Solar photovoltaic plants are designed to last at least 20 to 25 years. They are built in various climates (tropical, industrial, etc.), locations (sea shores, islands, etc.), or geological soils (including the most aggressive).

Supporting structures

The supporting structures for PV panels must withstand these conditions while generating minimal maintenance costs. These requirements are extremely demanding. For these reasons, ArcelorMittal offers Magnelis® - a steel with excellent corrosion resistance that is at least three times better than traditional galvanised steel. Magnelis® exhibits a self-healing effect in the event of scratches, which also improves edge protection.

Magnelis®: best in class solution

With excellent in-use properties and a wide range of feasibility, Magnelis® is one of the best in class and most cost-effective alternatives to post-galvanised steels. Since its launch in 2012, Magnelis® has been selected by many solar players around the world to provide superior protection for long-lasting mounting structures, even in the most adverse environments, and for several very large installations.

Innovations

The Magnelis® range is constantly improving, and the latest innovation is a new range specially created for rammed poles in soils.

Last but not least, the combination of Magnelis® with the new high strength steel grade S550GD-HyPer® offers additional opportunities for structural improvement for solar structures leading to reduced weight and costs.

Text: ArcelorMittal Europe Communications, Constructalia
Images: ES_SO / Shutterstock.com, Forming AG, PVH, CWF

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Solar panels

Solar farm

Solar panel mount

Solar panels under snow

Demand for convenient car parking is rising dramatically. However, the land available for parking is severely limited in many locations. This is making multi-storey car parks a very attractive option in city centres, near transport hubs, and at public buildings such as hospitals. To meet this demand in a cost-effective way, Kingspan, a leading building materials company, has developed a complete portfolio of solutions for car park builders. A key element is Magnelis® from ArcelorMittal Europe – Flat Products which Kingspan uses to form the deck of each level in the car park. As well as cost-effective forming and quick assembly, Magnelis® offers long-term protection against corrosion to ensure the safety and viability of parking structures.

The challenges of multi-storey car parks

Multi-storey car parks offer unique challenges for their owners. As well as providing safe and welcoming spaces for potential customers, they must withstand weathering from the elements – and the effect of de-icing salts and other chemicals which are tracked into the structure. Floors are particularly vulnerable due to the high level of moisture which enters the structure through its open sides or via rain and snow on vehicles. Moisture in the atmosphere typically condenses on the underside of the floor, making this part of the structure particularly susceptible to corrosion.

A complex product requires Magnelis®

To address these concerns, Kingspan has developed a multideck floor system based on Magnelis®. The system is quick to produce, lighter than alternative solutions, and simple to assemble on-site. “We create the deck panels by roll-forming the steel in our factory,” explains Phil Smith, Kingspan’s Managing Director for the UK and Ireland. “It is a complex product – the deck panels need to include cut-outs to ensure the concrete adheres to the steel. But Magnelis® is easy to form.”

In the final step, the ends of the Magnelis® deck panels are engineered to ensure that the concrete does not slip off as Phil Smith says: “The process involves crushing the ends of the panels slightly so that the concrete has a rough surface to adhere to. This is done about two to three weeks before the panels are installed.”

Once the steel decking panels are manufactured, they are transported to site and lifted into place. Concrete is then poured over the steel to form the deck. “In the past we have used pre-cast concrete slabs to form the deck, but this is costly,” notes Phil Smith. “Another option is to use pre-coated or galvanised steel, but the coatings on these materials are often damaged in handling, transport, and on-site. Magnelis® is the best and most cost-effective option as it does not damage easily during transport or handling on-site. And if it is damaged, the self-healing property of Magnelis® repairs any cuts or scratches that do occur.”

10-year guarantee a major advantage

A key advantage of Magnelis® for Kingspan is the guarantee ArcelorMittal can provide on request. Phil Smith explains: “By using Magnelis® we can offer a 10-year guarantee on our decks. That can be extended up to 20 years depending on the location of the car park and the thickness of the Magnelis® coating. Currently we use Magnelis® ZM310, but we are working with ArcelorMittal to test Magnelis® ZM430.”

Kingspan utilises ArcelorMittal’s technical support at all stages of the project. “We are quite often involved in projects where the environment is aggressive such as swimming pools, car parks, and installations which generate energy from waste,” says Phil Smith. “In these projects we involve ArcelorMittal during the design phase to ensure we are selecting the right materials. ArcelorMittal also organises R&D workshops to Kingspan to help us get the most from their offer.”

ArcelorMittal’s dedicated Client Technical Support (CTS) personnel also provide a direct link between the customer and the steelmaker. They connect the customer’s technical team to ArcelorMittal’s support and R&D teams to provide quick feedback and advice on technical questions.

Sustainability at every step

Kingspan offers a complete range of solutions for multi-storey car parks including the Magnelis® composite decks explains Phil Smith: “We also have barrier protection systems, perforated facades, and solar panels for the top floor so the car park can generate energy for lighting, ventilation, and electric vehicle charging points. Our goal is to create sustainable solutions at every stage. And steel is our material of choice to reach this goal.”

That commitment to sustainability has seen Kingspan switch both of its production centres in the UK to 100 percent renewable energy. Kingspan is also one of only 130 companies to make the CDP A-list (formerly the Carbon Disclosure Project), a position the company has held since 2016.

About Kingspan

Kingspan is a global leader in high-performance insulation and building envelopes. Originally founded in Ireland in 1965, Kingspan now operates in over 70 countries around the world and employs more than 14 000 people. The company manufactures a range of complementary building envelope solutions for both the new build and refurbishment markets.

More info: www.kingspan.com/gb

Text: ArcelorMittal Europe Communications
Images: Raised Floor Solutions

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Multi-storey car parks can accommodate a large number of vehicles in a relatively small space

Magnelis® can resist the corrosive effect of moisture which accumulates underneath each deck

Kingspan engineers the ends of each Magnelis® panel to ensure maximum adhesion of the concrete layer

Kingspan uses Magnelis® in their multi-storey car parks

Kingspan partnered with MetparkUK Ltd to install the Magnelis® decks in multi-storey car parks

Kingspan uses Magnelis® in their multi-storey car parks

Phil Smith, Managing Director of Kingspan in the UK and Ireland

Multi-storey car park banner

A multi-storey car park under construction in Manchester, UK

Headlines throughout the world reveal that a global energy transition is underway. Oil and gas and electricity companies are announcing massive investments and strategic moves that embrace renewable energy.

Steel: a key material in a less carbon-intensive world

Renewable energy, which includes solar, wind, geothermal, hydro, and others, is at the centre of the transition to a less carbon-intensive society, which also puts steel at the centre of the conversation.

“Steel is required by each of these markets. Without steel, none of the renewable energy sources would be possible. Every renewable energy structure – a wind turbine, a solar panel - requires steel,” says Johannes De Schrijver, CEO of ArcelorMittal Projects.

An expansion of renewable power capacity

According to the International Energy Agency, renewable power capacity is set to expand by 50% between 2019 and 2024. This increase of 1200 GW is equivalent to the current total power capacity of the United States. Solar is expected to account for nearly 60% of the anticipated growth and onshore wind 25%.

Steel will play an important role in all renewables, including and especially solar and wind. Each new MW of solar power requires between 35 to 45 tons of steel, and each new MW of wind power requires 120 to 180 tons of steel.

The solar market

The solar market is divided into two areas. The first are smaller-scale rooftop panels mounted on homes, museums, and stadiums. The second is utility-scale projects, which are larger consumers of steel. These plants produce a standard 100 to 300 MW of energy while some in development are approaching 1000 MW.

Johannes De Schrijver notes: “These are basically small power plants, football fields full of solar panels. If you consider that each new MW requires 35 to 45 tons of steel, that’s a tremendous opportunity for us. This is an area that has our attention.”

Solar technologies

Solar power plants use three technologies, all of which use steel in the structure on which the PV modules or mirrors are attached:

• Solar Photovoltaic (PV) – panels are mounted on a fixed or moving structure that allows the panel to be optimally oriented to the sun throughout the day; the moving structure is gaining ground on the fixed structure with tracker technology accounting for half of all PV structures by 2025.
• Concentrated Solar Power (CSP) - panels with lenses that focus the sun’s ray on a small cell with a much higher energy generation capacity.
• Concentrator Photovoltaics (CPV) - converts sunlight to electricity by PV cells made of semiconductor materials; usually the material is salt, which becomes liquid and generates steam to create electricity.

ArcelorMittal has been a key player in supplying steel to major solar projects around the world including the Beryl Solar Farm in Australia and Mohammed Bin Rashid Al Maktoum Solar Park in Dubai as well as solar farms in Chile, Egypt, France, Israel, and the United States. The company is also finalising agreements with power-generating companies on solar plants using CSP or CPV technologies. One is the first of its kind that combines both Solar PV and CSP for a revolutionary capacity of 950 MW of energy.

Steel in the wind energy market

Steel is also a major contributor to wind energy, which can be grouped into three key markets:

• Onshore wind farms - relatively small and produce between 2 and 3 MW of power per turbine. A variety of steels is used for the structural tower itself, the house of the turbine, the turbine blades, plus electrical steels for electricity generation
• Offshore wind farms - much larger, with recent turbines producing 5 to 8 MW of energy. Offshore wind consumes more steel than onshore and is an area of interest among investors. Offshore has two advantages: the ability to go much higher with no obstructions and the free flow of wind. Offshore requires a combination of steels to support the huge foundations that are anchored to the sea bed. Steel is also found in the structural tower itself and the blades, which are much thicker and longer.
• New generation wind farms – these wind farms go the distance, literally. These farms will be built even further from shore, requiring a floating structure. Each turbine will produce 7 to 12 MW of energy.

ArcelorMittal: supplying steel to windfarms

ArcelorMittal has been a supplier of steel to some of the world’s largest windfarms, including:

• BorWin3, a 900 MW offshore wind grid connection in the German North Sea.
• East Anglia One, a 714 MW wind farm in the North Sea off the coast of England.
• Greater Changhua, a 2.4 GW wind farm in the Taiwan Strait.

ArcelorMittal Global R&D plays an important role in supporting this market through the development of new steel products and solutions:

• Magnelis®, a breakthrough corrosion resistant steel product, has enjoyed much success in the solar energy market. Magnelis® is the industry’s reference product for ground mounted structures and the product of choice in harsh outdoor and indoor environments.
• A-motion is a new steel solution for solar panels created by ArcelorMittal. A-Motion is a single-row, self-powered, and wireless solar tracker which features a wind-friendly design dimensioned to be safe in any position with no stow position required. With a limited number of components, a global supply chain with possibilities of local content and reduced O&M, the product answers the market’s needs.

“The future of steel in the energy transition is exciting,” says Johannes De Schrijver. “As the world’s largest steel producer with extensive downstream capabilities and fabrication and construction knowledge, we are in an excellent position to provide safe, sustainable steel for the future of energy.”

Text: ArcelorMittal
Images: ArcelorMittal

Related link(s)

East Anglia One wind farm

Mohammed Bin Rashid Al Maktoum solar park

BorWin3 offshore wind farm grid connection

Despite the challenges of COVID-19 on our daily and professional lives, some projects have continued and have even been successfully completed these past months. Since March 2020, Industeel's site in Charleroi, Belgium has been equipped with 1512 photovoltaic panels on its roof. The green electricity generated will allow Industeel to produce cost-efficient steel while reducing its CO2 footprint. The panels have been fixed on a steel structure coated with Magnelis®.

A strong illustration of sustainability

With this project, ArcelorMittal reinforces its commitment to energy efficiency, renewable energy, and CO2 emissions reduction across all facilities. This project represents one more step towards sustainability and a cleaner future while reducing expense and generating positive EBITDA savings.

Throughout the 20 years of the contract life, the supplier PERPETUM will take on the full maintenance and operations of the panels and will guarantee both the performance and the output of the panels. After 20 years, the panels will belong to Industeel Belgium and will continue to produce energy. The electrical power of each panel is 320 Wp (watt-peak). This corresponds, with southern exposure, to an expected annual global electricity production of 500 MWh, which is equivalent to the energy consumption of 120 households.

Protected by Magnelis®

Industeel worked with Green4Power, who invested in the project, and entrusted the supply, assembly, and commissioning to PERPETUM. The structure supporting the 1512 solar panels was entirely built with Magnelis® - a product of ArcelorMittal Europe – Flat Products - in grade ZM310 and produced in Liège.

Magnelis® is an exceptional metallic coating with a chemical composition including zinc, 3.5% aluminium, and 3% magnesium. This unique composition allows Magnelis® to provide an unprecedented level of surface and cut-edge protection against corrosion even in the most hostile environments.

This project was successfully completed thanks to the excellent teamwork between Industeel and the European Procurement Organisation's energy efficiency projects team, who implement various energy efficiency projects including on-site solar photovoltaic projects on the roofs and land of ArcelorMittal sites.

"The renewable energy generated by these 1500 solar panels supports us in achieving ArcelorMittal's ambition to be CO2 neutral by 2050," concludes Alex Nick, CEO Industeel.

Text: ArcelorMittal Europe Communications
Images: Marc Burton, Energy Management and Optimisation, Industeel Belgium

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Solar panels for Industeel Charleroi roof with Magnelis®

Industeel Charleroi solar panels with Magnelis®

Industeel Charleroi solar panels with Magnelis® banner

Solar panels for Industeel Charleroi roof with Magnelis®