One in 9 people all over the world do not have access to drinking water. (Source: World Finance)

However, it seems the world just can’t get enough of water. Global water demand is projected to increase 55 percent by 2050. Most of the demand will be driven by the agriculture industry, which currently makes up 70 percent of freshwater consumption, but is projected to grow another 69 percent to meet the food demands of the growing population. New-growth industries will put additional pressure on freshwater supplies. For example, water used to cool power stations is projected to increase by more than 20 percent by 2055 and water demand from the manufacturing industry in developing nations will grow by 400 percent by 2055. Unfortunately, 97.5 percent of earth’s surface water is inadequate for human use.

The growing demand is putting heavy pressure on current water supplies that appear to be shrinking due to global warming and climate change. As a result, there have been extensive efforts by individuals and households to conserve and recycle water. However, in major cities around the world, water is wasted before it even reaches people’s taps.

Water leaking through the cracks

In the U.S., about 2.1 trillion gallons of water slip through the cracks, literally, each year, or about 6 billion gallons of water per day. The ancient water infrastructure throughout the country is full of leaking pipes, cracked mains and broken meters.

For example, the largest water filtration plant in the world, Jardine Water Filtration Plant, is located in the city of Chicago and pumps out purified water to about 5 million residents via thousands of miles of pipes. However, about 22 billion gallons of water leak through old pipes and broken water mains in the city every year. In Philadelphia, the Water Department pumps out 250 million gallons of purified water daily to nearby residents, but more than 60 million gallons are lost through the pipes every day.

Billions of gallons of drinking water are wasted through cracks and leaks in water pipes. (Source: UCLA)

In Canada, home to some of the most abundant supplies of freshwater, there are cities with 35 to 45 percent water loss. Ontario, for example, has outdated and leaky pipes responsible for the loss of about  CAD 700 million per year in wasted drinking water.

In the UK, about 872 million gallons, or 20 percent the nation’s treated water supply, leaks through old pipes before it reaches residents. This is 62 million gallons more per day than water loss rates from a decade ago, showing the severe consequences aging pipes can have.  

Faulty water pipes

The biggest problem with water systems around the world is simply their age. They were built ages ago, often with insufficient materials and outdated technology, and now, they’re too expensive and extensive to repair or replace.

However, old pipes can pose a number of problems. Besides the gallons of wasted purified water, an outdated water system can pose major health risks. In the U.S., 1 in 4 people drinks unsanitary water due to insufficient water infrastructure. It has already been proven that contaminants can enter the water system through leaks that are most often caused by corrosion and material defect.

Cast iron pipes are highly susceptible to corrosion and structural damage. (Source: Micro Power Grids)

Water pipes installed decades ago are traditionally made of cast iron and laid on wooden blocks or rocks. Such pipes are highly corrosive and most susceptible to damage. Also, a well-functioning pipe keeps contaminated water out with pressure from mains that forces water out of minor cracks, but not in. Over time, damage to a certain section of a pipe can cause this pressure to drop, and groundwater often finds its way in through cracks.

Making it right with steel

The ideal solution for outdated, faulty water pipes would be to replace them with new ones equipped with the latest damage detection and repair technologies. However, such projects are not only expensive, but a city’s water system is often politically, regionally and physically intertwined with other entities, making it difficult to take on such a mammoth task.

Thus, cities opt for isolated repairs instead, either placing a stainless steel clamp over the damaged area or inserting a smaller stainless steel pipe inside the existing, cracked pipe. Stainless steel is the most common material for repairing and replacing outdated cast iron, concrete and lead pipes due to its excellent strength and resistance to corrosion. Higher grades of stainless steel, such as POSCO’s PossSD, can also resist high levels of pressure and are naturally resistant to microbes. Stainless steel can also be manufactured to withstand extreme temperatures.

Major cities such as Tokyo, Seoul and Taipei are undergoing massive projects to replace the majority of their water pipes with stainless steel to ensure safe and abundant drinking water for residents. For other cities, repairing leaky pipes with stainless steel will save millions of dollars currently leaking through the pipes and prevent illnesses associated with contaminated water. As the global demand for water continues to grow and fresh water supplies continue to shrink, conservation is becoming more important than ever, ensuring that stainless steel will play a vital role in water pipe repairs and replacements for years to come in efforts to correct and maintain the system that serves the basis of all human activities.

Cover photo courtesy of The Spruce.

Besides utility managed solar farms, solar developers are targeting other open spaces, such as auto parking lots, for large-scale energy savings (Source: Phys.org)

The surge in these installations is prompting a parallel upswing in solar infrastructure, which is seeing its own technology advances as a result of high demand and the need for greater cost efficiencies. While sturdy racking is important to protect against the ravages of nature, one of the main requirements for large solar farms — and any larger installation — is solar tracking equipment.

Solar tracking offers grid operators the opportunity to squeeze efficiency from sunlight at all hours of the day. While fixed-panel arrays are highly efficient for general-purpose energy harvesting, single-axis solar tracking can increase a solar farm’s annual output by roughly 30 percent. Dual axis trackers can add 10-20 percent beyond that. For example, air mass tables for solar panels show that a panel mounted on a tracker can harness as much as 60% of solar intensity in the late afternoon at an angle of 15 degrees, 50% at 10 degrees, and capture 25% at a mere five degrees. In large installations these gains can mean the ability to respond with enough power to satisfy peak demand.

Solar tracking systems explained

A solar tracking system is used for a variety of applications. Depending on the applications, the mounting systems will differ somewhat. Typically solar trackers hold single or multiple standard flat panels, arranged in rows and funneling power to an energy storage site or directly to a substation.

Parabolic mirrors can focus sunlight onto solar collectors. (Source: EU Solaris)

However, solar trackers are critical for large-scale solar installations using concentrated solar power (CSP). These trackers hold mounted mirrors that reflect sunlight to a central collector tower containing hot liquid or gas. They are also a key element in concentrator photovoltaic (CPV) installations that use parabolic mirrors or lenses to focus sunlight (and even ambient light from the sky) into solar collectors that are part of each unit. These panels and mirrors require precise angles to enable optimized concentration of the light onto a fixed-location tower, into Fresnel lenses, or into a solar thermal collector. The tracking system may be centralized, where a single motor moves many rows of panels at once, or a distributed system, where an individual motor moves one row or table of panels.

Horizontal single axis trackers (pictured above) are better suited for lower latitudes. (Source: Energia Solar)

Solar tracking devices can be classified by the number of axes around which they rotate and by their orientation. Horizontal single axis trackers (HSATs) are horizontal to the ground and mounted on rotating tubes supported by pylons or frames. Horizontal single axis trackers with tilted modules (HTSATs) are similar but installed at an angle, for higher latitudes, but rotate the same way. Vertical single axis tracker (VSAT) panels, also for higher latitudes, rotate around a vertical axis, but the layout must be designed to prevent the rows of panels from casting shade on each other. A hybrid horizontal/vertical tracking system is referred to as a tilted single axis tracker (TSAT).

A tilted single axis tracker is a hybrid of horizontal and vertical tracking systems. (Source: The University of Queensland)

In addition to the panels or mirrors, tracker hardware may include steel posts or rails, cables, junction boxes, slew drives to rotate the panels, and hydraulic dampers to provide flexible resistance against the wind. The structures must be robust, well-anchored, easily transported and installed, and must be able to withstand the elements, including hot or cold locations, strong storms, heavy rain or snowfall, and even seismic activity.

Perceptions of solar tracking

For a time, solar tracking for large-scale installations had a reputation as a more expensive and maintenance-intensive technology despite the higher energy capture rates. Some of these reliability perceptions still linger. In actuality, according to Greentech Media, solar tracking systems boast a 99.9 percent uptime rate and advances continue in mechanical functionality and software-based optimization. In fact, the U.S. Energy Information Administration reports that of all utility solar projects constructed in the US in 2016, 79% used solar tracking rather than a fixed panel.

Advances in solar tracking

Despite being perceived as a less exciting infrastructural component of the solar industry, solar tracking has seen a number of technological and mechanical breakthroughs that promise increased growth due to lower costs and increased weather resistance.

One of the challenges is the economics of land use and site preparation. Until recently, utilities and third-party solar farm developers had to plan carefully to ensure that the needed amount of power could be generated from a particular site size given solar tracker configurations (e.g. HSAT vs VSAT). Additionally, they had to take into consideration the site contours and how much grading and preparation would be required to adapt the site to optimized solar tracker deployment. As a result, there has been stiff competition for flat sites.

Utilizing slopes and rolling terrain

In California, a company called Nevados Engineering is on the verge of launching single axis trackers designed to work on south-facing and sun-facing slopes and varied terrain, which offer better solar exposure. The company’s All Terrain Tracker (ATT) technology uses unique bearings that allow articulation with the driveline so it can fit the terrain using the same kind of posts as on flat land. Every post in the row is used to withstand the slope load, which is the toppling force exerted by the structure being pulled down the hill by gravity. The tracking units can handle slopes of over 20 degrees and can also handle side-to-side, and vertical, post misalignment of up to two feet. The advance vastly reduces the need for grading and landscaping, enabling solar developers to purchase significantly cheaper sloped or contoured terrain to maximize solar energy capture.  The company’s software enables developers to predict solar production for a site to calculate the economics.

Nevados Engineering’s All Terrain Tracker technology and help install solar trackers in all kinds of terrains. (Source: LA Cleantech Incubator)

“We need to look beyond what we expect solar trackers to do,” said Yezin Taha, CEO of Nevados Engineering. “Installing trackers on a slope can capture 7% more solar energy than trackers on flat ground, and 32% more energy than fixed tilt systems.”

Leveraging non-standard sites

Another recent development, floating ground mounts, has also made more large-scale solar sites available. While most solar trackers are mounted on posts that are driven directly into the ground or less frequently, on posts that use concrete foundations or ballast, certain kinds of terrain won’t support driving posts or invasive concrete structures. These sites, such as capped landfills, can be highly suitable for solar installations due to their height, restricted access, and unsuitability for other uses. The development of floating ground mounts, where the tracker is placed on a gravel pan that can be filled with a variety of materials, has made possible the use of these kinds of sites where posts can’t be driven.

Resisting the elements

Advances in resistive materials also show promise for the solar tracking industry. Posts and other tracking components are typically made of galvanized steel, which means they are coated with a high zinc content layer. Galvanization has been the most weatherproof and anti-corrosive solution to-date, but it still allows rust to form over time. Moisture can be an electrolyte that enables galvanic corrosion to occur, so that as humidity increases, the rate of corrosion increases. Also, atmospheric contaminants can catalyze the chemical reaction. Chlorides in marine environments, as well as and sulfur dioxide and nitrous oxides in industrial locations, may present a higher risk of corrosion.

Recently steel companies such as POSCO have begun to add magnesium to the coatings for further protection, a process that had been prohibitively complex until now.  POSCO’s PosMAC is a combination of zinc, aluminum and magnesium that “heals” any exposed parts of the steel by forming a layer of simonkolleite, a stable compound, over the vulnerable area. The development promises greater ruggedness and durability for tracking components.

Streamlining operations and maintenance

Finally, the advent of sensors, drone-based inspections, and the Internet of Things (IoT) will have a growing impact on solar farm operational costs by enabling remote monitoring, hardware predictability, just-in-time replacement and streamlined functioning. An operator in Germany could easily determine when to clean the solar panels in a Dubai installation after a dust storm or know when a tracking mechanism becomes jammed.

Solar tracking mechanisms can be monitored easily with the help of artificial intelligence. (Source: Micro Power Grids)

These advances, coupled with the cost efficiencies of solar and the increasing availability of grid-level energy storage solutions, will continue to boost the utility-scale solar energy market and take market share from fossil fuel power plants. The expansion of solar power offers a significant opportunity for multiple industries, from materials providers to solar panel manufacturers, tracking system component manufacturers, sensor distributors, battery makers, software developers and even drone suppliers. By leveraging the confluence of these technologies each industry can ensure that they participate in the solar market’s return on investment.

Tom Breunig is the publisher of Cleantech Concepts, an online magazine and market research firm tracking cleantech R&D and innovative business models.

Aging Water Pipeline Systems Around the World

Outdated water pipelines systems such as prestressed concrete cylinder pipelines (PCCP), lead pipes and corrosive iron pipes are causing problems worldwide.

PCCP is common throughout the U.S. They are large in diameter, meaning that when they fail, it can be catastrophic. PCCP failures have ruptured and leaked, cracked and dented, or otherwise ceased to hold up to the high capacity, high-pressure needs they were once installed to meet.

Why are they failing? Generally speaking, PCCP was not held to high standards during 1970s-era installations. The reinforcing wires used within those pipes were not manufactured with enough thickness, ultimately leading to corrosion and brittleness as the pipes reach the earlier-than-expected end of their usefulness.

An example a ruptured PCCP (Source: Hazen)

These pipes are failing wherever they are in use – all over the United States and all over the world. Florida and Maryland have been forced to handle catastrophic failures. In California, PCCP in need of repair or replacement cost USD 40 million for 4.5 miles of relining work. The overall cost of fixing pipes underneath southern California is estimated at $2.5 billion.

That’s just a drop in the bucket, looking at the overall cost of repairing or replacing PCCP in the U.S. The U.S. Environmental Protection Agency and American Water Works Association estimate that national replacement and repair work could cost $40 billion.

Governments do not want to make the same mistake again while replacing or repairing water pipelines, and there is a clear need to choose a material that can withstand time, pressure and environmental stresses.

The Solution: Stainless Steel

Stainless steel is the material of choice in modern pipe installation and replacement projects.

As an example of how this material can offer great benefits, Tokyo’s Bureau of Waterworks began replacing leaky, old cast iron pipes with stainless steel in the 1980s. The material was chosen because of its strength and its well-known resistance to corrosion. All of the pipes in the water distribution system were replaced with stainless steel by 2012, drastically reducing water loss.

A worker inspects a steel pipe during pipe replacement in Japan. (Source: World Steel Association)

Choosing stainless steel for this kind of work is becoming a global standard. Seoul is another major city that replaced its outdated water pipelines with stainless steel. Around 96 percent of Seoul’s pipes were replaced by 2013, and the remaining pipes will be replaced by 2018.

In Taipei, pipes installed before 1979 were mostly made of lead- causing health and safety concerns for Taipei’s citizens. Over 70 percent of existing lead pipes were replaced with stainless steel by the end of 2016, and more replacements are underway.

Why Stainless Steel is Superior

It is clear that PCCP is not an option many would consider, given the huge costs related to replacing it. Even with the vast material options available, there is a clear reason governments and agencies are choosing stainless steel for waterworks systems.

High-density polyethylene (HDPE) is chemically resistant and lightweight, like steel, but can easily be degraded by sunlight. Because waterworks systems need a long lifespan, it does not make sense to choose a material that can be affected so heavily by environmental factors.

Ductile iron is an option, but is generally rejected because it requires more infrastructure to work, owing to its weight and short laying lengths. More and larger support foundations are required to hoist systems made from this heavy material. Ductile iron requires special lining when used in waterworks systems, as it can be affected by iron bacteria and precipitation.

High-grade stainless steel is naturally resistant to corrosion. It offers high strength and pressure resistance. It is a material that maintains resistance to microbes, and can be manufactured to resist heat.

POSCO’s stainless steel, particularly duplex steel, is ideal for waterworks, for all of the above-mentioned reasons. POSCO’s Lean Duplex steel or PossSD features superior anti-corrosion and intergranular corrosion resistance. It is employed regularly for applications such as water pipelines, and sea-water and chemical equipment. Watch the video for more details.

As cities see PCCP and other old pipe systems failing, materials like PossSD will ensure that replacement water pipelines do not suffer the same fate.

When creating new pipelines, and bringing old systems back to life, stainless steel is the best choice. It is lightweight yet strong, resistant to microbes, corrosion and other damage, and it can withstand all the pressures, temperatures and elements that exist within a pipeline system.

As the majority of the world’s pipeline systems have or will be reaching the end of its lifespan, cities will have to plan ahead and incorporate the best possible materials to ensure clean and safe water delivery, as well as to minimize future costs for repairs and replacement. Stainless steel is already relining or replacing outdated pipes all over the world, and will help governments eliminate safety and budget concerns.

Cover photo courtesy of Overeem.

Craft beers (Source: tvo)

In recent years, there has been a mass movement away from mass-produced, commercial beer to craft beers. Craft beers are usually made in smaller batches, have customized flavors and are generally more expensive. The new generation of beer drinkers are willing to shell out the the extra buck or two for a good, quality brew. This trend is apparent in all different parts of the world including Europe, the U.S. and Asia. In response to the popularity of craft beers, large distributors are buying up independent craft brands at an alarming rate, leaving consumers wary of the number of craft choices they will be left with.

Most craft beer devotees prefer their local breweries for high quality beer, but others have started to experiment on their own. Even 10-time NBA All-Star Chris Bosh is an avid home brewer. Whether it is to save money on unique brews or to experiment for the love of flavor, homebrewing is taking off around the world.

BYOB (Brew Your Own Beer)

Homebrewing is what Brandon Fenner, head brewer of the Hand and Malt Brewing Company in Korea, started doing in his 20s after developing a taste for craft beer. He started with a homebrew kit and experimented with different flavors, ultimately making a career out of his passion. He has worked as the head brewer in various breweries in the U.S., including Magic Hat Brewing in Vermont and Maui Brewing Company in Hawaii.

Brandon Fenner, Head Brewer at the Hand and Malt Brewing Company (Source: The Hand and Malt Brewery)

When asked about the single most important advice for homebrewers, his answer was: “cleanliness above all else.”

“You can get lucky and make a good beer even if you don’t know what you’re doing, but if you’re not clean it’s very unlikely you will make good beer.”

Cleanliness is crucial for local breweries and commercial breweries alike, because unsanitary equipment can lead to corrosion. Because the corroded metals of beer kettles or vessels come into direct contact with beer, it will lead to a metallic taste and ruin the taste. For Brandon and his team, the choice of steel was an easy one.

[clickToTweet tweet=”‘(Our equipment) starts with good quality steel and the appropriate grade of stainless, and our knowledge on how to treat and maintain it is also very important.’ – Brandon Fenner” quote=”‘(Our equipment) starts with good quality steel and the appropriate grade of stainless, and our knowledge on how to treat and maintain it is also very important.’ – Brandon Fenner” theme=”style6″]

Stainless steel vessels for beer

All metals differ from one another on an electrochemical scale of passive to active. The more active the metal, the more it will rust. Corrosion happens between two types of metals when there is an electrolyte present. In this case, beer is the electrolyte through which electric current can flow. This will trigger the more active metal to ionize, thus react with oxygen to form oxide and or other corrosive materials. Many metals used for beer kettles naturally have a passive layer of oxide film that can inhibit corrosion. The trick is to clean and maintain the kettle without compromising this oxide layer.

Brandon and his team custom-built a lot of their equipment out of stainless steel, and make adjustments to it when necessary with a sanitary welder. Between Brandon and his engineer, they have 35 years of experience handling such equipment, but for those who are just starting out, finding and maintaining the right equipment can be tricky.

Choosing the Right Kettle

Traditionally, the most common materials for beer kettles were copper, stainless steel and aluminum, but today, most kettles are made out of stainless steel. Copper was an ideal material because of its high heat conductivity, formability and ease of maintenance. The biggest downfall is it can form an oxide called verdigris, composed of several chemical compounds that can react with beer and lead to copper poisoning. Aluminum is a cheaper choice, but the hardest to maintain because it requires special care to build and maintain an oxide layer. For homebrewers, this is a hassle and mistreatment can lead to a foul tasting beer.

Stainless steel pots

The most common stainless steels used for beer kettles are the 304 and 316 types. They form a chromium oxide layer that protects the stainless steel from corrosion. Compared to other metals, stainless steel is highly formable, easy to maintain and available just about anywhere.

Crafting Customized Creations

Along with the right-sized stainless steel kettle, here are some other basic equipment homebrewers need: either plastic or glass fermentation buckets (also known as carboys), airlock, hydrometer, syphoning tube, cloth bag for the malt and bottles and caps for packaging.

Once the equipment is all set, the fun part begins; crafting the beer.

The perfect pairing: chocolate and beer (Source: Berries.com)

The main ingredients for beer are malt, hops, yeast and water, but lately, professional and home brewers are experimenting with additional ingredients such as coffee, chocolate, lactose, fruit and dry hops for sour beers. Others are aging their beer in wooden barrels and adding high-quality art to their packaging labels. Even with the emergence of new trends, classic brews and IPAs still remain the most popular. For those just starting out on the brewer’s journey, it may be best to start by following an existing recipe. Here are a couple of tutorials for inspiration:

Chefs at the White House brewed their own beer as requested by former U.S. President Barack Obama, using honey harvested on the grounds. The chefs were willing to work in their spare time to perfect the White House Honey Ale and Honey Porter.

Another home brewing enthusiast is Wil Wheaton, the actor who starred in Star Trek: The Next Generation and The Big Bang Theory. Not only does he experiment with craft beers at home, he was on the team of brewers who came out with a beer called “Stone Farking Wheaton W00tstout.”  He also partnered with Northern Brewer to make his very own home brewing kit.

Here he is with brewers from Northern Brewer making a batch of his craft beer at home. When explaining his equipment, Wheaton says he prefers stainless steel equipment because “it looks like it came from the future.”

Finally, for a more unique brew that can be paired with delicate dishes such as veal, watch Gordon Ramsay and Dougal Sharp brew a craft beer in Ramsay’s own backyard. This recipe requires the brew to ferment in an oak barrel formerly used to hold bourbon for a smooth flavor.  

Beer is a staple beverage in many cultures around the globe. Thanks to the rise in popularity of craft beers, beer is now a trendy, hip beverage that has a young following. More and more beer lovers are testing out their own creations at home and even making a career out of it. All they need is reliable equipment, the basic ingredients and whatever additions that will make their beer unique. Not everyone can agree on which beer is best, but then again, that is the beauty of craft beers. Cheers to beer and happy International Beer Day!

In-hwan Oh, President of POSCO, said, “We implemented a customer-oriented core research infrastructure to help us evaluate products in a production environment similar to that of customers. By doing this, we aim to develop leading technologies and provide preemptive and proactive solutions to customers.”

The Steel Forming Laboratory will be used exclusively to evaluate the products ordered by POSCO customers by looking at properties such as formability, weldability, coating weight, corrosion resistance, and fatigue life. These evaluations will also be used to provide basic customer support such as quality certification. The new Steel Forming Laboratory will primarily be used for more differentiated tasks such as providing application technology solutions involving steel products.

The Steel Forming Laboratory houses various equipment, including roll forming machines and presses, which are used to evaluate the formability of steel products such as POSCO GIGA STEEL and develop new forming technologies. POSCO is the first steelmaker in Korea to use the 2,000-ton hydraulic press in order to evaluate the formability of large components such as the side outers of automobiles. In addition, other equipment such as the high-speed crash test machine, full-scale fatigue test machine, and wheel durability test machine can evaluate the impact and durability of the molded parts of automobiles. They also provide customized analysis results using 3D scanners.

POSCO’s new Steel Forming Laboratory has various facilities for the evaluation and advancement of large components for customers. Above, a POSCO employee can be seen operating the 2000-ton hydraulic press, the first to be purchased by a domestic steelmaker.

POSCO will use these machines to implement its “POSCO One-Stop Development” system, making it possible to perform every step from developing application technologies for steel products to production verification testing without the involvement of customers, a move towards further reinforcing its Solution Marketing services.

Customers may find it difficult to adopt newly developed steel grades right away, but with POSCO evaluating formability (one of the mandatory criteria for selecting steel products) on behalf of its customers, the burden of selecting new steel grades will be reduced.

POSCO will continue to pursue shared growth by conducting joint research with not only large OEM companies, but also small and medium-sized parts companies that find it relatively more difficult to operate various testing machines.

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Advancements in products, production methods, and new technologies have helped POSCO expand the expectations of what a sustainable steel company should be.  

In honor of Earth Day, The Steel Wire takes a look back at seven recent initiatives & breakthroughs from the last year that have helped POSCO become an industry leader in sustainable development.

POSCO GIGA STEEL: Lighter for EVs, Less Production Emissions

As the auto industry heads toward producing lighter, more fuel efficient vehicles, they need materials that are both strong and light. Car bodies manufactured with POSCO GIGA STEEL and other advanced high strength steels could see a 26% reduction in total weight. Also, based on its life cycle assessment measuring carbon dioxide emissions from production to recycling, POSCO GIGA STEEL performs remarkably well as an eco-friendly material. According to the World Steel Association, steel emits 2.0 to 2.5 kg of carbon emissions when producing 1 kg of material while aluminum emits 11 to 12.6 kg when producing the same amount.

See how POSCO GIGA STEEL offers an ideal material solution for automakers looking to make more lightweight and fuel efficient cars.

POSCO’s Smart Factory Introduces Artificial Intelligence

When POSCO introduced artificial intelligence into its smart factory operations in February, they were able to create higher quality products using a more sustainable production method. Coating weight control is a highly sophisticated process that keeps the coating layer consistent. Quality can deviate depending on the worker, but with POSCO’s new AI technology they can ensure quality control while reducing wasted zinc during production.

Read more about how POSCO is using AI and smart factory technology to make its operations more efficient and sustainable.

POSCO’s Advancements in Lithium Extraction Recharge the Battery Industry

Lithium extraction traditionally takes anywhere from 12-18 months using a slow evaporation technique. However, POSCO’s new extraction method, which came online in February of this year, takes from 8 hours up to one month while also offering a purity rate of 99.9% and increasing the lithium recovery rate to over 80%, which reduces the resources needed for extraction making the process more sustainable and eco-friendly. Also, in a first for the industry, POSCO developed a way to extract lithium from recycled batteries. Both of these innovations have helped create more eco-friendly processes for an industry that is expected to grow exponentially in coming years.

Find out more about POSCO’s developments in lithium extraction and its efforts to reshape the industry.

POSCO Expands Production of its Non-Oriented Silicon Steel for Electric Vehicle Drive Motors

Top-grade non-oriented silicon steel is a core ingredient in high-efficiency premium consumer electronics and electric vehicles. It is an environmentally-friendly material that saves energy and reduces CO2 emissions. With the completion of its non-oriented silicon steel (Hyper NO) facility on February 20, production has increased from 80,000 to 160,000 tons, which is enough to supply parts for approximately 2.6 million electric vehicle drive motors.

Read more about POSCO’s efforts secure its position as a leading supplier to the growing electric vehicle market.

POSCO Humans Selected as Innovation Leader for Sustainable Solar Power Development

POSCO Humans received excellent evaluations last January for its steel structures that were built for solar facility installations. In particular, POSCO Humans received high marks for its structure that are used exclusively for floating solar power generation facilities and exclusive bolts that utilize PosMAC. It is a bolt-assembled structure that eliminates the need for hole machining and special tools.

Discover how POSCO developed floating solar panels using PosMAC.

POSCO’s World Premium Stainless Steel Shows No Corrosion After 18 Years at Incheon Airport

The first passenger terminal at Incheon International Airport was built in 2001 using POSCO’s 446M steel, and after 18 years, few signs of corrosion have been seen. Building exteriors and roofs are the most visible parts of buildings, while also being the most vulnerable to corrosion. Materials used in their construction should be both corrosion-resistant and aesthetically pleasing. Therefore, when planning for the second terminal, they decided to use the same type of steel along with the application of the bead blast process that will create a rough texture on the roof to lower the reflectivity rate for aircraft pilots during take-offs and landings.

Find out how POSCO’s stainless steel products offer decorative and durable interior and exterior options in buildings.

PosMAC Shines at Renewable Energy India

PosMAC was recognized at the Renewable Energy India expo for its unique properties that make it uniquely suited for solar energy development. PosMAC is not just lightweight, it is also non-corrosive and durable enough to last 20-30 years.

Find out more about PosMAC at the Renewable Energy India expo, or find out more about PosMAC.

Throughout April & May, The Steel Wire will explore the uses and benefits of POSCO GIGA STEEL and what POSCO is doing to lead the industry with new automotive steel solutions.   Subscribe to our newsletter today.

For some artists, steel can be heavy and difficult to work with. In addition, considerations for ductility, corrosion resistance, and price must also be taken into account. Working to address these issues, POSCO has partnered with many artists, architects, and designers to provide the right steel to match their artistic vision.

In the three pieces below, POSCO’s World Premium Products were used to offer unique solutions for each design concept. See how these three pieces of art utilized steel to not only make them stronger and longer-lasting, but also to make them more beautiful.

POSCO’s Solar Pine – Art that Generates Energy

The Solar Pine sculpture is located at POSCO Energy’s headquarters in Incheon, South Korea. POSCO Energy wanted to install a structure in its Green Park that utilized solar power, could be mass-produced, and displayed an aesthetic beauty that could be used in parks and green spaces around the globe. Its pattern resembles the geometric shape of a pine cone with an angled roof with solar panels. During the day, its unique pattern casts a beautiful shadow on the ground below, and at night the energy absorbed by the solar panels is used to power lighting on the Solar Pine and also within the park.

At night the Solar Pine lights up using the energy absorbed through its solar panels. (Photo courtesy of Kyungsub Shin)

The upper structure is 7.2m in diameter and contains nine separate modules with 54 solar panels that can generate 1200W per hour. Also, because it is made for mass production, each piece is made in the factory and bolt-assembled on location – making construction simpler while also lowering costs.

The Solar Pine roof is tilted to provide maximum energy absorption for the 54 solar panels. (Photo courtesy of Kyungsub Shin)

POSCO’s Solar Pine is built with PosMAC steel, an advanced, high-strength steel that is lighter and thinner than galvanized steel and more resistant to corrosion. PosMAC is ideal for structures like the Solar Pine, which require strong, lightweight steel that can withstand the elements. PosMAC has also been used in other designs requiring this combination including POSCO Humans’ floating solar power system, high-durability homes, auto parts, and several new green energy projects in India.

During the day, the light shines through the roof of the Solar Pine, replicating its geometric design in shadows on the ground. (Photo courtesy of Kyungsub Shin)

POSCO’s Steel Igloo

Steel is typically used as structural support; however, when designing the Steel Igloo, architect Kim Chan-joong decided to use POSCO’s World Premium Product PossSD, an advanced steel that offers superior strength and ductility.

The reflective surface of the Steel Igloo combined with the punctured surface creates a unique viewing experience. First constructed for an exhibition at Kumho Art Museum, it was later moved to a forest near Suwon, Korea.

The Steel Igloo is made from 177 steel sheets, each punctured with holes allowing light to break through. The combination of the holes and the reflective surface of the steel create a very unique experience for those lucky enough to see it in person.

POSCO worked with Kim during the manufacturing process, helping with the polishing, bending and reflective effect that was requested in the original blueprint.

PossSD, which stands for Super Ductile Duplex, was used because of its notable characteristics that make it suitable for an outdoor art display like the Steel Igloo.

The punctured holes of the Steel Igloo allow light to come through and create shadows on the surrounding walls.

PossSD combines austenitic and ferritic steels to maximize the strength of each while minimizing the weaknesses. Austenitic and ferritic steels are both considered fairly easy to produce, but both have certain drawbacks. Austenitic steels are low-strength and but also offer high resistance to corrosion. Ferritic steel, on the other hand, is stronger but less resistance to corrosion. They also use less nickel than austenitic steel, making it slightly more economical.

By combining those two types of steel in PossSD, POSCO was able to create a unique product that is stronger and more ductile than most ferritic grades, while also being twice as strong as both types of steel by themselves. It also offers stronger corrosion resistance while also being more cost effective.

Stepping inside the Steel Igloo allows viewers a completely different experience with light shining inward.

Pangdolane – Resting in a Rock Made of Steel

Pangdolane is a wordplay on the Korean words pang-dol, a type of volcanic rock found on Jeju Island and an-ae, meaning inside. POSCO worked with multiple artists, scientists, and architects to create this public art piece that also provides a small shelter for those visiting Jeju Island.

Pangdolane sits near a beach on Jeju Island. (Photo courtesy of Scale.kr)

With its gray color and holes of varying sizes, the exterior of Pangdolane resembles the basaltic rock for which it is named. Inside Pangdolane, visitors can rest while enjoying the shadows created by the design of the structure.

Sitting inside Pangdolane lets visitors see a completely different view. (Photo courtesy of Scale.kr)

Located on a beach on Jeju Island, designers were faced with issues of corrosion. The air in coastal regions typically has a higher saline density, which causes metals, including steel, to corrode much more quickly. Therefore, POSCO’s World Premium Product PosMAC was used to construct Pangdolane. PosMAC is specifically designed to be both more resistant to corrosion and self-healing. When designing Pangdolane, PosMAC was the obvious choice as its special properties ensure that it will stand the test of time – even on the beach.

Steel is often used in buildings to make them stronger and long-lasting. But steel does not have to be behind walls and floors; it can also be used on the exterior. In each of the art pieces above, POSCO’s World Premium Products were used in order to provide specific benefits that fit each situation’s needs. Whether it is having a higher resistance to corrosion or providing a lighter solution that can be mass-produced and bolted on site – POSCO’s World Premium Products have been able to overcome many of the problems that come with working in steel to make sure that these pieces of art can be enjoyed for decades to come.

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POSCO supplies magnesium sheets for Samsung Electronics’ “2017 model of Samsung Notebook 9 Always.” The Notebook 9 series is Samsung Electronics’ flagship model that touts ultra-light, high-strength metal materials. (Photo courtesy of Samsung Newsroom)

Samsung Notebook has been working to develop laptops that are slim and lightweight without having to sacrifice durability. Typically, durable laptops and electronics had to come with heavy metals. In order to keep their laptops lightweight, Samsung previously used magnesium-lithium sheets from overseas suppliers, which had good machinability, but low hardness, making them vulnerable to dents.

Starting with duralumin (a high-strength aluminum alloy made by mixing copper, magnesium and other elements) in 2011, Samsung has been aggressively pursuing metals that are lightweight yet durable. In 2016, POSCO began supplying its magnesium sheets for the Notebook 9 that was just 840g. In 2017, Samsung’s Notebook 9 was brought down even further to 799g – helping to significantly expand Samsung’s presence in the ultra-light notebook market.

In World War II, magnesium sheets, known to be one of the lightest metals, were used in long-range bombers. More recently, they have been used in high-performance sports due to their high-strength and lightweight qualities. POSCO leveraged its own process technology to further enhance these properties and began to mass-produce and supply them in 2015. These magnesium sheets, made with a rapid solidification process that is capable of precision control, are tempered several times and undergo a special heat treatment until they reach a final thickness of 0.5mm. POSCO succeeded in improving the surface hardness by more than 20% and the yield strength by more than 50%, compared to its competitors, while still maintaining a high level of machinability.

In addition, Samsung Electronics applied the state-of-the-art plasma surface treatment method, the MAO (Micro Arc Oxidation) method, to the formed magnesium body. This improves its durability against external impacts, corrosion, and scratches – further enhancing its value as a premium product.

POSCO’s magnesium sheets were used in the bottom casing of the Samsung Notebook 9

POSCO is continuing to develop new products through close cooperation with Samsung Electronics – the two companies plan to leverage their respective strengths and technologies to launch various products according to customer needs. By developing their technology and customized materials, POSCO aims to reach their goal of providing more magnesium materials for mobile devices as well as making magnesium sheets the new standard for various mobile products.

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Daniel Libeskind says, “[I]n buildings that move us, there’s an element of care. It’s not a question of whether a building makes us feel good or bad. It’s about being moved. It’s something that goes very deep.”

Take a look at these three unique buildings that used steel in creative ways. Most architects and engineers work to hide the steel underneath the walls and floors, but these three architecture firms brought the steel to the exterior – and to dramatic effect. Even if you have never seen or been in these buildings, we can all imagine what it would be like. Try to focus on the emotions you may feel when you read about the buildings and tell us about it in the comments below.

Zaha Hadid’s Investcorp Building, Oxford University

The Investcorp Building, located in Oxford University’s St. Antony’s College, is part of the school’s Middle East Center. Named after the investment firm that donated £11 million to have it built, the building includes a library, classrooms, and offices. Designed by the late Zaha Hadid, considered to be one of the most famous avant-garde contemporary architects of our time, the project has evoked a multitude of emotions from those on campus.

Zaha Hadid’s Investcorp Building at Oxford University stands out among the Victorian buildings surrounding it. (Photo courtesy of Forgemind ArchiMedia)

Conspicuously different from the other Victorian buildings found on Oxford’s campus, the Investcorp Building has brought out supporters and detractors. Some said that it “Looks like a beached whale,” or “No, a crashed airplane.” While some of Hadid’s supporters, like the center’s director Eugene Rogan said, “Every line meant something. It bends the brain. I’m in love with this building and I can’t hide it… there’s something Daliesque about it.” The Independent even went so far as to say that it was “undoubtedly Hadid’s most intriguing small building.”

The glass walls underneath the Investcorp Buildings allow students to see the grounds of Oxford University campus. (Photo courtesy of Forgemind ArchiMedia)

Many will argue that the building does not blend in well with its surroundings on Oxford’s campus, but it is also hard to deny the precision and expertise that went into the design. Love it or hate it, Hadid’s Investcorp Building is one that will fuel debate for decades to come.

Turkey’s Raif Dinçkök Yalova Cultural Center

The modern Raif Dinçkök Yalova Cultural Center was designed by Istanbul’s Emre Arolat Architects. It is a mini-city in a box with different multi-purpose facilities inside that are connected by a vast maze of ramps and walkways.

Its unique exterior is made of corten steel, short for “corrosion resistance” and “tensile strength,” a type of weathering steel that has no need for painting. Over time it develops a rust-like appearance while maintaining its resistance to atmospheric corrosion.

Turkey’s Raif Dinçkök Yalova Cultural Center uses weathering steel to striking effect. (Photo courtesy of ArchDaily)

The intentionally rusted facade offers a blank canvas for the city and serves to heighten expectations of what might be inside.

Arch Daily says, “The surface, which is also suitable for recycling, acts as a natural palette, containing the changes it will go through, like the color and tone changes caused by oxidation. This movement will make the relationship between the city and the building more interactive.”

Frank Gehry’s Walt Disney Concert Hall, Los Angeles

Frank Gehry’s stainless steel Walt Disney Concert Hall remains one of the famous architect’s most well-known works – as well as one of the most famous buildings in LA. Architectural Digest called Gehry the “most important architect of our age,” and the LA Times said that “Disney Hall accomplishes all the things Gehry has become famous for and all the things he was supposed to be incapable of doing.” The stainless steel jutting out into the landscape is both striking but soft.

“Ten years after its debut, it remains the city’s greatest room.” -Christopher Hawthorne, LA Times

Frank Gehry’s Walt Disney Music Hall has become one of LA’s most well-known landmarks. (Photo courtesy of Milo & Silvia in the world)

Some patrons have argued that entry into the hall is rather abrupt as one must move from the sidewalk directly into the lobby, with little fanfare. Then, having entered the hall, even the lobby is considered “narrow and asymmetrical.” But Gehry seemingly did this on purpose “in an effort to save the architectural and emotional payoff for the moment when you walk into the auditorium itself.” He realized that this building was to be a monument to the music and musicians that played there, and so he wanted the focus to be on that aspect – minimizing the rest for emotional effect.

What do you think of these buildings? Tell us about some other buildings that sparked an emotional response in you.

*Cover image: Walt Disney Music Hall, photo by Prayitno.

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Almost everyone can picture a sports stadium, an airport, or a bridge – we have all either been in, at or on one of them at one point in our lives. A huge football stadium that can close its roof, an airport by the sea that is impervious to corrosion, and a glass-bottomed bridge that allows only the most steel-hearted of pedestrians to look deep into one of the most famous canyons on earth – all made possible through innovations in steel.

Rolling Back the Roof at NRG Stadium

This year’s pro-football championship game between Atlanta and New England will be held at Houston’s NRG Stadium where hardcore Falcons and Patriots fans are rushing to get their hands on some of the few tickets left. Tickets are reselling for an average of $5,101, but if you want a view from the 50 yard-line it is going to set you back USD $11,000 to $12,000.

NRG Stadium, completed in 2002, is famous for being the first-ever NFL stadium with a retractable roof – allowing events to be held in open air or air-conditioned comfort.

The Houston Texans play at NRG Stadium (formerly Reliant), November 18, 2007. (Photo courtesy of Ed Schipul)

Designed to utilize the principles of kinetic architecture, the roof is able to open and close without reducing the overall structural integrity. The roof’s panels are 117m x 152m and supported by two sections of five trusses each that meet at the 50-yard line. These two sections are supported by two supertrusses that run for almost 300m each along the field’s sidelines. Along each supertruss is a wheel rail to guide the roof as it opens and closes, in as little as 10 minutes.

With so many moving parts, the retractable roof represents an amazing feat of engineering. The steel beams, trusses, and motors weigh thousands of pounds, but it is still able to zip open in a few minutes. Come rain or come shine, ticketholders will be able to stay dry until the winner raises the Lombardi Trophy at the big game on Monday.

Stainless Steel at Incheon International Airport
With over 49 million passengers each year, Incheon International Airport is one of the busiest airports in the world, and consistently ranked as one of the best. Internationally praised for its remarkable facilities and services, which include a spa, golf course, movie theater, museum, and ice skating rink; the airport also prides itself on its efficient design.

A bird’s-eye view of the second passenger terminal at Incheon International Airport. Because of its non-corrosive properties and stylish appearance, POSCO’s 446M steel will be used as an exterior material.

When the first passenger terminal was built in 2001, they decided to use POSCO’s 446M stainless steel. The 446M steel contains high amounts of chromium (26%) and molybdenum (2%), which gives it superior corrosion resistance – excellent for use in exterior construction near coastal areas, like Incheon.

Seventeen years after the construction of the first terminal, there have been little signs of corrosion. So, as preparations began for a new second terminal, the airport decided to use the same type of stainless steel. Also, a bead blast process will be applied to the steel that will give it a rough texture to lower the reflectivity rate for aircraft pilots during take-offs and landings.

Despite being located on a small island in the Yellow Sea, the stainless steel used at Incheon Airport has been almost completely unaffected by corrosion. Already in its 17^th year of operation, the stainless steel exterior will ensure that it lasts much longer.

Seeing Deep into the Canyons at Zhangjiajie, China

The majestic Zhangjiajie Grand Canyon, located in the western part of Hunan Province, is one of the most beautiful sites in China. Made famous in the Western world when James Cameron used it as inspiration for the landscapes in his film Avatar (2009), it is best seen atop the world’s highest and longest bridge.

Zhangjiajie Grand Canyon Glass Bridge view from west side of gorge. (Photo courtesy of HighestBridges)

Sitting 300m over the canyon, the Zhangjiajie glass bridge gives visitors a breathtaking, and terrifying, view of the park. The bridge is supported by 4 support towers and a steel frame with over 120 glass panels set into its walkway. The towers are installed directly into the canyon sandstone and each panel of glass is layered, so that even if one layer cracks, the others will hold.

Those with stomachs of steel can enjoy the bridge while experiencing one of the most beautiful parts of the world. The glass floor may seem fragile, but the steel frame holds it together to create one of the most amazing yet vertigo-inducing views.

If we look around, we will see that steel is everywhere. For something that seems so ordinary, it can also change the way we see buildings, and even change the way we see the world.

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