarations)
• Train qualified personnel in view of increasing requirements, ie IZA Interactive Training Tool