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The UK Reinforcing Industry:The UK Reinforcing Industry:Current Innovations & DevelopmentsCurrent Innovations & Developments

Richard HowellsRichard HowellsMarket Development ManagerMarket Development ManagerCelsa Steel UKCelsa Steel UK

ContentsContentsCelsa Steel UK Celsa Steel UK –– A Brief IntroductionA Brief IntroductionGrade 500C ReinforcementGrade 500C Reinforcement

Changes to StandardsChanges to StandardsDuctilityDuctility

Modular ConstructionModular ConstructionWhat is it?What is it?Case study Case study –– Airbus, BristolAirbus, BristolApplication to Bridge DesignApplication to Bridge Design

EcoEco--ReinforcementReinforcement

Celsa Steel UKCelsa Steel UKAn introductionAn introduction

Celsa Group companyCelsa Group companyLargest producer of reinforcing steel in EuropeLargest producer of reinforcing steel in EuropeCelsa Steel UK Celsa Steel UK -- employs over 550 Peopleemploys over 550 PeopleProduces:Produces:

Is the largest UK mill producing reinforcing bars and Is the largest UK mill producing reinforcing bars and coils, supplying the UK market with more than 60% of coils, supplying the UK market with more than 60% of itit’’s reinforcing requirementss reinforcing requirements

Celsa Steel UKCelsa Steel UK

Tpy Products

700,000 Rebar300,000 Merchant bar200,000 Wire rod

1,200,000 Total

Grade 500C ReinforcementGrade 500C Reinforcement

EN1992EN1992--11--1 (1 (EurocodeEurocode 2)2)Code is valid for specified yield strengths in the range 400 Code is valid for specified yield strengths in the range 400 –– 600 600 N/mmN/mm2 2

Code is valid for ribbed bars only Code is valid for ribbed bars only Adequate ductility is requiredAdequate ductility is requiredSeismicSeismic

BS4449:2005BS4449:2005Updated in line with EN10080:Updated in line with EN10080:Previously:Previously:

Grade 460Grade 4602 ductility classes: A and B2 ductility classes: A and B

Introduction of European StandardsIntroduction of European Standards

Now:Now:Grade 500Grade 5003 ductility classes: A, B and C3 ductility classes: A, B and C

In the UK, we have 3 grades of reinforcing steel:In the UK, we have 3 grades of reinforcing steel:

The main difference is the ductilityThe main difference is the ductility……

≥≥ 7.5%7.5%≥≥ 1.15 1.15 < 1.35< 1.35B500CB500C

≥≥ 5.0%5.0%≥≥ 1.081.08B500BB500B

≥≥ 2.5%2.5%≥≥ 1.051.05B500AB500A

AAgtgt((ffss / / ffyy))GradeGrade

(fs / fy) = Ultimate Tensile Strength /Yield Strength

Agt = Elongation and maximum load

BS4449:2005BS4449:2005

Highest quality reinforcing steel specified in EC2Highest quality reinforcing steel specified in EC2

50% more ductile than standard grade B50% more ductile than standard grade B

Exactly the same as other grades of reinforcement, Exactly the same as other grades of reinforcement, other than its rib pattern and its ductilityother than its rib pattern and its ductility

Only grade of reinforcement produced in Spain and Only grade of reinforcement produced in Spain and Portugal and is also being produced and used in many Portugal and is also being produced and used in many other countries around Europeother countries around Europe

Grade 500C ReinforcementGrade 500C Reinforcement

Tensile strength:Tensile strength:Minimum yield stress (Minimum yield stress (ffyy) of 500 N/mm) of 500 N/mm22

Minimum Ultimate Tensile Strength (Minimum Ultimate Tensile Strength (ffss) of 575 N/mm) of 575 N/mm22

Fatigue performanceFatigue performance5 Million cycles under BS4449 fatigue conditions5 Million cycles under BS4449 fatigue conditions

Bond performanceBond performanceTo meet requirements of EN10080To meet requirements of EN10080

DuctilityDuctilityClass CClass C

Elongation under Max Load (AElongation under Max Load (Agtgt) ) ≥≥ 7.5%7.5%

Ratio Ratio ffss/f/fyy ≥≥ 1.151.15

Grade 500C Steel PropertiesGrade 500C Steel Properties

Design ApplicationsDesign ApplicationsAA

Moment redistribution < 20%Moment redistribution < 20%No plastic analysisNo plastic analysis

BBMoment redistribution < 30%Moment redistribution < 30%Plastic analysisPlastic analysis

CCAs B, but is also suitable for Seismic conditionsAs B, but is also suitable for Seismic conditions

DuctilityDuctility

Ductility is the extent to Ductility is the extent to which a bar will deform which a bar will deform and extend past itand extend past it’’s yield s yield point before fracturepoint before fracture

DuctilityDuctility

Overload Conditions:Overload Conditions:ExplosionExplosion

CollisionCollision

Excess floor loadsExcess floor loads

FloodingFlooding

Seismic activitySeismic activity

Foundation movementFoundation movement

Increased ductility allows longer deformation before Increased ductility allows longer deformation before failurefailure

Advantages Advantages -- SafetySafety

Modular Construction:Modular Construction:Adding value through developments Adding value through developments

in reinforcement supply to sitein reinforcement supply to site

Beam CagesBeam Cages

Tunnel SegmentsTunnel Segments

Pile CagesPile Cages

Reinforcement innovationReinforcement innovation

Standard preStandard pre--fabricated cagesfabricated cagesDifferent types of matsDifferent types of matsModular constructionModular construction

Carpet ReinforcementCarpet Reinforcement

Special MatsSpecial Mats

Bent Special MatsBent Special Mats

Typical Modular ElementTypical Modular Element

Modular ConstructionModular ConstructionFabricator involvement at the design stageFabricator involvement at the design stage

2 situations:2 situations:Early involvement: e.g. designer provides design intent Early involvement: e.g. designer provides design intent –– fabricator fabricator engineers & detailsengineers & details

Later involvement: e.g. designer provides GA drawings & Later involvement: e.g. designer provides GA drawings & schedules schedules –– fabricator refabricator re--engineers/reengineers/re--detailsdetails

3D design detailing/modelling (Building Information Model 3D design detailing/modelling (Building Information Model –– BIM)BIM)

OffOff--site fabricationsite fabrication

Applicable to the whole project, or individual elements onlyApplicable to the whole project, or individual elements only

Why?Why?

Why use Modular Construction?Why use Modular Construction?

To be more economical onTo be more economical on--sitesite

Fabricator engineers & details in order to optimise design Fabricator engineers & details in order to optimise design for management, project, site or material savings:for management, project, site or material savings:

Construction speedConstruction speed

Minimum transport of materialMinimum transport of material

CraneageCraneage

Health & SafetyHealth & Safety

Material savings i.e. reduction of lapsMaterial savings i.e. reduction of laps

Labour reductionLabour reduction

3D Modelling3D Modelling2.8m Deep Raft Slab2.8m Deep Raft Slab9 Layers H50 Bottom 9 Layers H50 Bottom ReinforcementReinforcement2 Layers H40 Top 2 Layers H40 Top ReinforcementReinforcementPrefabricated Prefabricated Extendable Support Extendable Support CagesCagesWalerWaler ReinforcementReinforcement3m Deep Drainage 3m Deep Drainage SumpSumpColumn StartersColumn StartersMacalloyMacalloy BarsBarsWall StartersWall StartersCoupled Stop EndsCoupled Stop EndsShear Key Slab Shear Key Slab ConnectionConnection

Building Information Model (BIM) for Building Information Model (BIM) for LeadenhallLeadenhall ProjectProjectBasement Slab (Level 3, Pour 8)Basement Slab (Level 3, Pour 8)

Case Study Case Study -- AirbusAirbusAirbus Building 07D, Airbus Building 07D, FiltonFilton, Bristol, Bristol

25 x 15 metre reinforced ground slab for Airbus wing 25 x 15 metre reinforced ground slab for Airbus wing testing facilitytesting facility

Originally 94 Tonnes of reinforcement detailed by Atkins, Originally 94 Tonnes of reinforcement detailed by Atkins, Bristol to suit short lengths for manhandling Bristol to suit short lengths for manhandling –– all in loose all in loose barbar

Number of fixers: 6Number of fixers: 6

Estimated time to slab completion: 10 daysEstimated time to slab completion: 10 days

Main constraint: costsMain constraint: costs

Airbus Building 07D, Airbus Building 07D, FiltonFilton, Bristol, Bristol100% re100% re--detailed by Express Reinforcements into detailed by Express Reinforcements into RollmatRollmat & prefabricated cages & prefabricated cages

Minimise double handling & Minimise double handling & craneagecraneage –– material placed material placed on delivery for immediate useon delivery for immediate use

Final tonnage Final tonnage –– 83 Tonnes (15% reduction in steel 83 Tonnes (15% reduction in steel costs)costs)

Placed by 6 men in 1 day (9 day program saving)Placed by 6 men in 1 day (9 day program saving)

Only 0.6 Tonne loose bar Only 0.6 Tonne loose bar –– H&S benefitsH&S benefits

Associated costs also need consideringAssociated costs also need considering

Case Study Case Study -- AirbusAirbus

Rollmat – B1

Modex Modex –– Slab ConstructionSlab Construction

Rollmat – B1

Prefab – B2/T2 Support Cage

Rollmat – T1

Slab complete

Can be applied to small or large projectsCan be applied to small or large projects

Other examples include T5, CTRL, Other examples include T5, CTRL, SladenSladen Valley Valley Wastewater Works, Highbury Stadium Redevelopment, Wastewater Works, Highbury Stadium Redevelopment, NovotelNovotel PaddingtonPaddington……....

Modular ConstructionModular Construction

Can Modular Construction be applied Can Modular Construction be applied to Concrete Bridge Design?to Concrete Bridge Design?

A challenge to industryA challenge to industry……

Concrete BridgesConcrete BridgesIntricate and wide rangingIntricate and wide rangingTraditional approach preferredTraditional approach preferredProject specific i.e. skew, horizontal/vertical alignmentProject specific i.e. skew, horizontal/vertical alignmentWhere can modular construction benefit?Where can modular construction benefit?

Highly dependent on structure type!Highly dependent on structure type!Some initial thoughtsSome initial thoughts……....

SubstructureSubstructure

PilesPiles

Pile CapsPile Caps

SuperstructureSuperstructure

Abutments/PiersAbutments/Piers

DeckDeck

ParapetsParapets

Approach slabsApproach slabs

Concrete BridgesConcrete Bridges

Speed of constructionSpeed of constructionStandard loose bar fixing rates: 1.3 tonnes/man/hourStandard loose bar fixing rates: 1.3 tonnes/man/hour

Modular cage fixing rates: up to 5 tonnes/man/hourModular cage fixing rates: up to 5 tonnes/man/hour

Health and SafetyHealth and SafetyLarge structures i.e. big pile capsLarge structures i.e. big pile caps

Reduces time spent working at depthReduces time spent working at depth

Continuity of steelContinuity of steelA prefabricated rather than precast approach allows lappingA prefabricated rather than precast approach allows lapping

MaintenanceMaintenance3D modelling provides an electronic blueprint for the location o3D modelling provides an electronic blueprint for the location of f reinforcing steelreinforcing steel

Avoid clashes when undertaking future maintenanceAvoid clashes when undertaking future maintenance

EcoEco--Reinforcement:Reinforcement:Developments in Sustainability Developments in Sustainability

& Responsible Sourcing& Responsible Sourcing

The UK Reinforcing IndustryThe UK Reinforcing Industry

More than 95% rebar used in UK More than 95% rebar used in UK produced via EAFproduced via EAF

Raw material is 99% Scrap Raw material is 99% Scrap ––recycling processrecycling process

1/3 embodied energy and 1/6 CO2 1/3 embodied energy and 1/6 CO2 emissions of traditional steelmaking emissions of traditional steelmaking processesprocesses

Scrap Scrap -- Locally sourcedLocally sourced

Fabricators Fabricators –– low delivery distanceslow delivery distances

Traceability through ISO 9001 Traceability through ISO 9001 ––CaresCares

The Raw MaterialCycle

BRE Sustainability StandardBRE Sustainability Standard

BES 6001:2008 BES 6001:2008 –– Standard for the Responsible Sourcing of Standard for the Responsible Sourcing of Construction ProductsConstruction Products

Wide scopeWide scope

Certification for companies, products and production processesCertification for companies, products and production processes

EcoEco--Reinforcement Reinforcement is the sector standard and certification scheme is the sector standard and certification scheme for responsibly sourced reinforcing steel to BES 6001for responsibly sourced reinforcing steel to BES 6001

Developed with relevant industry stakeholders:Developed with relevant industry stakeholders:

Arup, Skanska, Arup, Skanska, BovisBovis, LO, LO’’R, R, WilmottWilmott Dixon, ODA, CLG, Dixon, ODA, CLG, BREEAM, CEEQUAL, ICE, BAR, TCC, BREBREEAM, CEEQUAL, ICE, BAR, TCC, BRE

Mills and fabricators equating to 70 Mills and fabricators equating to 70 –– 80% of UK market supply80% of UK market supply

Open to all steel reinforcement producers providing they are Open to all steel reinforcement producers providing they are committed to addressing sustainable issuescommitted to addressing sustainable issues

Clients/contractors will know that their material is responsibleClients/contractors will know that their material is responsiblesourcedsourced

Pick up a label from any EcoPick up a label from any Eco--Reinforcement product on any site and Reinforcement product on any site and see how far that steel has travelled and the transport COsee how far that steel has travelled and the transport CO22 emissions emissions from raw material to site (Celsa Group initiative)from raw material to site (Celsa Group initiative)

Tick several boxes on sustainable sourcing questionnaires from Tick several boxes on sustainable sourcing questionnaires from clientsclients

BRE involvement will:BRE involvement will:

allow designers to pick up additional BREEAM points by allow designers to pick up additional BREEAM points by specifying itspecifying it

Feed directly into the code for sustainable homes and the Feed directly into the code for sustainable homes and the forthcoming code for sustainable buildingsforthcoming code for sustainable buildings

Reinforced concrete as a construction material can be completelyReinforced concrete as a construction material can be completelylocally sourcedlocally sourced

BenefitsBenefits

Introduction of EC2 allows designers to benefit Introduction of EC2 allows designers to benefit from higher ductility reinforcing steelfrom higher ductility reinforcing steelThe application of innovation and development The application of innovation and development to the supply of reinforcement to site can also to the supply of reinforcement to site can also bring tangible cost/time benefits to construction bring tangible cost/time benefits to construction projectsprojectsOverall project savings can be largeOverall project savings can be largeCan the concrete bridge industry benefit?Can the concrete bridge industry benefit?EcoEco--Reinforcement certification begins to Reinforcement certification begins to demonstrate sustainability/responsible sourcing demonstrate sustainability/responsible sourcing requirementsrequirements

ConclusionsConclusions

The UK Reinforcing Industry:The UK Reinforcing Industry:Current Innovations & DevelopmentsCurrent Innovations & Developments

Richard HowellsRichard HowellsMarket Development ManagerMarket Development ManagerCelsa Steel UKCelsa Steel UK

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