ArcelorMittal Global R&D capabilities for innovation in ... · ArcelorMittal steel cladding...

ArcelorMittal Global R&D capabilities for innovation in steel

building envelope

From performance qualification to digitalization

Frédéric Delcuve

Unit Manager, AC&CS – CRM GROUP

European Association for Panels and Profiles

19 October 2017

• 1,300 full time researchers - 2016 spending of $239m

• R&D operates as a global player transversally over the complete value

chain from mining to finished products in 3 main areas:• Process

• Products

• Applications and Steel Solutions

• Worldwide network of laboratories: 12 labs in Europe and Americas

• Main construction Labs: CRM (Flat), ESCH (Long), Maizières (Sustain.)

Product research (%)

Global R&D

Key Figures

0

10

20

30

40

50

60

Au

tom

oti

ve

Pla

tes

, T

ub

es

&

HR

fo

r E

ne

rgy

Ge

ne

ral In

du

str

y*

Co

ns

tru

cti

on

Oth

er

*Packaging, appliance, metal processing, electrical steels

Budget spending by focus area

Process

38%

Exploratory

6%

Product

& Application

56%

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12 research centres and at

customer locations on 3 continents…

Canada

Hamilton

USA

East Chicago

France

Gandrange

Le Creusot

Maizières

Montataire

Spain

Avilés

Basque Country

Luxembourg

Esch-sur-Alzette

Belgium

Gent

Liège

Czech

Republic

Ostrava

Brasil

Jardim Limoeiro

Construction

oriented

R&D for Construction

Overview

• Long Carbon Sections Steel and

Construction components /systems

– Fire resistant designs

– Earthquake resistance

– Composite construction

– Bridges

– Floor systems…

• Civil Engineering components & Systems

– Wind tower steel concepts

– Solar systems (HSS & Magnelis®)

– Road equipment's (HSS & Magnelis®)

– Infrastructures

• Flat Carbon Steels Steel Products

– High strength steels (HSS)

– Metallic coatings (Magnelis®)

– Organic coatings (Granite®)

– Functional coatings

– Smart coatings (PV, OLED…)

• Building components & systems

– Roofing solutions

– Façade systems

– Floor systems

– Sandwich panels

– Building retrofit …

– Light steel framing Structure

• Sustainability in construction Environmental assessment tools – LCA

• Total Cost of Ownership Assessment tools - Life Cycle Cost R&D

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Main market trends that need to be tackled

in our R&D projects portfolio• Need for lower construction costs

• Integrated modeling – Digitalisation

BIM is IN

• Higher & long lasting performances

Real Performance is a real issue

• Need for faster speed for construction (from design to turn-key)

Quicker, nicer, dryer, smaller impact

• Resource efficiency, e.g. energy and

sustainability along the life cycle

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• Need for lower construction costs

• Need for faster speed for construction (from

design to turn-key)




Mind the Gap


BIM is IN

© ArcelorMittal – All rights reserved for all countriesCannot be disclosed, used, or reproduced without prior written specific authorization of ArcelorMittalCONFIDENTIAL – Privileged Information - ArcelorMittal proprietary information

6

Office Building Case Study

Background—Study Drivers

• Highlight recent innovations in steel solutions and systems for safe and sustainable construction focusing on resource efficiency

• Demonstrate the benefits of high added-value (HAV) steel solutions to all players in the construction chain—considering economic, environmental, and social perspectives


7


Background—Study Methodology

• Assess quantitatively and explicitly the impacts of various material solutions on full building performance

• Compare a set of 17 indicators for equivalent-building performance between:

– Best-in-class steel solutions

– State-of-the-art traditional solutions

• Solicit peer review by independent experts, to ensure the neutrality

of the assessment

• Maintain a robust, holistic, multi-criteria approach to the data


8


Background—Assessment Methodology

• The SiMCo study performance assessment methodology quantifies the impacts and aspects of building performance with respect to three impacts:

– Economic

– Environmental

– Social

• The assessment methodology uses both quantitative and qualitative indicators.


9

Environmental Impact

Environmental footprint and related metrics

Social Impact

Societal acceptance and human well-being

Economic Impact

Building costs and value metrics

Life-cycle costing, before-use stage

Life-cycle costing, use to recycling

Speed of construction

Energy efficiency

Renewable energy

Consumption of natural resources

Harmful emissions

End-of-life, life-cycle analysis (LCA)

Indoor visual comfort

Thermal comfort

Indoor air quality

Acoustical comfort

Structural robustness

Architectural quality

Design for flexibility

Safety/nuisance of site construction process


Background—Assessment Indicators


10

Geometrical and layout definition

Building length [m] 13,60

Superstructure number of levels R+8

Infrastructure number of levels 2

Free height at ground floor [cm] 350

Free height at intermediate floors [cm] 270

Free height at infrastructure floors [cm] 240

Floor area excluding external walls [m²] 1728

Building characteristics

Location of the building Luxembourg

Type of the building Office

Number of occupants 1036

LCA - Life cycle assessment assumptions

Service life [years] 50

Considered boundary Environment

LCC - Life cycle cost assumptions

Service life [years] 30

Considered boundary Building owner

Dynamic thermal analyses assumptions

Climate Luxembourg average climate

Walls and materials Luxembourg EPB

Structure and Inertia Taking into account all the mass in the

open spaces and in the ceiling


Background—Typical 2020 Building


11

Based on the most representative system on the market

8.1m

Structure Floor Façade

Concrete

Option

Prefab concrete

structure

8 m + 5 m span

Pre-stressed hollow

slabs 20 cm + 5 cm

8.1 m span

Lightweight with solar

shading


Background—Baseline Scenario


12


Background—Constructive Options

[3B] Steel composite floor

AngelinaTM (13m span)

[3A] Steel CoSFB (8m+5m /

8,1m span)

[2B] Steel Pre-slab (13m /

4,05m span)

[2A] Steel SFB (8+5 / 8,1m

span)

[1B] Prefabricated concrete

(13m) Hollow core

[1A] Prefabricated concrete

(8m+5m) Hollow core

Concrete slab with

sloping shape Composite floor deck

with sloping shape Steck deck

Plasterboard partition Dismountable partitions,

Opaque

Dismountable partitions,

Half glazed

Dismountable partitions,

Fully glazed

Stone wool tile Acoustic stone wool tile Metallic tiles 41 db

Water pipes Ventilation ducts Cable trays

Systems

Constructive Options Considered

Structure

Façade

Roofing

Internal

Partitions

Ceiling

Access floors

Activated ceiling

Steel sandwich panel

with steel cassette 15/10

Façade F4 with alu.

cassette 20/10 25µ

Solar shading -

Horizontal Brise soleil


13

Using Best-in-Class steel solutions

Structure Floor Façade Interior

High Strength Steel

S460

cellular beam

Compact composite

floor

Steel Hook-on cassette

Advanced pre-paint coating

ZM coating sub structure

construction with solar

shading

Biosourced organic

coating

ZM coating for ducts and

cable trays


Background—Optimised Scenario

Structure Floor Façade 1 Façade 2

Steel option

Steel structure S460 -

Angelina Beam

each 2.7m

span 13m

Cofraplus 60 2.7m span

ArcelorMittal Construction

Globalwall system

IN235 Doublage

K7 Coque MD

Curtain Wall


14

ArcelorMittal

best-in-class

solutions provide

added value

at

competitive cost


Results

Compactness

Flexibility

Weight

Environmental

impact

Speed of

construction Site

traffic

Comfort

Design

BREEAM

LEED

rating

Savings for

façade, stairs,

and core Easy reconfiguration

of office space;

increased rental value

Savings for

building foundations

Sales and rental

premiums

Savings at the

construction site

Easing program

logistics and

decreasing nuisances

Improved level

of comfort

3D creativity,

unique textures

and colors

Higher

sustainability

score

Cost

Lower

life-cycle cost


15

CompactnessDue to cellular beams and composite compact floor, the building height is greatly reduced, resulting in

11% cost savings for the façade, stairs, and core.

Flexibility Cellular long span (13 m) without intermediate column is competitive with the concrete short span,

allowing easy reconfiguration of office space and increasing rental value.

Weight Best-in-class steel solution is 50% lighter than the concrete baseline, resulting in (at least) 39% cost

savings for building foundations.

Environmental

impact Best-in-class steel solution lowers the environmental impact by 16% compared to the baseline, leading

to sales and rental benefits.

Speed of

constructionBest-in-class steel solution in 13 m span can be erected up to twice as fast as the concrete benchmark

(8 m + 5m spans), resulting in 24% cost savings for construction site.

Site traffic Best-in-class steel solution reduces transportation needs by 34% compared to prefabricated concrete

components, easing program logistics and decreasing nuisances, especially in dense urban areas.

Comfort Best-in-class steel solution helps to optimize thermal behavior, thereby allowing improved levels of

comfort inside the office during summer.

Design ArcelorMittal steel cladding solutions provide 3D creativity, unique textures, and colors to the façade

design at a competitive price compared to baseline.

BREEAM RatingBREEAM building rating awards best-in-class steel solutions three (3) more credits than the concrete

baseline, thereby facilitating a higher sustainability score.

CostOverall life-cycle construction cost for the office building is reduced by at least 7% per building unit and

Total Cost of Ownership generates at least 20% added value relative to the baseline.


Results – Key Learning

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design to turn-key)




Mind the Gap


BIM is IN

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ArcelorMittal - Research & DevelopmentConfidential

Higher & long lasting performances

Mind the Gap

Bad workmanship

Bad / No Design

Airflow - The biggest uncertainty

• Real performance of buildings will become all the more critical.

• The whole building industry must get much better at understanding it, communicating about

it, educating people about it and developing solutions that really work

• Cooperation across the whole building chain and with academics will be crucial, but the

benefits for everyone are clear

In short: We must become better at building what we say we build.

Performance gap for dwellings in UK study (*)

(*) Sources – Bell et. al., Wingfield et. al. (2010), Wingfield et. al. (2009),

Wingfield et. al. (2008), Stevenson and Rijal (2008)

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• Qualification of 2D interfaces and junctions of

steel solutions

• 2D-lab-testing is usually used to assess

airtightness of various types of joints and fixing

elements.

• All sealing strategies can be investigated

according to their influence of porosity and

compression ratio measures.

• Dimension of the test sample 1.3 x 1.3 m

• Full 3D measurement

• Qualification of 1D to 3D interfaces and

junctions of steel elements

• Dimension of the test sample up to 2.4 x 2.4 m

Airtightness : 2D test bench

Airtightness : 3D test bench

Real and Long Lasting Performance


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2mm 3mm 4mm 5mm 6mm



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loose, permeable

Air-tight



These tests focus on:

• the airtightness of longitudinal and transversal joints with different sealing products and

materials (e.g. PUR, EPDM),

• the influence of product geometrical tolerances (compression difference) on airtightness,

• the influence of fixing elements (screws, rivets...) on airtightness,

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• Existing 2D test rigs are limited to testing joints and

fixings of sandwich panels.

• The development of airtightness test equipment in 3D

gives the option to measure air leakages of more

complex interfaces.



HAIR: Improved Durability of Steel Sandwich Panel

Constructions regarding Hygrothermal and AIRtightness.

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design to turn-key)




Mind the Gap


BIM is IN

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Shaping the Future of Construction

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A new smart construction process

Building Information Modeling (BIM) can be best described as “The shared use of

structured data” within the design, construction (or retrofit),

operations/maintenance and deconstruction of a building.

24 16/11/2017

FDE

A BIM consists of two major components:

– A 3D graphical reproduction of the geometry

– A related database in which all data, properties, interconnections

performances, functions are stored

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BIM is an opportunity for building manufacturers …

If we can deliver the correct level of detail, our product(s) have more of

an opportunity to be incorporated into the building’s specification at an

early stage.

Providing BIM Objects will allow us to:

Improve supply chain relationships with architects and specifiers

Engage earlier and easier within project

Differentiate and strengthen our product offering

Protect our specifications and avoid our solutions from being switched

for competitors’ alternatives

Ensure future specification compatibility: avoid planning mistakes and

complaints due to wrong application

Increase repeat specifications and become the supplier of choice

Why do we need to provide BIM Objects?

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Limitations of BIM?

Obstacles for BIM acceptance

More works and expertise at risk earlier in the project

High set up cost (expensive software and tools, training time

associated with implementing tools)

Issues linked to copyright, ownership and liability

Unclear roles, proprietary information issues

“BIM commodization” - just one set of numbers among many

competing offerings in digitized catalogue of materials

Accessibility to SME’s. SME’s have fewer chances to get BIM right

… but it is also a threat.

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27

LoD Representation Level of representation

1 Wall as a line

2 Wall as a simple volume

3 Wall as a simple volume with composition

3 Bis Wall as x independant layers

4Wall as a decomposition of x sub elements

(nearly as built)

5 Wall as objects as built

LoD = Level of Detail

A key issue

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How suppliers can contribute ?

The content is key

• Object libraries that can be used by designers

• What information does the BIM object needs to include for the specifier ?

ArcelorMittal Construction : Sandwich panel example

2D Constructive typical details

Coating database “colorissime”Descriptions

Material and geometrical caracteristics

Physical, thermal and acoustical properties

Certificates, warranties...

Commercial information

Availabilities

Standards

3D representation

Shape, outlines

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Image and Appearance

Texture, pattern, rendering• When relevant, material producers need to deliver texture / rendering / pattern

database in order to differentiate from commodities

• Material databases need to be compatible with specific rendering softwares

• Photorealistic rendering of the

ArcelorMittal Construction

organic coated finishes for

building envelope.

• Available for designers and

engineers by using their 3D

software without any additional

equipment and software.

From physical samples,

Make pictures in specific chamber,

Set up texture, reflection map, bumping map, shining map,

Set up coating material library,

Allow photorealistic rendering using specific software i.e. VRay

Creation of digital material for rendering includes:

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• Go on BIMObject website

• Download objects and format at disposal on BIMObject website

• Replace generic envelope components with specific BIM object

• Use in-built rendering engine (i.e Revit render) or specific rendering tools

(i.e VRay)

• Select the rendering from the coating digital offer and attach to the external

leaf of the wall component

How to specify components and coatings in

generic BIM model?

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• ArcelorMittal BIM Objects can be used by Architects and Engineers

directly for projects specification

• Example with Vray for Revit: IRYSA®, iridescent colors by Arval

Image and Appearance

Texture, pattern, rendering

© A

rcelo

rMitta

l2014 –

All

rights

reserv

ed f

or

all

countr

ies

Cannot

be d

isclo

sed,

used,

or

repro

duced w

ithout

prior

written s

pecific

auth

orization o

f A

rcelo

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FID

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Privile

ged Info

rmation -

Arc

elo

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lpro

prieta

ry i

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rmation

© A

rcelo

rMitta

l2014 –

All

rights

reserv

ed f

or

all

countr

ies

Cannot

be d

isclo

sed,

used,

or

repro

duced w

ithout

prior

written s

pecific

auth

orization o

f A

rcelo

rMitta

lC

ON

FID

EN

TIA

L –

Privile

ged Info

rmation -

Arc

elo

rMitta

lpro

prieta

ry i

nfo

rmation

Thank you for your attention!

Frédéric Delcuve

Unit Manager

CRM - ACCS

[email protected]

ArcelorMittal Global R&D capabilities for innovation in ... · ArcelorMittal steel cladding...

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Transcript of ArcelorMittal Global R&D capabilities for innovation in ... · ArcelorMittal steel cladding...