Australian Stainless #63

63 SPRING 2018

PROUDLY SPONSORED BY

The Emerging Dr agon A STAINLESS STEEL MASTERPIECE

Michael Van Dam’s award-winning stainless steel dragon sculpture plays a major part in Chinese culture dating several thousand years.

The dragon is a symbol of prosperity, strength, courage and resolve. The designer himself was born in the year of the Dragon (1964).

As a result of welding thousands of stainless steel links together, alongside Van Dam’s creativity, a durable and aesthetically pleasing piece of art came to life – The ‘Emerging Dragon’.

The Emerging Dragon has been showcased at various locations and shows on the Gold Coast. This stainless steel masterpiece was originally created for the 2015 Swell Sculpture Festival held on Currumbin Beach which attracted 250,000 visitors over ten days, winning both Kid’s and People’s Choice Awards.

The 3m high by 5m long sculpture was created from more than 4000m of 4mm 316 stainless steel chain and weighs an impressive 700kg. Following fabrication the sculpture was electropolished. All stainless steel chain used for Michael’s sculptures is supplied by ASSDA Member BRIDCO. Van Dam’s stainless steel art pieces are well equipped to face the rigours of outdoor display. This led to grade 316 stainless steel chain being his choice of material for all his sculptures. He believes the use of stainless steel for his pieces makes for a unique use of the material, it feels great to the touch, can withstand various environments and will outlast most other materials.

ASSDA MEMBER CONTACT: BRIDCO Nathan Bridge, Managing Director +61 7 5593 5688 | nathan@bridco.com.au www.bridco.com.au

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St ainless Opulence Exemplary stainless steel craftmanship has delivered a sophisticated and lavish cocktail lounge in the heart of the Gold Coast’s entertainment hub.

Cocktail connoisseurs have been flocking to Cherry, The Star Gold Coast to experience the designer drinks on offer in the grandeur of the lounge featuring a 22m long bar. Refurbished in 2017 as part of the first stage of the property’s major transformation, its upmarket look and feel was inspired by its sister venue at The Star Sydney.

Central to Cherry’s luxury design is the intricate, gold metalwork featured in the VIP booth screens, lounge surrounds and balustrades.

ASSDA Member and Accredited Fabricator Minnis & Samson fabricated these elements using grade 316 stainless steel tube and flat bar supplied by ASSDA Member Australian Stainless Distributors.

The stainless steel was mirror polished prior to the electrostatic application of a special coating to achieve the gold colour finish. Crystal hardware and lush red velvet furnishings complement the gold stainless steel to deliver the opulent design and vision of the cocktail lounge.

Stainless steel is a high quality and high strength material, and was specified for its longevity, hygienic properties and aesthetic appeal.

In addition, stainless steel offered better weldability to achieve the detail in the metalwork’s curvature design.

ASSDA MEMBER CONTACTS: AUSTRALIAN STAINLESS DISTRIBUTORS +61 7 3266 6211 | stainless.qld@asdsales.com.au www.stainlesssteelasd.com.au MINNIS & SAMSON Gary Donaldson, General Manager +61 7 3268 2471 | gary@minnisandsamson.com.au www.minnisandsamson.com.au

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AUSTRALIAN STAINLESS 63 3

St ainles s Steel: Sus t ainabilit y and Life Cycle Cos ting Humanity’s use of materials has progressed over the millennia from natural resources such as plants and stone to manufactured materials such as ceramics, metals and plastics with a corresponding increase in consumption of energy and materials – and increasing waste production. In parallel, the world’s consumers have grown exponentially from about 1 billion in 1800, to 7.6 billion in 2018 and a predicted 9.8 billion in 2050 – all demanding more infrastructure, facilities and resources to support the expectations of higher standards of living. This has led to an increasing realisation that green production, recycling, waste reduction and more efficient use of resources are essential.

The green or sustainable credentials of stainless steels largely derive from their corrosion resistance and consequent long life, without the need for more than cleaning by rain washing or routine water and detergent cleaning. A good example is the Chrysler Building in New York which was built in 1930. It has only been washed twice in 1961 and 1995 using low impact detergents and yet it still retains its bright appearance partly because of good drainable design, although the inherently smooth surface from its manufacture was also a factor.

In comparison, the Eiffel Tower in Paris is painted every seven years using 60 tonnes of paint in a 15-month campaign with 25 painters and their consumable equipment. Closer to home, the constant repainting of the Sydney Harbour Bridge provides a similar contrast to the penetration of stainless steel into the building and construction industry without the ongoing labour required for repainting and maintenance of carbon steel structures. At a smaller scale, current practice minimises maintenance in more aggressive environments by processing the surface after fabrication as shown by the bright surface of the electropolished railings beside the Brisbane River.

Above: Chrysler Building, New York.

Below: Stainless steel railings next to Brisbane River.

It is difficult to compare any corrosion (and therefore lifetime) of stainless steel with carbon steel or zinc because of the different mode of attack, i.e. stainless steel pitting vs. the general loss of copper or zinc. However, a South African 20-year atmospheric corrosion study of lifetimes used carbon steel as a baseline of 1 and found that zinc, copper, aluminium and 316 stainless steel had lifetimes of 25, 90, 170 and >5000 years respectively.

A secondary benefit of the long life of stainless steel is that the carbon dioxide emissions and the embodied energy required in manufacture are amortised over a much longer period of time. Raw CO2/kg metal and MegaJoule/kg metal data is given in Table 1 for these materials.

Stainless steel is not the lowest or highest in absolute terms of carbon dioxide emissions or energy required per kilogram of stainless steel produced, but when its long life is considered, its performance on these criteria is outstanding.

Stainless steel does not use volatile organic solvents in its production or use and does not contain lead, mercury or other leachable heavy metals. Stainless steel is routinely used in pharmaceutical, food and beverage processing because of this chemical stability due to the hydrated chromium-oxide passive layer.

In a confirmation study of the stability of stainless steel with water, a 3.5-year testing program of the hot and cold water in 316 pipework of a Scottish hospital found the chromium content was less than 1% of the 0.5ppb permitted for potable water and nickel content (a trace food requirement) was less than 3% of the 0.2ppb permitted.

Looking at environmental issues, Table 2 shows the results of a Scandinavian run-off study, commissioned because of concerns about heavy metals in environmentally sensitive areas. The zinc and copper values will obviously vary with time as the oxide layers form and leach. However, the passive film of stainless steel is substantially stable so that run-off can be used for potable water. A first flush discard system may also be used.

TABLE 1: MANUFACTURING INPUTS FOR VARIOUS METALS

TABLE 2: AVERAGE HEAVY METALS IN ATMOSPHERIC RUN-OFF FROM SHEET (ASTM STP 1421, 2002)

Metal

CS

Zn

Ferritic SS

Cu

Austentic SS

Al

Metal

mg/m2/year

CO2/kg

2

3

4

4

5

12

Zinc/galvanised steel

2,800-2,000

Energy MJ/kg

22

47

58

63

77

184

Copper

1,300-2,000

304 stainless steel NOTE: The austenitic and ferritic stainless steels both had approximately the same corrosion resistance, i.e. Pitting Resistance Equivalent (PRE) ~19.

Nickel*

0.30-0.40

Chromium*

0.25-0.30

NOTES: Chromium and nickel were frequently not detectable. *When coverted to mg/L in the run off, Ni and Cr were always well below the potable water limits.

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REUSE AND RECYCLING In a well designed and executed project, stainless steel will not degrade and therefore it is probable that the process or application will become outdated while the stainless steel is still operational as a pipe or vessel or tank or other component. Such repurposing may be on the same site or elsewhere in the same industry, e.g. from milk to wine or water or fruit juices or for a radically different process. However, it is rare for repurposing to move from chemical to hygienic industries. Since stainless steel has an inherently high value, there are multiple examples of building refurbishment where the stainless steel has suffered mechanical damage or the layout must be changed. The William Penn Place (Pittsburgh) rejuvenation shown was after 50 years of use but did not require material replacement.

Recycling may occur as part of the life cycle, e.g. re-melting of scrap, or at end-of-life. Table 3 indicates significant variations depending on the material and its proposed use. A study of the recycling at 14 European mills covered 18 products across two ferritic, two austenitic and one duplex grade, i.e. all but the small volume of specialised, niche grades of stainless steel. For each of the 18 products, the mean recycled stainless steel content was significantly greater than 65%. The six ferritic products were all above 90%, the nine austenitic products were between 68% and 78% while the three duplex product forms had between 69% and 76% recycled steel input.

While some mills show significantly higher percentages, a nominal 30-year life of stainless steel combined with the almost 6% compound growth of stainless steel use means there is insufficient scrap available now to substantially increase the recycled content from general use.

LIFE CYCLE COSTING AND SAVINGS FROM DURABILITY The minimal maintenance required on stainless steel buildings and structures is a significant direct cost saving, and increased availability of equipment is also important. For example, in a waste water processing plant, a decision to replace the wetted parts of a galvanised distributor with 316 and the notionally dry parts with 304, reduced maintenance costs by 92% and increased availability from 76% to 98%.

William Penn Place: Before and after rejuvenation.

A civil engineering example is the Progresso Pier as shown below where the original pier with carbon steel reinforcement is in ruins after 32 years exporsure. A Nickel Institute funded comparison between the 1940s construction using 304 reinforcement (right pier) and a theoretical pier constructed with carbon steel showed that the carbon steel would have contributed to a 44% greater overall life cost until 2020. It also showed that using stainless steel reinforcement had between 20% and 80% less environmental impact. This low figure was due to the predominance of the mass of concrete compared to the 240 tonne of stainless steel.

GREEN AND SUSTAINABLE Green projects minimise energy use and one option is to reduce solar loading by installing perforated sunscreens or fixed slats in locations where insolation is high and ambient temperatures are not extreme. Design of perforated sunscreens is a sophisticated but well understood process with standard programs available. There are multiple examples that use stainless steel because it does not require more than rain or simple water washing to retain a bright appearance.

Finally, increasingly the “green� label means growing plants or other flora along stainless steel wires or supports either in public places as a visual softening or as a deciduous sun screen where stainless steel is required because of the lack of maintenance access to the supports once the vegetation is mature.

In summary, the durability of stainless steel provides substantial reductions in maintenance costs, supports a considerable recycling and reuse process, and provides control mechanisms for energy use.

TABLE 3: RECYCLING VARIATIONS (HOUSKA, 2008) Metal

Recycled content

Life-end capture

Aluminium Extrusion Castings

Varies ~100%

70%

Carbon Steel Integrated mills Mini mills

25-35% >95%

70% 95%

Copper Electric wire Other products

0% 70-95%

>90%

Stainless steel

~60%*

>80%

Zinc

23%

>80%

Progresso Pier, Mexico, in 1974 and 2006. *Refer to text.

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AUSTRALIAN STAINLESS 63 5

St ainles s Steel for 10 0 Year+ Design Life Stainless steel has delivered the confidence it will provide the structural performance and meet the 100-year life-cycle of a new marina development on the New South Wales’ South Coast.

The Waterfront, Shell Cove, is a joint residential and mixed-use development between Shellharbour City Council and Frasers Property Australia located 22km south of Wollongong.

year life span, and the use of stainless steel provided the best solution, as well substantial cost savings around constructability and man hours per tonne required.

Central to the development is its waterfront location and worldclass marina that will offer pontoon berthing for approximately 270 vessels, direct access to the Pacific Ocean, charter boat operations, a public boat ramp and a variety of marina facilities and services.

Stainless steel rebar offers structural longevity in many environments with exceptional corrosion resistance in harsh marine developments. Its specification in this landmark waterfront development meets the expected minimum 100-year life and was also critical to minimising ongoing maintenance costs. This was an important consideration to avoid future maintenance closures due to corrosion issues and to ensure continued public accessibility to the waterfront promenade for all residents and tourists.

Stainless steel reinforcement has played a significant role in the structural design and construction of the marina, with over 318 tonnes of grade 2304 lean duplex stainless steel reinforcement bar (rebar) supplied by ASSDA Member Valbruna Australia.

Ranging in diameters from 8mm to 25mm, stainless steel rebar was used in all pre-cast elements to form the marina sea walls, marina steps and boat ramps and installed by Coastwide Civil.

The original project specification was for alternative materials and products with cathodic protection and sacrificial anodes that struggled to exceed a 50-year life-cycle guarantee. This specification was superseded by a requirement for a 100-

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In addition, the use of stainless steel rebar significantly reduced the amount of concrete cover required, also minimising costs and resulting in a more lightweight and higher tensile strength structure.

Valbruna Australia’s commitment to stock large volumes of stainless steel rebar on the floor in Australia meant no delays were experienced during the project’s supply term, including

meeting the 20% increase in supply quantity during installation.

Coordinated supply was critical to the on-time completion of the project, which was further impacted by narrow site delivery windows and limited set down holding areas.

The scheduling, cutting and bending of the stainless steel rebar to tight precast tolerances was completed by Mesh & Bar, and performed at a dedicated stainless steel facility to prevent contamination risks.

All stainless steel welds were completed in a controlled environment, and pickled and passivated by Waeger Constructions.

ASSDA MEMBER CONTACT: VALBRUNA AUSTRALIA Greg Childs, State Manager greg.childs@valbruna.com.au Scott Ford, Special Products Manager scott.ford@valbruna.com.au +61 7 3807 9733 www.valbruna.com.au

Construction of the residential and mixed-use infrastructure will continue into next year, with the marina due to take water by the end of 2019. Once completed, Shell Cove will also boast a vibrant town centre and retail precinct, community centre and library, foreshore dining and waterfront tavern, and boutique accommodation.

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MAJOR SPONSOR:

PROUDLY PRESENTED BY: Jotun blue

11–14 NOVEMBER 2018 | ADELAIDE CONVENTION CENTRE

The annual ACA conference is a 3 day gathering of world experts on corrosion mitigation.

This year’s conference to be held in Adelaide, South Australia will comprise a program of keynote speakers and presentations under a range of industry ‘streams’, integrated with an exhibition that will showcase the latest products and services of the corrosion mitigation industry.

Over 400 delegates and visitors are expected to attend from industries such as; protective coatings, water, defence, building and construction, mining, oil & gas, cathodic protection, power and more.

C&P2018 INCLUDES: • Quality Technical Program • Various Forums • 72 Booth Trade exhibition • Awards Dinner • Social & Networking functions • Partner Program

conference.corrosion.com.au

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CORROSION & PREVENTION 2018

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AUSTRALIAN STAINLESS 63 7

Stainless steel is one of the largest growth industries of the last 100 years. Since 1950, worldwide production has expanded from about 1 million tonnes to more than 48 million metric tonnes in 2017. During this time, the image of stainless steel has changed from an exotic, specialist alloy to an everyday material used in high quality, durable products.

The stainless steel industry has successfully expanded consumption of stainless steel by promoting the material’s outstanding characteristics and diverse product applications.

The Australian Stainless Steel Development Association (ASSDA) was established in 1992 to address and harness stainless steel’s growth trend in Australia, and today remains as the Association’s core objective.

ASSDA aims to foster the understanding and use of stainless in Australia by developing the competence and efficiency of the industry through promotion, education and training, the provision of adequate technical advice and industry accreditation.

ASSDA could not continue without the valuable support of its members, who work with it to grow the market for stainless steel.

For more information about ASSDA, including membership information, please visit www.assda.asn.au

ASSDA MEMBERSHIP AND BUSINESS DEVELOPMENT MANAGER: CHRIS WALTOS Chris Waltos joined the ASSDA team in July 2018, and his focus is on enhancing the position of the Association through delivery of continued membership growth and retention, while optimising revenue streams and actively seeking new opportunities for market growth and development.

Chris has an MBA and brings over eight years of professional engineering experience, with five of those in B2B sales and marketing across multiple industrial sectors. His strong technical and commercial skillset coupled with his exemplary background and knowledge of the stainless steel industry brings new energy to the Association.

ASSDA PLATINUM MEMBERS

ASSDA GOLD MEMBERS Fagersta Steels, Midway Metals, Stanch Stainless Steel Co., Ltd., Stoddart, Viraj Profiles Ltd, YC Inox Co., Ltd. ASSDA SILVER MEMBERS Arcus Wire Group, Austral Wright Metals, Australian Stainless Distributors, Callidus Welding Solutions, Ching-Hann Industries Co., Ltd., Dalsteel Metals, Daming International Import & Export Co., Ltd., Froch Enterprise Co., Ltd., Metal Centre Australia, Prochem Pipeline Products, Sanwa, Yue-Seng Industrial Co., Ltd.

MORE INFORMATION Enquiries for further information on any material presented in this publication should be directed to ASSDA: Level 9, 307 Queen Street T +61 7 3220 0722 Brisbane QLD 4000 AUSTRALIA E assda@assda.asn.au www.assda.asn.au EDITORIAL Contributions of story ideas specialising in stainless steel and its applications are welcome from members of ASSDA. ADVERTISING Advertise in the only publication that reaches a targeted group of 5000+ in the Australian stainless steel industry. Rates available at www.assda.asn.au CONTACT Lissel Pilcher, Editor: lissel@assda.asn.au DISCLAIMER ASSDA sources articles and advertisements from a variety of contributors and accordingly does not accept responsibility for the accuracy of the contents of this publication nor the suitability of specific applications referred to herein for any particular use. Competent advice should be sought before acting on any matter contained in this publication.