1 Stainless steel rebar . for bridges that last Building strong structures

Nickel lights up 31, No April 2016, Vol. remote communities THE MAGAZINE DEVOTED TO NICKEL AND ITS APPLICATIONS

nickel-containing BUILDING rebar extends BRIDGES the lifespan WIKIMEDIA COMMONS WIKIMEDIA

Pearl River Estuary

Hong Kong-Zhuhai-Macao Bridge Zhuhai Lantau Hong Island Kong Main Bridge

Macao r The main section of the bridge r The Hong Kong-Zhuhai-Macau bridge under construction r Artificial island and approach for the tunnel section r The main bridge will extend for 29.6km CASE STUDY 06 over the Pearl River Estuary. THE LONGEST SEA HONG KONG-ZHUHAI-MACAU JV ENGINEERING/ARUP HARBOUR TUNNEL/FIRST HPDI/COWI/SHANGHAI © BRIDGE IN THE WORLD BRIDGE The Hong Kong-Zhuhai-Macau Bridge is one of the world’s major infrastruc- he Pearl River Delta (PRD) in Guangdong province is one of the main hubs of China’s ture projects. It will be the longest sea economic growth. The industrial cities of the PRD have been called the “Factory of the T bridge in the world with total length of World” and the Pearl River Delta Economic Zone (PRDEZ) accounts for approximately one third 50km. Nearly 10,000 tons of Alloy 2304 of China’s trade value. The PRD is also one of the most densely urbanised regions in the world (UNS S32304) nickel-containing duplex with a combined population of around 57 million in the nine largest cities of the region which stainless steel rebar, rod and wire have include Hong Kong, Zhuhai and Macau. been specified to achieve its design life The PRDEZ is divided by the Pearl River Estuary. Road transport between the east and western of 120 years. The Alloy 2304 compo- sides currently involves a 200km journey via the Humen Bridge located to the north. The nents supplied by Taiyuan Iron & Steel governments of Hong Kong, Macau and Guangdong are now building a bridge over the Company (TISCO) will be used for the estuary to provide a direct link for passengers and freight, alleviating the heavy traffic congestion bridge bearing platform, tower founda- tion and pier shaft. This is the first time at the Hong Kong-Shenzhen frontier checkpoints and reducing the economic losses arising duplex stainless steel has been used in from the daily hold-up at these border crossings. bridge construction in mainland China. The Hong Kong-Zhuhai-Macau Bridge will link Hong Kong to Macau and the city of Zhuhai in The total cost of the project is esti- Guangdong province. The main bridge will extend for 29.6km from Macau over the western mated to be US $10.6bn (70bn yuan), portion of the Pearl River Estuary. It will land on an artificial island which is connected to another which is the largest investment in the artificial island by a 6.7km long underwater tunnel. The bridge then continues to mainland history of Chinese bridge construction. Hong Kong creating a combined bridge and tunnel structure. The bridge's dual three-track Construction of the bridge commenced highway will reduce travel time between Hong Kong, Macau and Zhuhai from four hours to just on 15 December 2009, and is currently 30 minutes. due for completion in 2018.

2 NICKEL CASE STUDY nickel, vol. 31, no. 1, april 2016 NICKEL, VOL. 31, NO. 1, APRIL 2016

The Magazine Devoted to Nickel and its Applications

Nickel magazine is published by Nickel Institute www.nickelinstitute.org David Butler, President Clare Richardson, Editor Contributors: Nancy Baddoo, Wenlei Chen, Parul Chhabra, Jo Claes, Gary Coates, Bernard Heritier, Jim Jenkins, Stephen Jones, Geir Moe, Carol Powell, Frank Smith, ISTOCKPHOTO.COM © PHOTAWA © ISTOCKPHOTO.COM Nigel Ward, Annabelle Wilson Design: Constructive Communications Nickel Institute can be contacted at: BUILDING THE FUTURE Rue Belliard 12 When President Obama said, “Twenty- rst century businesses need 21st century Brussels 1040, Belgium 1 Tel. +32 2 290 3200 infrastructure”, he was voicing the concerns of governments across the world charged [email protected] with replacing the many roads and bridges constructed in the last century which are Material has been prepared for the general information of now crumbling. the reader and should not be used or relied upon for speci c applications without rst securing competent advice. The numbers are stark: 65% of America’s major roads are in ‘less than good condition’ and 25% While the material is believed to be technically correct, 2 Nickel Institute, its members, sta and consultants do not of bridges require ‘significant repair or can’t handle today’s traffic’. In Germany, it is reported represent or warrant its suitability for any general or speci c that over half of all autobahn bridges are urgently in need of repair. And in the UK, the Civil use and assume no liability or responsibility of any kind in Engineering Contractors Association said in 2013 that the cost of infrastructure falling short of connection with the information herein. typical ‘developed economy standards’ amounted to £78 billion each year between 2000-10. ISSN 0829-8351 Printed in Canada on recycled paper by Hayes Print Group 57.3 Cover: Constructive Communications Global Investment (US$ trillions), 2013–2030 Cover images: Woodrow Wilson Bridge, Wikimedia 3 Commons © William F. Yurasko for global infrastructure needs Rebar, iStockPhoto.com © ansonsaw

16.6 9.5 11.7 12.2 4.5 TABLE OF 0.7 2.0 CONTENTS Ports Airports Rail Telecom Water Power Roads Total Case Study Most of us take for granted the infrastructure around us, and it is only when potholed high- Hong Kong-Zhuhai-Macau Bridge. . . . . 2 ways, disintegrating bridges and decaying transit tunnels impact our daily commute, that we In Focus take notice. Editorial ...... 3 Clearly, a long design life is desirable for infrastructure to minimise disruption as well as cost Special Feature and nickel-containing constructions have a great track record. The Progreso Pier in Mexico is Solutions to crumbling infrastructure . . .4-5 just one example of the benefits of nickel-containing stainless steel reinforcement bar (rebar) Longer life for bridges...... 6-7 to enable infrastructure to withstand the test of time in harsh environments—over 70 years Stainless steel-load bearing and counting in this case. applications...... 8-9 And now a new generation of mega projects is underway, including the Hong Kong-Zhuhai- In Use Macau bridge featured opposite and the new Champlain Bridge to be built across the Stainless steel course for students . . . . 10 St. Lawrence River in Canada (page 4). Both bridges will make use of the corrosion-resistant Technical help ...... 10 properties of nickel-containing rebar. Support for brick soffi ts ...... 11 This edition of Nickel looks at how nickel-containing rebar and other materials are contributing Solar powered lighting ...... 12-13 to bridges and quality construction. The nickel is hidden but its role in preventing corrosion of Sagrada Familia ...... 16 infrastructure is vital if governments and citizens are to get value for money with long lasting, In Brief fit for purpose bridges, roads and buildings. New publication ...... 14 UNS details...... 14 Clare Richardson Fuel cell technology...... 15 Editor, Nickel magazine Safer batteries...... 15 Web links ...... 15 1 State of the Union address, January 2015 2 Report by US National Economic Council and President's Council of Economic Advisors, 2014 3 Exhibit from “ Infrastructure Productivity: How to Save $1 Trillion a Year”, January 2013, McKinsey Global Institute, www.mckinsey.com. Copyright (c) 2013 McKinsey & Company. All rights reserved. Reprinted by permission.

, . , . ,   NICKEL IN FOCUS  stainless steel rebar in order to achieve ser- vice lifetimes of 75-100 years without major A solid solution repairs or rehabilitations. The Progreso Pier in Yucatan, Mexico con- firms these benefits. Completed in 1941, this

ISTOCKPHOTO.COM © PHOTAWA © ISTOCKPHOTO.COM to crumbling two km-long reinforced concrete pier juts out into the Gulf of Mexico and is continu- ously exposed to a harsh tropical marine infrastructure environment. Corrosion-resistant stainless steel rebar Recent concrete coring and detailed inspec- tions have found the pier, constructed with nickel-containing Type 304 (UNS S30400) s our infrastructure ages, concrete deterioration has become one of the most costly and reinforcement, to be in excellent condition widespread problems. Why? According to Dr. Karen Scrivener, Head of the Construction A after 75 years of service—without any signifi- Laboratory at the Swiss Federal Institute for Technology, corrosion attack on rebar is “the cant repair work. cause of over 90% of problems of concrete durability”.*

ISTOCKPHOTO.COM © TORTOON © ISTOCKPHOTO.COM Nickel’s role in the answer increase in volume exerts pressure on the And concrete structures that are exposed Alloy producers have made signifi cant surrounding concrete and causes it to crack. to de-icing salt, seawater or marine advances over the past two decades, devel- atmospheres are particularly susceptible to The cracks allow further penetration of oping and making commercially available accelerated deterioration. chloride, moisture and oxygen down to the a range of corrosion-resistant stainless steel Getting inside the problem carbon steel—accelerating the corrosion rebars (together with stainless steel tie-wire Technically speaking, chloride ions, moisture process. Over time, the cracks enlarge and and rebar couplers). In fact, for the past twenty and air (oxygen) migrate through the porous the concrete can spall. years or so, the most frequently specifi ed stain- concrete cover and cause corrosion on the Building stronger and longer— less steel rebars have been the nickel-contain- surface of the embedded carbon steel rein- a remarkable example ing alloys Type 316LN (UNS S31653) and two forcing bars (rebars). The resultant corrosion In response to this growing problem, numer- duplex grades, Alloy 2205 (UNS S32205) and products (rust) occupy a greater volume than ous laboratory tests and life cycle cost analy- Alloy 2304 (UNS S32304)—together with a the steel from which they were formed. This ses have highlighted the benefits of using smaller amount of Type 304. s Life Cycle Assessment shows that the choice of nickel-containing rebar over 70 years ago has By adjusting alloy compositions, stainless been a good investment for the Progreso Pier in Mexico steel rebar producers have been able to achieve an optimal combination of corrosion resistance, strength and formability. Alloy 2304 represents an attractive combination of these important properties—at a competi- tive price. This combination has led to the alloy being specified for several large bridges WIKIMEDIA COMMONS WIKIMEDIA in recent years. MAJOR BRIDGE PROJECTS The new alloys in action STAINLESS STEEL TONNAGE Alloy 2304 was recently selected for the new LOCATION YEAR ALLOY/TYPE (approx.) Champlain Bridge to be built over the Michigan, USA Bridge on I-696, near Detroit 1984 304 33 St. Lawrence River at Montreal, Canada. With a proposed span of approximately 3.4km New Jersey, USA Garden State Parkway 1998 2205 165 (excluding approaches), it is estimated that Ireland, Broadmeadows Bridge 2003 316 90 this bridge will require about 15,000 tonnes Oregon, USA Haynes Inlet Bridge 2003 2205 400 of Alloy 2304 rebar. New York, USA Belt Parkway Bridge, Brooklyn 2005 2205 200 All of the nickel-containing stainless steel New Jersey, USA Driscoll Bridge 2005 2205, 316LN 1300 rebars retain good tensile strength and impact resistance at sub-zero temperatures. Virginia–Maryland, USA Woodrow Wilson Bridge 2007 2205, 316LN 1100 These properties are important for highway Hong Kong, Shenzhen Western Corridor Bridge 2007 2205, 316 1300 bridges which must endure severe winters— Hong Kong, Stonecutters Bridge 2009 304 3000 together with the application of lots of cor- rosive road salt. Rhode Island, USA Sakonnet River Bridge 2010 2205 800 Additional applications Minnesota, USA Hastings Bridge 2010 2304 367 Rebars made from Type 316LN and Type 304 Minnesota, USA Lafayette Bridge 2011 2304 1963 retain good mechanical properties down to *Chemistry World, Vol 5, No3 March 2008

 NICKEL SPECIAL FEATURE , . , . ,   ROYAL CANADIAN MINT CANADIAN ROYAL

r Spanning the St. Lawrence River in Canada, r Alloy 2304 stainless steel rebar for the Hastings Bridge, Minnesota, USA project supplied by the new Champlain Bridge will contain Contractors Materials Company 15,000 tonnes of Alloy 2304 rebar. WWW.CMCMMI.COM INFRASTRUCTURE CANADA FRANK SMITH FRANK r Stainless steel rebar samples: A reel of tie-wire (bottom left), a threaded rebar

coupler (centre) and (top right) a tight ©WWW.TESOLUTION.COM U-bend illustrates formability. r A model of the Temburong Bridge is wind tunnel tested by TESolution. cryogenic temperatures which has led to their use in LNG storage facilities. Type 316LN is also a non-magnetic material and several TEMBURONG BRIDGE BRUNEI hundred tons of this alloy rebar have been round 3500 tons of nickel-containing Type 304 (UNS S30400) stainless steel used in the construction of MRI facilities at A rebar will be supplied by TISCO for the US$ 1.6 billion bridge to cross Brunei hospitals and clinics—as well as for special Bay. The ‘mega’ bridge will connect the districts of Temburong and Brunei-Muara. laboratories and data storage facilities. These two districts are separated by Malaysian territory, and travel between them Longevity, corrosion resistance and strength requires either a 1.5 hour journey by land crossing through Malaysia or 45 minutes reinforces the many uses of nickel-containing by boat. The 30 kilometre bridge, which will consist of a dual two-lane highway is stainless steel rebar as a cost-effective, anticipated to cut travel time to about 20 minutes. Construction started in 2014 farsighted solution. and the bridge is expected to be completed by 2019.

nickel, vol. 31, no. 1, april 2016 NICKEL SPECIAL FEATURE 5 r Schaffenhauser Bridge was designed with an 80 year lifespan The new Allt Chonoglais bridge under construction r Original Allt Chonoglais Bridge prior to demolition and showing signs of rebar corrosion  Longer lifetimes for major bridges

EUGENIO MERZAGORA (WWW.STRUCTURAE.DE) MERZAGORA EUGENIO Marginally higher initial costs for stainless steel results in much lower life cycle cost

he use of nickel-containing stainless steel rebar in bridges Tworldwide has been growing—although perhaps not as Significant savings are to be quickly as motorists wish when queuing impatiently while had using stainless steel after a lane or two of a bridge or elevated roadway is being dug up and repaired. The relatively quick corrosion of carbon or epoxy only 25 years, with even greater coated rebar results in cracking of the concrete and thus the need for major maintenance, leading to blocked off lanes of savings extending well into traffic while the concrete is removed and the rebar replaced. the future. Today, transportation authorities are increasingly factoring in the indirect costs to society of traffic delays (wasted fuel, wasted time) as well as environmental costs (air pollution, would have only added marginally to the cost of the project. landfill costs) when specifying construction materials. This Many factors can affect the amount of chloride that will reach holistic thinking makes the selection of stainless steel even the rebar, including cement type, depth of cover, and water/ more clearly justifiable. cement ratio. This means that not all rebar in the structure needs to be in stainless steel. Rebar positioned deeper in the Even without considering these less tangible factors, stainless structure, or not otherwise exposed to higher levels of chlorides steel is the best choice in many cases when looking at costs over can be supplied in the lower cost unalloyed steel. Using a the life of the bridge. When the Schaffhausen Bridge, which combination of stainless steel in the top layer and carbon steel spans the Rhine in Switzerland, was planned in the mid-1990s, in a lower layer of a bridge deck is a common practice. Tests have the design called for it to have an 80-year life with minimal shown that galvanic corrosion is not an issue here. maintenance and no loss of structural integrity. The use of conventional reinforcement materials, either coated or plain Today, designers are specifying longer lifetimes for major carbon steel, would mean major repairs roughly every 25 years, bridges, as great as 125 years. The initial cost of some bridges whereas the use of Type 304 (UNS S30400) stainless steel rebar may be a few percent higher with the selective stainless steel would meet the 80 year criteria. By the selective use of stainless option, but in all cases, results in much lower life cycle cost. steel, the total cost of the bridge was increased by only 0.5%. The Allt Chonoglais bridge near Orchy, Scotland is a more Significant savings can be realized after only 25 years when recent example of stainless steel rebar use. The old bridge was stainless steel is used, with even greater savings accumulating found to be under strength for the future loads it would carry, over the life cycle of the structure. If this bridge had higher road and could not be economically repaired. De-icing salts over salt loadings, or was near to seawater, a higher alloyed rebar time had caused corrosion of the carbon steel rebar resulting in material such as Alloy 2304 (S32304), Type 316L (S31603) or cracking of the concrete and leading to a reduction in structural even Alloy 2205 (S32205) may have been needed, and that too integrity. A new and stronger structure was engineered with

6 NICKEL FEATURE nickel, vol. 31, no. 1, april 2016 OUTUKUMPU Navy Pier Point Loma ll steel hulled sea-going vessels pick up a magnetic sig- Anature as they travel the globe. For naval vessels, this magnetism can be detrimental, as it can be used by enemy magnetic mines and other magnetic sensing equipment to identify and destroy them. Many navy vessels therefore undergo a deperming operation (also called degaussing) that removes that permanent magnetism and helps to cam- ouflage them. The pier where this operation takes place should show no magnetic response either, hence the need for nickel-containing austenitic stainless steels. When the U.S. Navy selected concrete reinforcing (rebar) and stranded wire for their pier at Point Loma, San Diego, California, they used both Type XM-29 (UNS S24000) and Type 304 (S30400) stainless steel. The chosen alloys in the pier had to with- stand the effects of the Pacific Ocean salt water diffusing into the concrete combined with warm temperatures. The magnetic permeability of Type XM-29 remains very low even after severe cold working, so the pre-stressing strand used in the square piling, pile caps and in the deck were also of this alloy. Where the stainless steel strand was only lightly stressed, Type 304 was used. In 2008, after 20 years of ser- vice, an inspection was made of the whole structure. The only minor corrosion found was on the Type 304 stainless steel where there had been insufficient concrete cover (less r Stainless steel reinforcement having been fully cut and bent at than 12mm). Where there was 25mm or greater cover, the Outokumpu’s Sheffield Stainless Bar facility for the new Allt Type 304 and all the Type XM-29 was found to be in excel- Chonoglais bridge lent condition. Similar piers have been constructed at King's Bay, Georgia and Pearl Harbour, Hawaii. a requirement for a design life of 120 years. After considering s Point Loma the expected chloride levels over its lifetime, the Highways Agency and Transport Scotland chose Alloy 2304 (S32304) stainless steel for selected areas, such as the bridge deck, abutments, wing walls and bearing plinths. The total cost of the construction was £1.8 million (about US$2.5 million) with the 123RF STOCK © F8GRAPHER © STOCK 123RF new bridge open to traffic in August 2013. In 25 years or so, motorists driving on the A82 between Glasgow and Inverness will appreciate the forethought given by the Scottish engineers for using a nickel-containing stainless rebar that will last the 120 design life of the bridge.

nickel, vol. 31, no. 1, april 2016 NICKEL FEATURE 7

KILLION O'SULLIVAN KILLION

 NICKEL FEATURE , . , . ,  

Stainless steel takes the strain e role of nickel-containing stainless steel in load-bearing applications

tainless steel is a highly versatile material, possessing a unique temperatures above 500°C and retains its stiffness better at all tem- Sselection of useful properties which can be exploited in load- peratures. Because of excellent ductility coupled with significant bearing applications. The main property distinguishing stainless steel strain hardening behaviour, stainless steel can absorb considerable from carbon steel is its inherent corrosion resistance, due to the impact without fracturing. This has led to its use in structures and tightly adherent protective layer of chromium oxide which equipment required to resist extreme loading, such as fire and blast spontaneously forms on its surface in the presence of oxygen. This walls for the oil and gas industry as well as security walls, barriers, means that stainless steel components can be exposed to a wide doors and gates. The corrosion resistance of stainless steel makes it range of environments without the need for protective coatings and ideal for components in aggressive environments which are inacces- is ideal for projects where an exposed metallic finish is required. sible or difficult to inspect, maintain or replace. For this reason, stain- Due to differences in chemical composition, a stainless steel struc- less steel is a popular choice for load-bearing components in the tural member subjected to a fire behaves differently than a carbon nuclear industry. Here we take a look at some recent diverse uses of steel member: stainless steel loses strength at a slower rate for stainless steel in structural components.

vs Stainless steel canopy at Gasholder Park, sSteel-concrete-steel test specimen prior to sStainless steel fire and blast walls were close to King’s Cross, London, UK concreting (carbon steel plate on the left, installed on the Arkutun Dagi platform stainless steel plate on the right) MTE LTD MTE VTT JOHN STURROCK JOHN

Gasholder Park Blast resistant Gasholder No. 8 was constructed in the 1850s. Bearing the load in the nuclear industry Nearly 300 tonnes of Alloy 2304 (UNS S32304) Part of the largest gas works in London, UK, Load-bearing steel-concrete-steel modu- duplex stainless steel (containing 4% nickel) 2 it became a well-known landmark until it lar structural units in new nuclear power were used in the fabrication of 13,400 m of was decommissioned in 2000. The 25m tall plants are a popular choice, speeding up fire and blast walls, heatshields, wind walls and blast relief panels for the Arkutun Dagi guide frame was dismantled in 2011 and construction, simplifying the attachment development. This is one of three offshore refurbished before being re-erected in of equipment support points and reducing fields developed by the Sakhalin-1 project, 2013. To provide an interesting contrast to costs. When one side of the unit is exposed which has combined reserves of 2.3 billion the gasholder frame, Architect Bell Phillips to a corrosive environment, modules with a designed a 30m diameter polished stainless barrels of oil and 17.1 trillion cubic feet of carbon steel plate on one side and a stain- steel circular canopy within the perimeter gas. Sakhalin is a remote, sparsely populated less steel plate on the other present an eco- of the frame. The canopy is supported by island in the icy Okhotsk Sea, just off the nomic solution and have been used in the 150 columns, made from 25mm thick mirror east coast of Russia. The fire and blast walls Westinghouse AP1000 pressurised water polished 316L (UNS S31603) stainless steel, are lightweight, high integrity, fully welded, reactors in China and the US (Sanmen 1 & 2, containing around 10% nickel. The columns gastight systems manufactured from pro- Haiyang 1 & 2, Vogtle 3 & 4). are positioned at a wider spacing near the filed stainless steel and insulated to achieve canal to encourage people to enter the park Although design codes for modular steel- specified fire ratings up to H120 and 120 min- and give unobstructed views towards the concrete-steel construction in nuclear power ute jet fire, and to resist blast pressures up to canal. Away from the canal, the columns are plant exist in Japan, South Korea and the 1.5 bar. The walls were designed, engineered closer together, creating a greater sense of USA, there is no code in Europe. This is being and manufactured by MTE Ltd in Darlington, enclosure. The canopy roof is 15mm thick addressed by a major EU-funded project led UK before being shipped to South Korea, for 316L stainless steel plate, and incorporates by the UK’s Steel Construction Institute. The final assembly. ExxonMobil started produc- a geometric pattern of perforations, formed SCIENCE project, due for completion in 2017, tion at the Arkutun Dagi field in January 2015. by water jet cutting. The perforation density includes tests on 9m long beams where one These are just some examples of how the increases towards the canal to create a sense plate is carbon steel and the other 10mm versatile nature of stainless steel is provid- of openness, and a dappled effect as sun- thick Type 304L (UNS S30403), stainless steel ing solutions for a wide range of structural light filters through. which contains about 10 % nickel. challenges.

, . , . ,   NICKEL FEATURE 10 NICKEL IN USE A A studentsInspiring To access the service go to www.nickelinstitute.org To service the access (9%). &Petrochemical (14%) Chemical and Construction and Building (36%); Architecture, Engineering including sectors of end-use variety for a received were Inquiries answered. and received were inquiries 500 2015, around In outcomes. successful with applications appropriate for effectively cost them to use and materials of nickel-containing benefits the to understand users enables service the addition, In use. and handling safe performance, optimum to ensure uses and properties its nickel, about knowledge technical offering specialists, qualified of highly network aworldwide by provided is Expertise service. The course covers 11categories, divided where appropriate into thatfittheircurriculum. the parts steel. Lecturers canusethecourseinitsentirety, orpickandchoose educate students andyoung civilengineers abouttheuseofstainless comprehensive andconcisecourse aimedto lecturers helpuniversity from academiaandindustry, havewith apanelofexperts compileda and available teaching time. To answer the problem, the ISSF together according isthelackoftimefor tocurricula Heritier coursepreparation The mainreason for stainlesssteel beingexcluded from university stainless steel costs more steel!” thancarbon stainless steel. areto Instead, that they holdthesimplisticview likely of the benefits, applications or design considerations specific to Forum (ISSF). “As aresult, architects andcivilengineers are notaware studies,” Stainless Steel says of the International Bernard Heritier taught to architecture their and civil engineering students during sustainable alternative isnotusually materials to otherconstruction ofstainlesssteel to capability provide and anattractive “The sector.building andconstruction with themultiplepossibilitiesandadvantagesofstainlesssteel inthe aims to inspire studentsofarchitecture university andengineering ask our panel of experts TECHNICALNI HELP produced by experts fromproduced thestainlesssteel industry. by experts The course new ‘pick and mix’ coursefor university studentshasbeen including stainless steel, can contact the Nickel Institute’s free Technical Help Help Technical free Institute’s Nickel the contact can steel, stainless including materials, nickel-containing and nickel about questions specific nyone with

and click on Technical Help. on Technical click and It ispublishedinFrenchIt andEnglishwithotherlanguagesplanned. www.nickelinstitute.org orwww.worldstainless.org/training/ Civil Engineeringisavailable for free download from: The course, StainlessSteelsforLecturers andStudentsofArchitecture and applications.”stainless steel in structural and use the in material specialised workshops, for example on version year to architectural allfourth studentsaround thecountry AssociationDevelopment is anenthusiast. present a condensed “We chapter. John Tarboton StainlessSteel Africa oftheSouthern reference guide as there is a useful list of sources at the end of each in tutorials, others are usingitfor trainingandalsoasa internal ofways. usethematerial The Some courseisbeingusedinavariety are allcovered. andfinishes, as joiningandfabrication well assustainability steel surfaces applications, of stainlesssteel structural stainless mechanical properties green walls, furniture andwater urban distribution. The corrosion and Topics to applicationssuchasfacades, rangefrom stainlesssteel inart, intoincorporated theoverall product. years by academicswhosefeedback apanelofuniversity hasbeen over thepastcoupleof hasbeenfine-tuned more detailedsections.It Development Association.Development hosted by Stowarzyszenie Stal Nierdzewna (SSN), the Polish Stainless Steel r Architecture students in Poland take in astainless part steel workshop nickel, vol. 31,no. 1,april 2016

ISTOCK PHOTO © © IGOR TEREKHOV PHOTOS MDN MEDIA – AG WAGNER PHOTO © SIEMENS AG , . , . , 

makes light brick soffits of work steel stainless Nickel-containing B the rate of construction and reduce build costs. Innovations in nickel-containing stainless steel fixing products are helping to accelerate Behind abeautiful façade, asignificant contribution is made by fixings and fasteners. ing flawless brick soffits for masonry for masonry soffits brick flawless ing to creat solution simple and a quick to produce Kevington Ibstock specialist cut-brick with partnership in vation inno an come with up have They tion. construc concrete and for brick fixings steel of stainless range awide ufactures man and designs UK, Sheffield, in tered headquar Products, Building Ancon applications. structural these in steels or galvanised carbon over solution long-lasting a provides steel Therefore, nickel-containing stainless involve. it would inconvenience and costs substantial due to the impractical or due to inaccessibility impossible often is or replacement maintenance inspection, and once installed, invisible are They load. under permanently are and or structure, abuilding within tions connec critical provide products Fixing easily. and quickly building for look anew desired the creating and on-site soffits masonry time-consuming complicated, to build need the removing are units prefabricated steel Now stainless façade. masonry to the dimension extra an ing recessed windows) are an increasingly popular design feature on buildings add on buildings feature design popular increasingly an are windows) recessed for example, out from, extends that of cladding (the area reveals and soffits rick ------today’s fast-track construction. fast-track today’s for appropriate it particularly making significant savings in installation time, offers This equipment. lifting specialist without installed to be units the allow will cases most in which of concrete, weight the half about has system soffit Nexus new The alternative. concrete cast more traditional the over benefits considerable offers unit brick-faced the to backing steel stainless lightweight The angle. support brick steel stainless S30400) (UNS aType 304 with module building brick-faced less-steel-backed astain combines system Nexus® The Kelly. Lisa Manager, Ancon's Divisional explains façade,” brickwork main the with alignment fect per achieve and soffits brick to create it quicker makes design modular weight light advanced “The façades. building - - - - r r brickwork façade. are simply pointed to match the main ment, and once in position the brick slips and adjusted easily, align creating perfect design allows units to installed be two-part and then bolted into position. This simple angle the support pre-fixed and pre-drilled site. are simply They offered by up hand to prefabricated to and made measure off- angle. Individual unitsbrick support are faced building with module astainless steel (UNS S30400) stainless-steel-backed brick- system Nexus combinesThe aType 304 London, UK. redevelopment, in Kensington and Chelsea, sively in reveals the on Silchester Estate system Nexus new has usedThe been exten

NICKEL IN USE - -

 ANCON BUILDING PRODUCTS HAWORTH TOMPKINS ARCHITECTS AND KEITH HUNTER 

NICKEL IN USE FLORIAN COAT temperature is the most sensitive environmental factor for a factor environmental sensitive most the is temperature Air for Sunna. of R&D Head Baillot, Raphael account,” explains into taken to be had all of to 100km/h up winds desert and storms sand as well as heat intense and radiation solar “Rainfall, conditions. extreme in used be can which technologies battery compared researchers e Energy. for Solar Institute National of the part CEA-INES, laboratory, research French with study year of atwo result the was battery of anickel-based choice e system. management battery the into programmed are and charge, over-dis- and over-charge to prevent used are methods detection end-of-discharge and End-of-charge element. key the is agement man- discharge and charge life, along has battery the To that ensure chemistry battery Durable connections. electrical or external for cabinets need the as well as ground, the in battery the to bury having both avoids and installation simplifies significantly is of top amast. the at placed and lamp of the head the inside integrated are batteries NiMH Small at height. set when advantage important an be can battery weight alight systems, lighting solar For stand-alone to install. simple and quick and vandalism limit to designed free, maintenance essentially is which remote areas in lighting public provide lamps e system. management energy a smart with coupled battery, (NiMH) hydride nickel-metal a with equipped are which panels solar with topped posts lamp developed has Sunna difficult. are maintenance on-going and installation where regions or desert arid for rural, adapted tions solu- of lighting arange with problem this tackling is lighting, of solar manufacturer and designer aFrench Design, Sunna immense. are for citizens, security and of safety terms in benefits Yet the conditions. climatic extreme in so especially and challenge A areas of the world without a grid system is a considerable aconsiderable is system agrid without world of the areas in lighting air open and street reliable and consistent chieving

communities in extreme climatescommunities inextreme light andasafer environment to hydride bring batteries Nickel-metal WAYTHE LIGHTING ever the weather and enhances the battery lifespan.” NiMH offers offers NiMH lifespan.” battery the enhances and weather the ever what- program lighting the optimizes system management energy electronic “A smart Sunna’s of Marketing. Head Pargade, Laura says costs,” maintenance additional prevents batteries NiMH by provided “Reliability ayear. than less in expire can and years two of to up alife have systems similar in batteries acid lead countries, African In critical. is storage system’s energy of the efficiency night, at for use day the during energy solar stores battery the “Because applications.” lighting for solar technology battery best the is “ is Mercadal. Nicolas engineer, Sunna says on earth,” environments harshest the under even performance optimum to get an us allows metal of this resistance temperature high e Baillot. says products,” for our lifespan unrivaled an to reach us allow batteries based nickel- “ e range. temperature awide over reliably function to needs therefore battery e freezing. to around fall even can year of the times at certain some regions in and 10°C at night, to day the during 58°C around from range can temperatures Here conditions. operating desert East or Middle for Africa suitability as well as years of ten alifespan predicted and efficiency for its technology NiMH confirmed tests aging Accelerated lifespan Unrivalled conditions. tough in lifespan and performance its improve and environments, for desert chemistry battery resistant most the to find was objective the and battery “ “ The nickel-based batteries allow for our products.”for our us to reach an unrivalled lifespan , . , . ,  , . , . , 

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sustainably. and reliably everywhere, to everyone, light to bring potential the with technology battery on NiMH based systems lighting solar to thanks past of the athing be could remote areas in Blackouts Jordan. in camp arefugee as well as Cameroon, and Nigeria Senegal, including Africa, in are Many systems. the from now benefiting are 20 countries over in Communities -20 from to +70°C. nologies, tech- battery rechargeable for available ranges temperature largest one of the covers and (55 to 70 Wh/kg) energy specific reasonable enhances thedurability ofthebattery, offeringatenyear lifespan. electronics systemmanagesenergy, optimisesthelightingprogram and to +70°Cpowers highlyefficientLEDlights. The unit’s intelligent whichwithstandstemperaturesA longlastingNiMHbattery from -20°C s Sunna’s developedNanogridsystemconnects newly asolarstreetlight to eighthomesofferindoorlightingandmobilephonecharging. s Before thesolarlightingsystemfishermenrelied onimprovised Z hours market Extending which start there at 4 a.m. are being developed. are being there at 4a.m. start which commercial lights, street activities solar the of aid the with now, but darkness the of because restricted was dockside the at arrived Selling fishing fish the boats when dark. in the work flashlights to to them to enable tape heads their with attached fishermen the system, street-lightSunna solar “Maxi” Design the installed municipality the Before sold. and are smoked caught fish locally where areas to fishing the dedicated industry harbour, has and abustling River Casamance the with of mouth r Sunna’s iSSLMaxisolarpowered lightsystemislightingthe head torches. harbour ofZiguinchor, Senegal. Senegal and has a population of over 230,000. It lies at Itlies the over of 230,000. has and apopulation Senegal is area chief town Casamance iguinchor the the of of NICKEL IN USE

 FLORIAN COAT BENOIT POITEVIN FLORIAN COAT 14 p. 4, 5, 6, 7, 6, 5, 4, 11p. S30400 7 p. S24000 UNS No. UNS p. 9 p. S30403 p. 4 p. S31600 p. 6, 9 6, p. S31603 p. 4 p. S31653 p. 2, 4, 6, 7, 6, 4, 16 2, 9, p. S32304 16 6, 4, p. S32205

NICKEL ZHENG CHEN UNS details treatment to obtain optimum properties for properties optimum obtain to treatment heat and manufacture during control strict requires but also hardening allows which complex, is microstructure Their 5% nickel. around have alloys used commonly most The forms. cast and wrought in both manufactured are alloys The tools. sparking non- and propellers valves, and pumps water sea to bearings gear landing aircraft from range uses End properties. galling excellent offer also alloys These bronzes. aluminium nickel producing iron, with combination in of nickel addition the with improved be can strength and resistance corrosion A Guidance on nickel aluminium bronze for engineers New Publication New overheating batteries batteries overheating offer asolution for nanotechnology and Nickel spiky nanoparticles of graphene-coated nickel. spiky nanoparticlesofgraphene-coatednickel. battery whenitcools.Thefilmisembeddedwith ion batteryfromoverheating,thenrestartsthe s

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C Co ------21.5- - - Chemical compositions (in percent by weight) of the alloys and stainless steels mentionedinthisissueof ofthealloysandstainlesssteels Chemical compositions(inpercentbyweight) 22.0- 18.0- 18.0- 16.0- 16.0- 16.0- 17.0- 20.0 20.0 23.0 19.0 18.0 18.0 18.0 24.5 rCu Cr 0.05- 0.60 ------downloaded from www.nickelinstitute.org. from downloaded be can 222 Publication ofCDA A PDF version appendix. an in included are requirements property mechanical and tion composi- related and specifications nations, of desig- details Full provided. is publications useful and of references alist and described are fabrication and welding of manufacture, Methods performance. goodobtain service to given information and explained is iour behav- corrosion Their sectors. other and aerospace for marine, components bronze aluminium nickel or produce design ify, spec- to wishing for engineers guidance cal practi- offers publication A newly-released applications. specific repeated heating cycles cooling and over revived and shut down that be can battery Stanford. first the "We've designed professor of chemical engineering at Zhenan a Bao, said batteries," lithium-ion accidental of fires problem the insolve different havestrategies to "People tried hoverboards. and systems computers and to recliners navigationfrom devices, battery-powered of range awide on firesof that havepromptedbans and recalls could prevent kind the technology new The cools. temperature the immediately when restarts then overheating before and down that shuts S developed the first lithium-ion battery battery lithium-ion first the developed researchers havetanford University bal. bal. bal. bal. bal. bal. bal. bal. Fe 11.5- max. max. max. max. max. max. max. 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 2.00 14.5 2.50 nMo Mn 2.00- 2.00- 2.00- 3.00- 0.05- 3.00 3.00 3.00 3.50 0.60 ------0.20- 0.14- 0.10- 0.05- 0.40 0.20 0.20 0.16 N - - - - Nb - - - - practical battery applications." battery practical great holds promise for strategy "This improved and safety," Cui performance said. high battery that achieve both can strategy reversible a reliable,design provides fast, "Compared with previous approaches, our again. electricity producing starts battery reunite the and particles the cooling, During current flowing. stops electric and separate particles the overheats, battery the When electricity. nickel conduct graphene-coated of together,Bunched nanoparticles to nanotechnology. turned Chen Zheng scholar postdoctoral To Cui, Yi and problem Bao the address without compromising performance.” 10.0- 10.0- 10.0- 14.0 10.5 14.0 12.0 14.0 8.0- 8.0- 4.5- 3.0- -3.7 2.3 5.5 6.5 Ni 0.045 0.045 0.045 0.060 0.045 0.045 0.045 0.045 0.040 0.045 0.030 0.030 max. max. max. max. max. max. max. max. S P nickel, vol. 31,no. 1,april 2016 0.040 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.030 0.020 0.020 max. max. max. max. max. max. max. max. max. max. Nickel max. max. max. max. max. max. max. max. 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 Si . Ti ------

NICKEL CATALYST RESEARCH moves into high gear

n the search for cheaper, clean, renewable energy, North IAmerican researchers are working to develop new nickel catalysts that will make fuel cells more affordable. Transportation by passenger cars, trucks, buses, rail, marine and air accounts for 20% of energy use in the US, primarily in the form of fossil fuels, so the search is on for environmentally- friendly alternatives. The two most promising candidates for cars are rechargeable batteries and fuel cells, which convert the chemical energy of hydrogen to electricity. Battery cars have a short driving range and long battery charging time. By contrast, fuel cell cars can be charged in less than five minutes and be driven for

more than 500km/300 miles in one charge. UNIVERSITY DELAWARE OF While rechargeable batteries, to date, have had the greatest r Yushan Yan, at the wheel of a fuel cell vehicle, is conducting commercial success, Dr. Yushan Yan and his colleagues from research on the use of nickel as a catalyst in an alkaline electrolyte the University of Delaware recently reported a breakthrough that promises to bring down the cost of hydrogen fuel cells. that promises to make fuel cells more affordable by replacing expensive platinum with catalysts made from nickel at a fuel cell, HEMFC), opens up the possibility of using nickel significantly lower cost. catalysts and other less expensive components. The commercialization of fuel cells is hindered by the high Peak power density of HEMFC is less than PEMFC, but price of platinum (~$50 per gram). The current state-of- Dr. Yushan and his colleagues synthesized Ni nanoparticles the-art fuel cell is the proton exchange membrane fuel cells supported on nitrogen-doped carbon nanotubes which (PEMFC) using platinum for both the anode and cathode. displays activities similar to Pt in HEMFC. “This new hydroxide However, switching the operating environment from an exchange membrane fuel cell can offer high performance at an acidic to a basic one (that is, a hydroxide exchange membrane unprecedented low cost,” Yan says.

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, . , . ,   NICKEL IN BRIEF  STAINLESS STEEL SELECTED FOR GAUDÍ’S BARCELONA MASTERPIECE LA SAGRADA FAMILIA

years after the first stone was laid, Antoni Gaudí’s magnificent basilica, the Sagrada Familia has amounted to over its 134 Sagrada Familia in Barcelona is approaching the final stages of construction. lifetime, the annual costs of construction Nickel-containing stainless steel is playing an important role in this extraordinary structure. and maintenance are currently around Gaudí, a committed Roman Catholic, was Completion is scheduled for 2026, to €25 million a year, funded by the three himself relaxed about the time taken for his coincide with the centenary of the million annual visitors to the site and massive edifice to be built saying “ e work architect’s death. When completed, the private donors. of the Sagrada Familia progresses slowly 18 towers of the Sagrada Familia will because the master of this work is in no reach heights from 94 to 172 meters great hurry,” referring to his ‘client,’ God. and nickel-containing stainless steel is an important structural component. Selected because of its high strength, exceptional corrosion resistance and reduced life cycle costs, stainless steel rebar, machined components and plasma- cut plate products are being supplied by Outokumpu. Alloy 2304 (UNS S32304) and Alloy 2205 (S32205) nickel- containing duplex stainless steels have been selected as cost-efficient and long lasting solutions for the demanding structures. Six new towers have still to be added to the structure, the highest of which will r Nickel-containing duplex stainless steels are an important structural component. make the basilica Europe’s tallest reli- The Sagrada Familia’s 18 towers will reach gious building. While it’s impossible to heights from 94 to 172 meters. estimate how much the construction of the OUTOKUMPU COURTESY OF SAGRADAFAMILIA OF COURTESY OUTOKUMPU