Join Steligence® for this free English-language webinar on Thursday 24 June 2021 at 14.00 CEST.

Topic: Disproving the myth that clear span construction costs the earth

Scope: Europe

Presenter: Walter Swann, Steligence® Construction Engineer

This webinar will address the social, economic, and environmental advantages of steel for your office building.

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Widely used for the construction of a variety of structures such as quay walls and breakwaters in harbours, bank reinforcements on rivers and canals, underpasses, as well as global hazard protection schemes, sheet piles have proven their performance in seismic areas in many countries around the globe.

Chile, the country that has suffered the strongest earthquakes in recorded history, provides an excellent example: Whereas its concrete-based ports have been severely damaged, the Port of Mejillones, constructed in 2003 using an HZ®/AZ® combined wall for the quay wall and AS 500 straight web sheet piles for the breakwater, has not suffered any damage throughout many heavy earthquakes with magnitudes of up to 7.7. This is the perfect example of the effectiveness of flexible sheet pile structures under extreme seismic conditions.

Nevertheless, a certain reluctance to use sheet piles in seismic areas remains common among some designers. This concern may come from their experience of conventional design methods which do not favour flexible walls in seismic areas. These design methods are usually comprised of pseudo-static calculations using the Mononobe-Okabe theory (1931).

Numerical studies and physical experiments (centrifuge testing) have shown that these conventional methods of design are overestimating the loads on retaining walls - especially in the case of flexible walls. Although EN 1998-5 allows for a reduction of the seismic action depending on the acceptable displacements (reduction factor “r”), this only applies to gravity walls and not to anchored walls such as sheet pile walls, despite their inherent ductility.

Today, powerful design tools using Finite Element Modelling (FEM) allow for dynamic calculations that can accurately predict the behaviour of the retaining walls undergoing different seismic loadings, including internal forces, deformations, increases in pore water pressures, and expected modes of failure.

Material cost savings thanks to dynamic design methods

A research project led by ArcelorMittal R&D and a study carried out by world-leading maritime consultant engineering company SENER demonstrated significant optimisation potential. In the study, a wide spectrum of cases was analysed (four water depths; four seismic accelerations; two soil conditions) that compared the conventional pseudo-static method based on EN 1998-5 using elasto-plastic subgrade reaction software and the fully dynamic advanced method using FEM software.

All of the cases studied showed substantial optimisation potential when using FEM design. The bending moments in pseudo-static design are 40% to 126% higher than those of FEM design. When considering the respective sheet pile sections, this could result in up to 50% of material cost savings using the advanced seismic design methods.

Hydrodynamic loads properly analysed contribute to additional material savings

Hydrodynamic loads are commonly considered pseudo-static and calculated according to EN 1998-5 using the Westergaard formula as a permanent load from the water during the entire duration of the earthquake. SENER used FEM and Computational Fluid Dynamics (CFD) to calculate the impact of hydrodynamic loads on a sheet pile wall during seismic action, considering soil-fluid interactions under dynamic analysis.

Using the traditional Westergaard formula in EN 1998-5 matches the hydrodynamic loads obtained by CFD at a certain point of time during the earthquake. However, as Westergaard considers these to be permanent loads during the entire earthquake, an overestimation of its effect is evident.

The FEM calculations carried out using Plaxis 2D compared the results obtained when using the traditional Westergaard load with those obtained when using a realistic time-dependent variable load (through a dynamic load or added masses). The results showed an increase of 24.5% in the bending moment (with respect to the effects from the purely seismic action) when using the traditional Westergaard load compared to 4% when using the instantaneous load. In this case study, considering a realistic hydrodynamic load translated into a material cost saving of 14% when considering the corresponding sheet pile sections.

Brochure - Seismic design of sheet piles: economic benefits of advanced design methods

To further enhance design and project efficiencies with sheet piling solutions in areas of high seismic risk, the brochure ‘Seismic design of sheet piles: economic benefits of advanced design methods’ presents innovative design methods for extreme dynamic loading conditions in ports and waterways and other infrastructure domains.

Feel free to contact ArcelorMittal Sheet Piling for more detailed information or for assistance with the dynamic design of sheet piles using FEM.

Text:
ArcelorMittal Sheet Piling
Constructalia

Images:
ArcelorMittal Sheet Piling
Puerto Angamos

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Seismic design of sheet piles: economic benefits of advanced design methods

Join Steligence® for this free German-language webinar on Thursday 17 June 2021 at 12.30 CET.

Topic: How the right choice of rolled sections, steel grades, and subgrades can economically impact your project

Scope: Europe

Presenter: Marc May, Steligence® Construction Engineer

The European standards offer many possibilities for the selection of rolled profiles and structural steels in terms of design, execution, and building products. The underlying, reciprocal requirements of the different standard families can sometimes look confusing.

This webinar offers best practices for selecting suitable rolled sections, steel grades, and subgrades to support standard-compliant, economical design and execution for different applications.

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Text and images: ArcelorMittal Construction

Offering aesthetic appeal, high performance, sustainability, and safety, carrier panel solutions are becoming increasingly popular with architects and specifiers seeking the perfect facade for their projects.

The facade, a complex part of the building

As buildings account for roughly 40% of global final energy use, sourcing sustainable ways to construct buildings with optimised energy performance is of increasing importance (researchgate). A building’s facade directly impacts the overall environmental footprint of a development, as well as the end users' comfort.

Designing a building’s facade means meeting complex aesthetic and technical demands while taking into account humidity, light, appearance, and weather-resistance as well as multiple safety, engineering, and energy efficiency regulations. A carrier panel system enables project specifiers to meet all of these needs due to its factory guaranteed performance and versatility.

What is a carrier panel solution?

A carrier panel facade solution consists of a metal faced sandwich panel, which works as both insulation and carrying structure; a fixing system to connect the outer skin of the building to the panel; an air spacer; and an external skin, which is the visible part of the facade. It is an all-in-one solution that offers architects and specifiers a way to lower a building’s energy demand whilst remaining functional and aesthetically pleasing.

Carrier panel systems also allow for reduced building costs due to the ease and speed with which a facade can be installed, repaired, or revamped. Carrier panel systems also deliver a great deal of architectural freedom as they are suited to a range of external skins, textures, profiles, and custom colours. For architects and specifiers, this means almost any design is possible - without compromising on build quality and technical performance.

What are the benefits of a carrier panel system?

Carrier panel systems are designed for projects which need to utilise the benefits of a sandwich panel wall whilst also offering creative freedom for the facade design. The system provides office buildings, collective residential buildings, and leisure and shopping facilities with functional and visually attractive external cladding. There are even more benefits to carrier panel systems:

•     Faster build times

By removing the need for conventional building materials and methods, insulation, and some subframe structures, carrier panel systems ensure the application of facades is simple and quick. By rendering a building wind and waterproof immediately after application is completed, the internal fit-out can be started immediately. All-in-one systems also mean fewer complex products, suppliers, and deliveries, so your project can stay on schedule.

•     More sustainable

Quality insulated sandwich panels and cladding boast excellent sustainability credentials. In addition to faster build times, the speed and simplicity of installation cuts down significantly on emissions in the construction phase, while their light weight reduces emissions in transit. Predominantly made from steel, the embodied energy of carrier panels (that is, the energy required to produce them) is also low. For example, 40% of the steel used by ArcelorMittal Construction comes from recycled sources. Finally, thanks largely to their reduced thermal bridging and superior air tightness and insulation, carrier panels result in fewer emissions over the course of a building’s lifecycle.

•     High performance

From excellent thermal performance to fire safety, air tightness, sound insulation, and load-bearing qualities, carrier panel systems offer long-lasting, durable construction solutions which can be adapted to any design with total flexibility of external skins, colours, profiles, and textures.

ArcelorMittal Construction carrier panel solutions: freedom to design

As a leading manufacturer of smart building systems, ArcelorMittal Construction’s carrier panel solutions offer sustainability, technical performance, and aesthetic appeal as well as complete architectural freedom for designers and specifiers. Our interlocking carrier panel systems are also designed for fast and easy application and regulations compliance.

Archisol® is a carrier panel with visible fixings that has been developed with high performance in mind to meet new standards in thermal insulation: the system combines superior weather and heat resistance with outstanding airtightness and low thermal transmittance. Other benefits include very good mechanical resistance to wind actions, allowing for larger spans.

Also available is Promisol® S Hybrid, a double skin facade solution with hidden fixings and (similarly to Archisol®) outstanding thermal insulation and durability. In addition, Promisol® S Hybrid has superb fire reaction standards and is Fire EI30 certified.

Both solutions deliver limitless aesthetic freedom of design; have no complex proprietary system or installation guidelines; and, unlike other systems available on the market, use sustainable organic coatings.

Our technical support team studies every project case by case to provide the best solutions in terms of mechanical resistance and thermal insulation. We will also assist you in choosing the most suitable aesthetical solution from our broad range of external cladding products, from architectural profiles and sidings to cassette systems - all with a wide choice of finishes and colours.

Based in Turkey, Meko Metal is a leading advocate for Magnelis®, actively promoting the highly advanced coating with its global customer base. Meko Metal uses Magnelis® to create profiles and tubes which are utilised in: solar support structures; greenhouses; agricultural applications such as chicken farms; prefabricated housing; and heating, ventilation, and air conditioning (HVAC) applications. To ensure that their customers can access Magnelis® quickly, Meko Metal maintains its own high stock levels of the coated steel in Turkey.

Convincing major customers

Meko Metal launched a campaign to ensure their customers are aware of the benefits of Magnelis® for their various applications. They began “by branding Magnelis® as ‘MekoMag,’” says Serkan Gürler, Vice President of the KMC Group that acquired Meko Metal about ten years ago. Working in collaboration with ArcelorMittal on co-marketing materials, Meko Metal is dedicated to sharing the advantages of Magnelis®.

Meko Metal’s efforts have seen Magnelis® being adopted by customers in many different industries. “We work with a major global company active in the construction, energy, and manufacturing industries,” says Serkan Gürler. “After eight months of tests and discussions they switched around a third of their products to Magnelis® as a trial. After seeing the benefits of this unique coating, they now request Magnelis® in most applications.”

As well as being easier to work with than hot dip galvanised material, Magnelis® offers long-term protection against corrosion in many applications. “For our customers in the solar industry, ArcelorMittal’s guarantee on Magnelis® of up to 25 years is extremely interesting,” says Serkan Gürler. “It assures them they will be able to obtain an adequate return on their investment.”

Magnelis® stocks reduce lead times

With demand for Magnelis® being very strong, Meko Metal decided to stockpile the material to ensure they can offer customers very short lead times. Meko Metal now receives coils of Magnelis® coated material directly from ArcelorMittal’s mills in Bremen, Germany; Liège, Belgium; and Avilés, Spain. “If we cannot supply Magnelis® within their deadlines, many customers will consider galvanised steel instead,” explains Serkan Gürler, “but thanks to our warehouse of material, we can offer customers just-in-time deliveries. We also provide this service for ArcelorMittal’s HyPer® high strength structural steels.”

Dedicated R&D capabilities

Another focus for the company is on research and development. Meko Metal has its own in-house tooling facility which gives the company great flexibility and accelerates its R&D activities. During 2020, Meko Metal completed a €3 million investment in a 46-station roll forming line dedicated to R&D. The line can handle material up to 4 mm thick and is used to process steels including S700MC, HyPer® grades, and the dual-phase grade DP1180.

The line is used in conjunction with Copra FA optimisation software, as Serkan Gürler explains: “The software is a great way to show customers how their designs can be realised, but they still want to handle the material. The new roll forming line enables us to provide them with real-life samples which they can use to test their own systems and products.”

About Meko Metal

Meko Metal was established in 1969 in Izmir, Turkey. Today the business is a part of the KMC Group and employs almost 200 people at their 80 000 m2 production facility in Turkey. This includes an R&D department with six engineers who work on optimising Meko Metal’s processes and developing new products. Meko Metal exports its products to Africa, the EU, the Caribbean, China, Gulf Cooperation Council (GCC) countries, Russia, the UK, and the US.

More info: mekometal.com.tr

ArcelorMittal Orange Book

Meko Metal is also utilising ArcelorMittal’s Orange Book, a website dedicated to helping design engineers to reduce the weight of their structures and optimise the structural, environmental, and economic performance of profiles made with ArcelorMittal’s high strength steels.

Text:
ArcelorMittal Europe Communications
Constructalia

Images and video:
Meko Metal

Related link(s)

Meko Metal

ArcelorMittal Europe – Flat Products has created a new product designed for use in extreme climates. Granite® HDXtreme is the latest prepainted steel in ArcelorMittal’s organic coated Granite® range. Granite® HDXtreme is uniquely beautiful, resilient against corrosion, sustainable, and can be used in both indoor and outdoor applications. A three-layer coating system provides high levels of protection against UV and corrosion. This enables ArcelorMittal to guarantee the steel’s performance. Granite® HDXtreme comes in a vast palette of colours and three different finishes to make any project unique.

Three-layer coating system

The strength of Granite® HDXtreme comes from its three-layer coating system which ranges from 70 to 75 microns (µm) depending on the finish. Each layer performs a different but integral function.

The primer layer plays a key role in corrosion protection by ensuring the top coat adheres tightly to the underlying steel. On top of that is a polyurethane basecoat which ensures the steel’s durability and provides the final colour. The coating is finished with a layer of varnish which adds texture to the coating, increases durability and surface robustness, and enhances the UV weathering potential of Granite® HDXtreme.

Weathering resistance

Granite® HDXtreme already meets the requirements of the updated EN 10169 standard for continuously organic coated flat steels. Its exceptional UV resistance offers colour stability for many years. Granite® HDXtreme is also ready to pass the upcoming new RUV5 UV resistance standard when it is published later in 2021.

The coating has also been evaluated by exposing prepainted samples of Granite® HDXtreme to accelerated UV, humidity, and temperature variations for up to 4000 hours. Natural outdoor exposure tests have also been carried out at locations around the world.

Automatic guarantees

ArcelorMittal’s extensive experience and testing, including in highly corrosive seafront locations, translates into a long-term guarantee of up to 40 years for Granite® HDXtreme. The guarantee is applicable to roofs and facades as well as the installation of rooftop photovoltaic modules.

Samples

Samples of Granite® HDXtreme are available through our online sample shop.

Three finishes, almost 50 colours

Created in consultation with architects and designers, Granite® HDXtreme is available in a huge palette of colours and three different finishes: satin, matt, and sparkling.

The satin finish is available in either 15 or 30 gloss units (GU) and has a grained texture. The matt (<10GU) finely wrinkled finish is available in four colours, and a sparkling, grained 30 GU finish is available in five colours. The latter are amongst the most attractive and sparkly steel finishes available on the market. More colours may be added depending on demand. The low gloss, matt finish is ideal for large flat panels and cassettes, while the standard and sparkling finishes are more suited to small panels.

9 solano colours have been added to the colour palette. Click on the image below to view.

Highly sustainable

The steel is designed for roofs and facades on buildings near the sea, and its performance is guaranteed for up to 40 years. Free of hexavalent chromium and heavy metals plus 100% recyclable, Granite® HDXtreme is highly sustainable: it has a lower CO2 footprint compared with alternative solutions such as aluminium.

The first building with Granite® HDXtreme

ArcelorMittal Ghent’s Indi building in Belgium is the first building to be clad with Granite® HDXtreme. Located close to the industrial environment of the mill and the sea, Granite® HDXtreme was the ideal choice.

Text:
ArcelorMittal Europe Communications
Constructalia

Images:
Jeroen Op de Beeck and Philippe Vandenameele
ArcelorMittal