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

Apparent Finished Steel Usage – World Rankings

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

R. Cornish, 2014 Intl Zn Conf

Aa

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

EGGA

Aa

Zin

c…es

sent

ial f

or li

fe

Trends in European Markets

EGGA

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

Aa

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

Aa

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

Aa

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%  

Aa

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 Developments in High Strength

Long Products and Plate

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)

Effect of Alloying in Advanced High Strength Steels on TTT characteristics

Zin

c…es

sent

ial f

or li

fe The QST Process Applied to

Beams

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 Solid model of the test frame

configuration for brace angles of 45⁰

Zin

c…es

sent

ial f

or li

fe Detail of pin ended members

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

Work quantified the effect of HDG on fatigue strength

Simonsen, EGGA 2013

Both small and large scale tests were conducted

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