POSCO Newsroom presents the story of premium construction material, INNOVILT, and today we will start with SP-CIP Pile(Smart(Steel) Pipe-Cast In Placed Pile)! Let’s take a peek at the note of POSCO’s researchers who developed the Steel pipe Pile together with clients — MS Pipe and Hankook Material.

l Bid Farewell to Heavy Rebar!

I am Dong-Wook Ahn, a senior researcher at POSCO Steel Structure Research Group. The field that I am interested in these days is ‘rebar’. You might wonder what rebar has got to do with POSCO since POSCO doesn’t manufacture rebar. Of course, I’m not talking about developing rebar. My goal is to develop a steel pipe that can replace rebar and make a premium construction material.

Rebar is the most commonly used material on construction sites. However, it has a major drawback: it is too heavy. Also, connecting the rebars by welding is impossible, so they should be tied together with wire, one by one making the rebar processing work highly dependent on manpower. Hence, the heavyweight of rebar causes great inconvenience to the workers at the site, and it is one of the main reasons why many construction workers suffer from musculoskeletal diseases.

All creation starts with a critical mind. The question of “Should it always have to be such heavy rebars?” led to the next question, “How about making a lighter yet stronger alternative to rebar?” How was this possible? With our very best steel technology! I soon started developing a lightweight steel pipe to replace rebar. With this lightweight steel pipe, my final goal was developing the construction material, ‘Steel Pipe-Cast In Placed Pile’.

A net pile made of rebar is commonly used for ground stabilization. It prevents cracks and degradation of the building. What if the rebar was replaced with steel pipes? It will become lighter and stronger, therefore, resolving the many problems mentioned earlier.

l Developing a High-Strength Steel Pipe with a Yield Strength of 800MPa!

The yield strength (YS) of rebars in the market is 400 MPa. This means that if a force of 400 MPa or more is applied to the rebar, it will deform and will not be restored. My task was to come up with a steel pipe that was at least equal or stronger compared to rebars. Considering that steel pipes are hollow in the middle, I decided to create steel pipes with a yield strength of 800MPa.

My team began research on POSCO’s high-strength steel, PosH690 (POSCO High strength 690). We made a steel pipe with this PosH690 at ‘MS Pipe’, our client company, to analyze yield strength caused by work hardening. Finally, we succeeded in deriving optimal production conditions.

With the steel pipe from MS Pipe, ‘Hankook Material’ produced the Steel Pile. (Hankook is another client company of POSCO.) The main rebar was replaced with a steel pipe, while the spiral rebar was used as it was, along with the wires used for tightening. Everything remained the same except for the main material. Test specimens — one where conventional rebar net pile was placed inside the concrete and the other Steel pipe pile inside the concrete — were made, and experiments were conducted to compare performances over and over again. The result turned out to be a huge success. The newly developed Steel pipe Pile showed similar performance to the rebar net pile. Finally, a Steel pipe Pile product using a steel pipe was all set!

▲ Testing of the flexural strength of piles

l Introducing the INNOVILT Steel Pipe-Cast In Placed Pile!

Hankook Material named the product Smart(Steel) Pipe-Cast In Placed Pile. The manufacturing process is a collaboration, and it is as follows: POSCO supplies PosH690 and MS Pipe produces steel pipes with it, and Hankook Material manufactures SP-CIP piles with the pipes.

Construction materials, especially those for ground construction, must be applied to the actual construction site and made sure that it is indeed as strong as the extracted research value. This means that research on construction materials does not end in the lab. Employees of MS Pipe, Hankook Material, and I carefully watched the construction process on site. It was also necessary to verify whether the product guarantees the desired performance after the construction was completed. After waiting for the concrete to harden for about a month, a dynamic load testing was conducted by striking a 10-ton hammer on the structure to measure the support force. A horizontal load testing was also carried out by pushing the structures away from each other to check seismic performance. Fortunately, both tests turned out to be satisfactory. The SP-CIP Pile went under two more on-site tests eventually proving that the product was indeed lighter, economical, and yet stable in strength compared to the use of conventional rebar pile.

l SP-CIP Pile with 100% POSCO Steel!

The weight of the product was dramatically reduced as intended, but there was one more task to be resolved — welding. As mentioned earlier, rebars cannot be welded because they do not secure chemical components. The steel pipe pile that we developed was woven with wire as well instead of welding. So we decided to go a step further and upgrade the product into a fully welded one. “Let’s make a steel pipe pile that can be welded with 100% POSCO steel!”

We considered using a steel wire rod that has two or more rows of bumps arranged on its surface, resembling the shape of rebar. Since the steel wire rod had already been qualified for the KS standard (KS D 3552), replacing spiral rebar with it became possible. Next, Hankook Material conducted welding tests on three types of products: 1) rebar & rebar, 2) steel pipe & rebar, and 3) steel pipe & steel wire. The results showed that the ‘steel pipe & steel wire’ product was the only one that could be welded with high quality.

We also acquired an official use certification from the Korean Construction Joints Association based on this test result. What started with the development of steel pipes to replace rebars eventually ended with producing Steel pipe Piles using 100% POSCO steel. It was an achievement that had taken four years.

▲ The automated welding facility of SP-CIP Pile at Hankook Material

l The Birth of SIP Pile: 3 Features in 1

In January, following joint marketing by POSCO and the client company, the product was finally applied to a construction site in Seoul for the first time. In the following six months, four additional sites adopted the product as well, and it succeeded in settling into the construction market. The response to the SP-CIP Pile is quite phenomenal, considering the conservative nature of the construction market. Here are some of the features that those who have used the SP-CIP Pile mention.

First of all, it is economical. Since the yield strength of the steel pipe is twice as high as conventional rebar, the sectional area required is reduced by half. Despite the unit price per ton being more expensive than that of rebar, the weight per meter is reduced by half, hence, the unit price per meter is also more economical than that of rebar.

Second, it is of stable quality. In the case of conventional rebar net piles, binding wires are used to bond the materials since welding is impossible. However, in the case of our products, they can be safely welded and supplied. Let’s skip the obvious explanation of which product is more stable.

Another feature is lightweight. It significantly reduces the labor intensity of workers on site. In fact, there was even a case that workers, who worked with steel pipes at the previous site, suggested changing the rebar to steel pipes at the new construction site.

One more thing. It is supplied through pre-production. SP-CIP Pile can be manufactured on site as well, but it is mostly pre-produced at factories and sent to the construction site.

In-Jeong Woo who was in charge of a construction site where SP-CIP Pile was applied said, “Since SP-CIP Pile is pre-produced in factories with excellent quality and only needs to be placed on site, it is especially convenient to handle in small-sized construction sites of downtown areas. The product is brought to the site in a complete form, so there isn’t any problem of handling the remaining rebars.” He also added, “Wire-connected rebar net pile is distorted when moved or placed for construction, but since Steel pipe Pile is produced by welding, the construction process becomes much safer.”

Hankook Material’s SP-CIP Pile was selected as an INNOVILT certified product in 1Q this year, and since then, it has been more actively applied at sites. Researchers at POSCO, including myself, are still working on technologies to expand the market. Our work will continue until the day comes where the steel technology required by clients is successfully realized into innovative products.

Jecheol Industrial Co., Ltd. is located in Gyeongsangnam-do Province. On arriving at the plant, there were rainwater storage tanks, well over the height of an adult, laid out in the yard. Since they were made with PosMAC, which is corrosion-resistant steel, it looked magnificent even in the rain. POSCO Newsroom sat down with Kwon-Duk Seo, CEO of Jecheol Industrial Co., Ltd., Director Sung-Yeal Bae, and POSCO’s Yu-Rae Jo and listened to the story of PosMAC rainwater storage tank produced by Jecheol Industrial Co., Ltd.

l The World’s Only Manufacturer of PosMAC Rainwater Storage Tank — Jecheol Industrial Co., Ltd.

▲ Kwon-Duk Seo, CEO of Jecheol Industrial Co., Ltd., introducing the PosMAC rainwater storage tank

Founded in 1999, Jecheol Industrial Co., Ltd. is a manufacturer specialized in corrugated steel pipes. Since its establishment, it has been producing more advanced corrugated steel pipes through continuous R&D resulting in several related patents. Among them, “PosMAC Rainwater Storage Tank” would be the most focalized product of the manufacturer. PosMAC stands for POSCO Magnesium Aluminum Alloy Coating. It is a ternary alloy coated steel composed of zinc, magnesium, and aluminum, and it is 5 to 10 times more corrosion-resistant material than conventional galvanized steel. All products produced by Jecheol Industrial, including PosMAC rainwater storage tanks, use PosMAC steel as a raw material.

“Jecheol Industrial has never used any other material but POSCO steel products ever since its establishment. This shows how much we trust its quality. Before PosMAC, we used galvanized steel sheets produced by POSCO, and as PosMAC — an upgraded material — was developed, we changed all our raw material to PosMAC,” said Kwon-Duk Seo, CEO of Jecheol Industrial Co., Ltd.

PosMAC rainwater storage tank is an sustainable rainwater harvesting system jointly developed by POSCO, Jecheol Industrial, and RIST (Research Institute of Industrial Science and Technology). Since PosMAC is a highly corrosion-resistant material, it has proved to be the perfect material for building a rainwater storage facility. PosMAC rainwater storage tanks are used for two purposes, one is rainwater utilization, and the other is stormwater management.

If the purpose is to collect, purify, and reuse rainwater, a rainwater utilization facility could be installed. Whereas if it is to retain water to prevent stormwater runoffs, a stormwater management facility is what does the trick. The reservoirs that we can see easily around factories and apartments are an example of stormwater management facilities. However, these reservoirs are hard to manage. Garbage piles up around them and they act as a breeding spot for larvae of pests, such as mosquitoes. By installing a stormwater management facility underground in the form of tanks, the surrounding environment becomes cleaner, and the surface can be used for various purposes, such as parking lots or green areas.

Jecheol Industrial is the only company in the world that produces PosMAC rainwater storage tanks. CEO Kwon-Duk Seo said, “We have seen some cases of rainwater storage tanks that use corrugated steel pipes overseas. However, they were made with galvanized steel and none of them used PosMAC.”

The company’s deep ties with POSCO and its passion for technology development played a key role in making Jecheol Industrial the world’s only PosMAC rainwater storage tank manufacturer. POSCO enabled the company to pioneer a new path with this rainwater storage tank. It was in 2001 when POSCO first knocked on the door of Jecheol Industrial in an effort to co-create a rainwater storage tank that meets the relevant requirements of Korea. Jecheol Industrial, POSCO, and Korea Institute of Construction Technology (KICT) put their heads together to develop the technology. The material for the new product was changed from galvanized steel to PosMAC, and it went through numerous trials and errors and several tests as well.

It took ten years for the prototype of PosMAC rainwater storage tank to be materialized. Director Sung-Yeal Bae said, “I remember the day we buried the 500-ton PosMAC rainwater storage tank prototype in Seoul in 2011. It marked the beginning of PosMAC rainwater storage tank. After inspecting the system in collaboration with RIST, we were able to handle trouble-shootings one by one, creating the product that it is today.”

CEO Kwon-Duk Seo added, “The technology that we possess is something that has been accumulated over such a long period of time. It cannot be copied by any other company. Moreover, our company also holds more than ten patents related to rainwater storage tanks.”

l PosMAC Rainwater Storage Tank: Easily Constructible, Economical, and sustainable

While the capacity of rainwater utilization facilities is usually 500 tons or less, stormwater management facilities boast its large-scale capacity, with total capacity reaching at least 1,000 tons. Jecheol Industrial mainly produces rainwater storage tanks for rainwater utilization facilities and stormwater management facilities of up to 3,000 tons.

The most common rainwater storage tanks in Korea are made of plastic and concrete. CEO Kwon-Duk Seo emphasized, “PosMAC rainwater storage tanks are more easily constructible, economical, and sustainable compared to the others.” He also brought some data to prove it. Based on the data, there are three main advantages of PosMAC rainwater storage tanks. The first advantage is its constructability. Let’s say that we are constructing a rainwater storage tank with a capacity of 1,000 tons. In this case, a plastic tank requires 15 days and a concrete tank may consume 40 days for installation. However, for PosMAC rainwater storage tanks, it takes just six days.

The second advantage is that it is economical. Since PosMAC rainwater storage tanks have a short construction period, the overall construction cost is also about 30% lower than others. In addition, the PosMAC rainwater storage tank is easy to maintain and doesn’t require additional waterproofing work. Plastic tanks have a complicated internal structure, which makes maintenance difficult, and partial repair is also hard in case of damages. Concrete tanks require regular waterproofing work since water leaks frequently through the gaps in the connection.

The third advantage is that it is sustainable. Steel, the material used to make PosMAC rainwater storage tanks, can be recycled over 99%. It is in contrast to plastic and concrete tanks that are disposed of as wastes. CEO Kwon-Duk Seo remarked, “Does it make sense to use concrete or plastic materials that pollute the environment in making rainwater storage tanks eventually built to protect the environment?” On acknowledging its distinctiveness and economic feasibility, Korea Land and Housing Corporation selected the PosMAC rainwater storage tank as the “LH Excellent New Technology of 2019.”

l From PosMAC Steel Plates to INNOVILT Rainwater Storage Tanks

Then, how is this award-winning rainwater storage tank made? PosMAC rainwater storage tank goes through eight stages of production. First, POSCO’s PosMAC steel sheets are cut and processed at the Coil Center into skelps — steel cut into strips. When these coil-shaped skelps arrive at Jecheol Industrial, they go under an Uncoiler, making them flat. Next, they are formed into wave shapes, and these wave-shaped PosMAC plates are gradually rotated to create a cylindrical rainwater storage tank. The cylindrical tank is cut according to the size required by the customer. After this, a cover or a partition wall is welded to the end and other subparts are produced as well. The completed rainwater storage tank and its parts are shipped after final inspection, and they are assembled and installed on-site. See the video showing the entire manufacturing process of the PosMAC rainwater storage tank.

PosMAC rainwater storage tanks help prevent drought and flooding that have become frequent recently due to climate change. In the event of a drought, the collected rainwater is utilized for bathroom, landscaping, and emergency use. In the case of heavy rain, the rainwater is stored temporarily and discharged later to prevent flood damage.

l PosMAC Rainwater Storage Tank, Is It Stable?

PosMAC rainwater storage tanks are assembled and installed on-site, then isn’t there any risk of water leakage? Welding seems like a safer option than the method of bolting when connecting the tanks. CEO Kwon-Duk Seo replied, “There is no risk of water leaking because the rubber used to seal the bolt and nut joints does not react to water. Related research and verification have shown that the bolt and nut joints using this material would last about 100 years.”

As the conversation continued, the topic moved on to water quality. Jecheol Industrial, together with POSCO and RIST, conducted a hydroponics test using PosMAC rainwater storage tanks at the Protected Horticulture Research Institute of the National Institute of Horticultural and Herbal Science (NIHHS) in 2018. The test result revealed that the rainwater quality collected in the PosMAC tank was similar or even better than groundwater and tap water. There was no trace of any E. coli or heavy metals as well. CEO Seo explained, “Rainwater is usually contaminated by sunlight and changes in temperature. PosMAC rainwater storage tanks are buried underground. Sunlight can’t reach there, and the temperature change is negligible, so the chances of contamination are fairly low.”

▲ Source: Test result of the hydroponics test using water from PosMAC rainwater storage tanks at the NIHHS Protected Horticulture Research Institute (December 4, 2018). Melon A, which showed better growth, was grown with rainwater from the PosMAC tank. Whereas, melon B was grown with groundwater.

l PosMAC Rainwater Storage Tank: Beware of Fake Products!

As mentioned earlier, Jecheol Industrial is the only company in the world that produces PosMAC rainwater storage tanks. These days, however, there are some fake products that mimic PosMAC rainwater storage tanks. These products use aluminum or zinc galvanized steel that are not as corrosion resistant as PosMAC is. They also adopt welding methods to connect each steel sheet instead of inserting rubber materials, thus damaging the inner layer. In short, the material degrades the durability of the product, and the processing method also downgrades stability.

Why is the company so sensitive to fake products? Is it just because they are competitors? The answer is no. CEO Seo replied that this was because it could cause customers to misunderstand Jecheol Industrial’s genuine products. When rainwater storage tanks are made in the form of corrugated steel pipes with aluminum or zinc galvanized steel, they are bound to be oxidized over time. The misunderstanding begins here. The moment people start to think that corrugated steel tanks rust easily, the negative image will spread in the market, and this will affect PosMAC rainwater storage tanks as well. In response to these worries, Jecheol Industrial put the phrase, “Beware of fake products” on the main page of its website, emphasizing the distinctiveness of PosMAC rainwater storage tanks.

CEO Seo said, “The PosMAC rainwater storage tank looks similar to other corrugated steel tanks, but it is a completely different product — from raw material to structure, function, and installation method.” POSCO’s Yu-Rae Jo added, “In addition, PosMAC rainwater storage tank is an INNOVILT product, guaranteed by POSCO. You can see it on the inspection certificate of the PosMAC rainwater storage tank.”

l The Synergy Between POSCO & Jecheol Industrial Continues

▲ The INNOVILT Alliance mark placed on the wall of Jecheol Industrial Co., Ltd.

POSCO and Jecheol Industrial are tied as INNOVILT Alliances. Ever since the PosMAC rainwater storage tank was selected as an INNOVILT product, inquiries from customers have been rising. CEO Seo said, “As POSCO guarantees product quality with the INNOVILT Alliance, customers trust our products more, and employees are able to sell them with more confidence.”

POSCO’s Yu-Rae Jo also expressed his gratitude. He said, “Last year, the cumulative sales of PosMAC exceeded 1 million tons. The reason how PosMAC could shine brightly in such a short time is that many companies like Jecheol Industrial credited and utilized PosMAC. In the conservative construction market, it isn’t easy to choose new material over conventional ones. But Jecheol Industries believed in us and used PosMAC from the very beginning. I think that such cases have come together and enabled us to cumulative sales of one million tons.”

Director Sung-Yeal Bae also added another story. It was about how Jecheol Industrial was able to resolve a client complaint with help from POSCO. He explained, “PosMAC tends to lose its gloss when exposed to excessive heat. In the early stages of development, a customer saw this and filed a complaint suspecting that the product was from stock and not newly made. At the time, the problem could be solved by showing the material related data that POSCO had provided. Since the data is from POSCO, a reliable company, we are receiving great help in terms of reliability.”

▲ (From left) POSCO’s Yu-Rae Jo, Jecheol Industrial Director Sung-Yeal Bae, and Jecheol Industrial CEO Kwon-Duk Seo looking at the PosMAC rainwater storage tank

Jecheol Industrial and POSCO are currently envisioning a new project. They are working on a strategy to create a demonstration case of a “river type corrugated steel tank” that is installed along a stream to prevent the stream from drying out or flooding. They are also working on the research and development of an “underground joint zone,” an upgraded version of the PosMAC rainwater storage tank. It seemed apparent that when the two join forces, the PosMAC market and the rainwater storage tank market will continue to expand. Using POSCO’s Sustainable steel to make tanks will benefit society as well — since it will help resolve water shortages and also protect the environment.

Seoul Botanic Park, a New Attraction in Seoul

A large scale botanical park finally opened in Seoul. In 2008, the Seoul Metropolitan Government held a global design competition for the park and selected the Waterfront Plan of Samoo Architects & Engineers as the winner. Plans for its creation were announced in 2013, and after opening some parts in October 2018, the park was officially open to the public in May 2019. Due to the COVID-19 issue, the park was closed down temporarily following government guidelines, but it has resumed operation since July 22. The conservatory in the Botanic Park features a beautiful and unique appearance. It has become a so-called “hot place,” with a large number of visitors and much satisfaction from them since its temporary opening.

A Glass Conservatory that Presents an Exotic Experience

Seoul Botanic Park consists of Forest Field, Botanic Garden, Lake Garden, and Wetland, among which the Botanic Garden and Conservatory are key attractions. Upon entering the Conservatory, visitors can see and also hear water fall from above. A giant rubber tree and the Bodhi Tree welcomes visitors as they walk around this exotic space filled with tropical plants. Many people stand and take pictures by the pond at the entrance where you can see floating Victoria Water Lilies. As you stroll along the streamlined skywalk in the Conservatory, you are presented with the joy of discovering various plants.

It is interesting to see visitors walk around this atypical space — made “artificially” and “futuristically” with the help of computer calculations from scratch to finish — as if hiking a mountain. A bridge with a gentle slope leads you to the second floor, where you can see the entire space from above. After passing through the Tropical Zone, you arrive at the Mediterranean Zone, where you can see olive trees, that reminds you of the Mediterranean Sea, and baobab trees from the “Little Prince,” that sparks your imagination. The exit is located at this end.

The Building Serves as a Mere Background for the Highlight, Plants

▲ Source: Seoul Botanic Park official website

The Conservatory is a transparent steel structure constructed in a bowl shape, which is different from the frequently seen dome shapes, so it has a concave top, rising toward the edge. In a dome-shaped design, a rare and gigantic plant was usually placed in the middle of the structure. However, in the case here, the rim was elevated to make more use of the space as a whole. Eye-catching plants are arranged everywhere, apart from each other. Given the gigantic scale of the conservatory, — 100 meters in diameter and 28 meters in height — theming it into 12 different cities and installing an elevating skywalk as a path were inevitable. Nevertheless, this distributed design and layout enables a more vibrant and three-dimensional experience. The huge glass building is supported with ten white steel frames from the outside.

[Architect’s Pick : INNOVILT PoSPACEs]

Chan-Joong Kim, director of The System Lab, was in charge of the design. He said that he wanted only the steel columns, which were the main structure, to stand out and make other elements unnoticeable. This intention is apparent on the exterior wall of the conservatory, where visitors come closer to than the white columns. A polygon of triangles and inverted triangles, repeating and intersecting themselves, forms the entire building without standing out excessively. The round outer wall is realized with 3,180 triangular windows, each with different shape and size, and some of them can be opened for ventilation as well. The material used for the outer glass wall reaching 5,654 m² is none other than PoSPACEs, a POSCO INNOVILT product. PoSPACEs is a high-performance product appropriate for constructing large-scale curtain wall with atypical designs, something previously challenging for conventional materials.

Director Chan-Joong Kim wanted only the blurry silhouette of glass to be visible from a distance. On mentioning his work with PoSPACEs material, he said, “Even though its profile was rather complex and designated individually, the PoSPACEs was manufactured with great precision. Its production was fully complete in the factory and required simple assembling onsite, so we could shorten the construction period and also reduce costs.”

Since the plan was to gather thousands of glass planes in three dimensions and slightly bend them to create a single round space, the material required for the challenge had to be one that fits the architect’s calculation exactly. The INNOVILT product, PoSPACEs, was probably the only option that met the specification — a material that could correspond with all different angles from top to bottom. The PoSPACEs that stretch out from the center in different directions was applied throughout the outer glass wall. Additionally, PoSPACEs is made of POSCO’s High-performance Steel for Architecture (HSA), which makes it possible to reduce the overall weight giving the structure a sleek and feathery look.

A visit to a botanic garden is more pleasant than one to a zoo. It’s a space where plants and humans are all equal. Visitors are presented with leisure and rest, while plants grow up well. A botanic garden acts as an institute for the preservation and research of plants as well. The many greenery and trees within the Seoul Botanic Park will live for a long time under the sunlight, winds, and water that come in through the triangular windows. Though it might seem too early to assess the achievements of this park, which has been open for just over a year now, the construction material utilized here has shown the possibility of a new spatial structure system and has certainly proved to be a true innovation.

The railing at the site of the first accident was an unclassified aluminum guardrail that failed to stop the three-ton van from crashing to the ground. On the other hand, the railing installed at the site of the second accident was an SB*4 grade steel guardrail designed to protect up to 14 ton-65 km/h trucks. Thus, the guardrail was able to withstand the 16-ton bus. ^*SB(Safety Barrier): A grade that indicates guardrail performance. Based on strength performance, it is categorized into 1 to 7, with a higher number meaning better strength. High level (SB4, SB5, SB5-B) guardrails are usually applied in hazardous areas.

The company to be introduced today is the manufacturer of these steel guardrails. Join us as we present to you DASCO, a company making reliable products that are in charge of the safety of drivers and pedestrians.

l DASCO: A Company that Laid the Foundation for Road Safety in Korea

Founded in 1996, DASCO specializes in manufacturing construction materials and road safety facilities. The main products of the company are guardrails that are installed on roads and bridges. DASCO currently operates four sites in Hwasun, Dangjin, Busan, and Seoul.

DASCO, which boasts the largest share in Korea’s road safety facilities market, is known for having conducted the first guardrail crash test in Korea. It was only in 2001 that the standard for the crash test of road safety facilities was established in Korea. DASCO CEO Sang-Won Han recalled, “In 1998, many guardrails broke when a vehicle running at 80 to 100 km per hour crashed into them. There were also frequent cases where cars ran over the guardrails.”

▲ DASCO CEO Sang-Won Han

Recognizing the importance of safety earlier, DASCO took its high specification guardrail, which was developed together with POSCO, to the U.S. in 1997. DASCO received verification of its technology here through a real crash test at the Texas A&M Transportation Institute (TTI), an authorized international testing agency. The product behind this story is the High Specification Guardrail, which was designated as the New Construction Technology No.101 and led to the growth of DASCO.

※ The actual car crash test of DASCO conducted by TTI in 1997

All of DASCO High Specification Guardrails are made of POSCO’s high-performance hot-rolled steel. Behind this decision lies DASCO CEO Sang-Won Han’s belief that national safety facilities shouldn’t be made with cheap materials. CEO Han said, “Using POSCO steel helps in preventing more accidents. There’s no point in comparing the safety of POSCO steel, which are manufactured under thorough quality control, with other cheap steel that can’t even be verified.”

▲ DASCO High Specification Guardrail which is designated as the New Construction Technology No.101

l From Beginning Till Now, Always “POSCO Family”

Besides their names that seem similar, POSCO and DASCO share something more than just steel materials. They share a collaborative relationship that has been lasting for 23 years, ever since the development of steel guardrails in 1993.

Steel materials are essential in manufacturing DASCO’s main products. This is why POSCO has been involved in active research and development since the beginning of DASCO. DASCO’s Yong-Ok Kim said, “We are POSCO Family. POSCO is working together with us through the entire process — from the early stage of product development to material research, as well as the final crash tests. POSCO also offers help when we need advice or verification on structure analysis or materials. If there’s a problem with the developed product on-site, we solve it together. In fact, I think I talk with POSCO researchers on the phone almost every day.” POSCO’s Ho-Jin Kwon added, “DASCO has an abundant field experience, so they are able to propose excellent product concepts. When DASCO’s ideas and POSCO’s solutions come together, they create synergy, and in the process, we also build up mutual trust.”

The collaboration based on trust yielded another outcome. In 2001, POSCO and DASCO succeeded in jointly developing a protective barrier (railing) optimized for bridges, the POS-Barrier.

There’s a high risk of falling in case of accidents on bridges, so barriers installed here have a more rigorous quality standard than other road guardrails. There are many things to consider, as it must have two functions at the same time: 1) preventing the fall of large vehicles, and 2) absorbing the shock of small vehicles is another.

▲ Steel Barrier for Bridges which was co-developed by DASCO and POSCO

In the past, concrete and aluminum were applied to most barriers for bridges. However, both materials have shortcomings. Concrete is much more solid than vehicles, so it directly delivers the impact of the collision on the vehicle and the driver, instead of absorbing it. Aluminum is ductile and can absorb shock, but since it lacks strongness, it is unable to prevent the collided vehicles from leaving the road. Then what material would be most appropriate? The answer is steel, which is high-strength yet ductile at the same time. With steel, POSCO and DASCO could come up with a barrier that supplements the shortcomings of concrete and aluminum barriers and maximize their advantages.

Recognized for excellence in many aspects — including passenger protection, vehicle induction performance, securing visibility, and constructability — this steel barrier for bridges was named as the New Construction Technology No. 294 and installed on Yeongjong Bridge for the first time in Korea. Since then, this product has been used on most large bridges, such as Incheon Bridge, Gwangan Bridge, Yeongdong Bridge, Cheonho Bridge, and Yi Sun-sin Bridge. As can be seen here, the railings on major bridges in Korea are mostly DASCO steel barriers. Following technology verification in Korea, DASCO succeeded in landing projects overseas as well, including the Kuwait Causeway Bridge and Saudi Arabia’s Riyadh Metro in 2015. The Causeway Bridge project is significant in that it was the first overseas project that DASCO had won with technical support from POSCO. The railing of the Causeway Bridge is the World’s longest with a whopping 207 kilometers.

l INNOVILT Steel Barriers for Bridges: How Are They Made?

Here’s one more interesting fact. So far, there has not been a single fatal accident on bridges that have installed DASCO steel barriers. Then how are these amazing structures are made? Let’s look into the story!

DASCO steel barriers for bridges are manufactured in five stages. First, high-quality hot-rolled coils from POSCO travel to processing centers where they are formed into skelps — steel cut into strips. When these coil-shaped skelps arrive at DASCO, they go under an Uncoiler, which makes them flat. Next, bolt holes that are used for tightening purposes are drilled on them, and they pass through the forming roll where they are shaped into desired forms. The dozens of forming rolls varying in shape and size bend the steel material to suit its application. Once the shaping process is finished, the product is cut according to the customer’s needs.

Lastly, the products are sent to a surface treatment plant for hot-dip galvanizing before being used on-site. The galvanizing process prevents rust and corrosion of the products when installed at the site.

l DASCO, Taking a Step Forward with New Renewable Energy

The reason why long-range bridges both in Korea and overseas require DASCO products is this: DASCO has the technology to develop and apply customized products according to the requirements of its customers. In most cases of Landmark bridges, they require a customized barrier design depending on their length. The Yi Sun-sin Bridge is a typical example. The client requested that the curb height be 5 cm, which is much lower than the national standard of 25cm, due to the wind load. At that time, there weren’t any products that could meet this requirement, so DASCO started from the initial design and completed the project with a newly developed product. DASCO considers that this competence — reflecting all on-site requirements — is why its clients credit the company.

DASCO is making further strides into the future as well. With the technology accumulated in the road safety business, the company is actively entering into the construction and new renewable energy (solar) market. It has secured a competitive edge in quality by adopting PosMAC, POSCO’s corrosion-resistant steel. Once more, new synergy is expected from the collaboration of the two companies. Check out other business areas of DASCO on its official website!

▲ The INNOVILT Alliance mark placed on the wall of DASCO

Following the steel barrier for bridges, the high-performance guardrail made with PosMAC was selected as an INNOVILT product as well, making DASCO a company of two INNOVILT products. DASCO’s Min-Gyun Nam said, “Thanks to the INNOVILT Alliance mark, there’s no need for further explanation. Unlike in the past, where we had to put in considerable effort in marketing and sales, these days, one simple explanation says it all: we are a POSCO-certified company. As we are making facilities for the safety of people, we will continue to gather credibility with our technology and products verified with POSCO.”

POSCO and DASCO share a special relationship, and it seems like there’s nothing that can’t be done if the two join forces together. POSCO Newsroom hopes that the achievements of mutual trust and effort that they share will further expand through INNOVILT Alliance.

A Historical Building Designed by Chung-Up Kim, a Pioneer of Modern Architecture

Namdaemun has always been a landmark of Seoul, no matter how many new modern skyscrapers are erected in the city. Namdaemun is a special place since it has its own history and memories that aren’t found in newly built buildings. This place serves as a setting in many Korean novels showing that it’s a real symbol of the capital of Korea. The Namdaemun-ro, a street that connects Seoul Station, Shinsegae Department Store, and Myeongdong Cathedral, was the socio-cultural center of modern and contemporary Seoul.

There is one building that has been standing in this symbolic place for a long time — it’s the Danam Tower. Danam Tower (formerly Tokyu Hotel) was designed by Chung-Up Kim, a master of Korean modern architecture. It is a high-rise building situated right next to Namdaemun, on the foot of Namdaemun-ro that leads to Namsan Mountain.

Born in Pyongyang in 1922, Chung-Up Kim studied architecture at Yokohama National University in Japan and left for Paris to work for Le Corbusier. On returning to Seoul in 1956, Kim opened his own architecture office and designed the French Embassy and the main building of Pusan National University (currently the Humanities Building). Chung-Up Kim has been known for his outstanding sculptures and also as a pioneer in Korean architecture. Though it is not well known, Kim designed many buildings in downtown Seoul, including the headquarters of Industrial Bank of Korea, the Rehabilitation Protection Center (currently Anguk Building), and the 31 Building, thus, opening the era of high-rise buildings in Korea. Many broadcasting stations and art centers in provincial cities are also works of Kim.

Danam Tower: from Tokyu Hotel to an Office Space Rental Building

Danam Tower was designed by Chung-Up Kim in 1968 and constructed by Hyundai Engineering & Construction. It was open for business in 1971. Since Danam Tower was built as a hotel and used for a long time, some people in Namdaemun Market still call it the Tokyu Hotel.

In 1962, the Korean government established the International Tourism Organization (currently the Korea Tourism Organization) and stepped forward to streamline the management of hotels. In the 1970s, the tourism industry became the core national strategic industry, and several measures were taken to promote the hotel business, some of them including funds for hotel management, reduced electricity & entertainment tax, and simplified licensing procedures.

At the time when the domestic capital base wasn’t abundant, direct foreign investments were active to attract foreign capital. The Tokyu Hotel was also constructed in this manner — as a joint venture between Korea’s Danam Industry and Japan’s Tokyu Railways Company, Ltd. At first, the building wasn’t well-received by the public because it was a first high-rise building constructed right next to Namdaemun, the National Treasure of South Korea. After being operated as a hotel for about 12 years, the building was renamed Danam Tower and has been used as an office space rental building.

A Simple, Straightforward Design and Remodeling Using PosART as Interior Material

There are two revolving doors at the entrance of the Danam Tower that features a magnificent cantilever canopy extending all the way to the sidewalk and a wide staircase below. The building has a rather simple space arrangement — with Starbucks and an optical store located on the first floor, and identical office spaces from the second to the 26th. In the initial design, Chung-Up Kim came up with a cantilever structure that would support the entire 89-meter building with just two columns but with the construction technology of the time, realizing it was a nearly impossible task. Hence, the plan was modified to place eight columns, two on each side, giving the bland square building a more impressive design. The center of the square plane features seven elevators, staircases, restrooms, and ducts. The interior of the office spaces is vast, with no columns or walls, as the exterior columns are supporting the entire structure. Glass windows are everywhere, providing a panoramic view of Seoul Station, Myeongdong, Inwangsan Mountain, and Bukhansan Mountain.

[Architect’s Pick: INNOVILT PosART Exterior & Interior Materials]

In 2018, the Danam Tower underwent large-scale remodeling. Deteriorated parts were renovated and the outer wall, which had been finished with ivory-colored exposed concrete, were covered with black terracotta panels, glass, and aluminum sheets. The lobby, which is considered the ‘face’ of a building, took on a new look as well. The former lobby, where an old chandelier hung on the curved ceiling, was reborn with a straightforward and sleek-looking appearance. Selecting the materials for the renovation was an important task, considering that the building was a historical one, and after careful reflection, PosART interior materials with Basaltina prints were selected for the walls. PosART is a new construction material that POSCO C&C has successfully commercialized for the first time. Inkjet printing technology on POSCO steel becomes PosART, and the material used here was specifically PosART Marble. It embodies the texture and looks of natural marble while providing easier construction and renovation at a lower cost. Radon, which is a defect found on synthetic marble, isn’t a problem here, and another feature is that it is a sustainable material. Also, PosART enables custom printing without additional molds for creating patterns or processing.

Although the material is still unfamiliar to architects as of present, it is expected to serve as an appropriate alternative to conventional construction materials, excelling in both functional and aesthetic features. In the case of Danam Tower, a dry construction method was applied, leaving the existing marble tiles as they are and installing an anchor on top to attach the PosART. In this way, there was no need to demolish the walls of the main building, therefore making the construction easier and shortening the period.

A cornerstone reading, “Placed on May 15, 1968,” can be seen when you come outside the building. The tower’s official logo is an abstract image of the building itself with “since 1970” written underneath. An architectural model created at the time of the building’s completion is displayed on one side of the lobby. The blueprint is preserved as well. All of these exhibit how much pride and affection the owner has for the building. Apparently, an employee who joined the Tokyu Hotel as a concierge is still working here as a parking management employee. There might be mixed evaluations following the remodeling plan, which is a complete transformation from its former structure. However, one thing is for sure — the building has become much cleaner and safer. Let’s hope that the now-sophisticated historic and iconic building will remain in its place for a long, long time.

You might have had an experience where you went shopping for shoes and found the exact design that you want. You asked the sales clerk for the size in 235 mm and found out that the shoe comes in 10 mm size units. Since you still wanted it, you bought it in 240 mm, but every time you wear them, it makes you wonder what it would be like if you could customize them to 235 mm.

This issue isn’t the case with clothes and shoes only. The construction market faces the same task as well: finding items that suit and fit perfectly. Pos-H, which is produced by Dong Yang S. Tec, is an excellent solution for the problem. How does Dong Yang S. Tec do this, and how is it related to POSCO? Find out the answers at POSCO Newsroom.

l POSCO’s Partner for 40 Years: Dong Yang S. Tec

Two signs on the outer wall of Dong Yang S. Tec factory caught the eye. A shiny INNOVILT Alliance mark was placed next to another sign that read “POSCO Processing Center.” The signs were evidence showing that the relationship between POSCO and Dong Yang S. Tec was truly extraordinary. To delve into the story, POSCO Newsroom sat down for an interview with Haeng-Jea Lee (in charge of the Steel Structure department of Dong Yang S. Tec plant), Jin-Young Kwack (Dong Yang S. Tec Marketing Group Sales Team), and Han-Jo Kang (POSCO Construction Steel Materials Marketing Office).

Founded in 1981, Dong Yang S. Tec is an official processing center that cuts, processes, and sells steel materials produced by POSCO. About 100 employees are working in Daejeon, two factories of Pohang, and Seoul. Dong Yang S. Tec made its name known in the Korean steel industry as POSCO’s processing center and was announced as POSCO’s INNOVILT Alliance earlier this year, thus further strengthening its partnership with POSCO. The reason behind the selection was its unique Pos-H. Pos-H is Built-up H (BH) section steel, a construction steel material used to build the framework of buildings. The unique feature of Pos-H is that it can be customized according to the needs of clients — a breakthrough in the conventional steel market.

The conventional Rolled H (RH) section steel can only produce products in a certain fixed size. However, in the case of Pos-H, the BH section steel, clients can choose the desired size, and the product is manufactured by cutting and welding as required.

▲ A sample Pos-H at Dong Yang S. Tec

Dong Yang S. Tec and POSCO have jointly developed Pos-H since 2015. It was a momentous occasion, with the cooperation between two companies taking the next step: becoming a new product development and production partner. Dong Yang S. Tec’s Jin-Young Kwack said, “Pos-H and INNOVILT Alliance was a breakthrough for us. In the past, our main business was simply processing and distributing products made with POSCO steel. However, thanks to Pos-H and INNOVILT Alliance, we could boost sales and client credibility, despite various difficulties in the market.”

Dong Yang S. Tec made bold investments regarding facilities by remodeling factories and introducing new machinery to produce Pos-H. POSCO also stepped in, providing technical research support to make sure that the investments of Dong Yang S. Tec would not be in vain but yield positive results. POSCO’s Han-Jo Kang said, “When proposing Pos-H to construction companies, POSCO, Dong Yang S. Tec, and the design engineering firm visit them together. The three of us join forces, like a three-way collaboration. Pos-H is much economical and more appropriate to meet delivery dates with enhanced productivity compared to convention RH section steel. As these advantages became known, the supply of Pos-H is gradually expanding in the conservative construction market, where the use of RH section steel is dominant.”

l Pos-H: Economical Yet Durable

The greatest advantage of Pos-H is its cost-saving effect made possible through weight reduction. Pos-H can save 15~20% of the total amount of steel needed for production compared to RH section steel. Let’s say that a construction site requires 100 tons of RH section steel. With Pos-H, it is possible to build a strong and durable building with just 85 tons. Haeng-Jea Lee of Dong Yang S. Tec remarked, “In the past, all buildings had to be constructed according to the fixed specifications of RH section steel. However, Pos-H allows new customized orders that suit the architectural design. For example, suppose you need steel with a height of 850mm. In the case of RH section steel, the standard is set at 900mm, so you will have to change the structure design to meet the specifications, but as for Pos-H, it can be customized to 850mm. Since the material becomes lighter, cost reduction is an obvious outcome.”

▲ Dong Yang S. Tec acquires stable product quality by applying an automated system in the welding process, the core phase in manufacturing Pos-H.

Now that we’ve seen the many advantages of Pos-H, what about its safety? One might think that Pos-H wouldn’t be as strong as RH section steel since it is made by welding. However, POSCO’s Han-Jo Kang said that this assumption wasn’t real. “After more than half a year of research together by POSCO, Dong Yang S. Tec, and RIST (Research Institute of Industrial Science & Technology in Pohang), Pos-H is revealed to have at the least equal or better performance compared to RH section steel. People might think that when pulled on both sides, the weld zone of Pos-H might break. However, after multiple series of high-strength tests, it turned out that the steel broke in the middle and not the weld zone. This shows how strong Pos-H is,” said Kang with a sense of pride and confidence.

Then how is Pos-H different from RC (reinforced concrete), a traditional material of architectural structures? Haeng-Jea Lee said that Pos-H has mainly three advantages over RC. First, Pos-H is a sustainable material. Compared to concrete, which is non-recyclable, iron, the raw material of Pos-H, can be reused indefinitely. Second, Pos-H is economical. RC has complicated processing stages and long construction periods that, in turn, lead to increased costs. In comparison, Pos-H can be produced and delivered in a shorter time, thus, reducing the overall cost as well. Third, Pos-H is resistant to earthquakes. The material used by Dong Yang S. Tec to produce Pos-H is SN355 and HSA500 — both POSCO’s earthquake-resistant steel.

l INNOVILT Pos-H: How Is It Made?!

Pos-H manufacturing was in full action at the factory. Several cranes installed on the ceiling were moving the large steel plates incessantly on the manufacturing process. At the end of the process, the steel plates bearing the POSCO mark were transformed into the strong Pos-H.

The manufacturing process of Pos-H can be divided into seven steps. When POSCO’s high quality hot rolled steel or steel plates are delivered, they are cut into the desired size ordered by the client. The material is then shaped into an H shape, welded firmly, and calibrated. The finished product goes under inspection regarding its length and weld. For a more vivid experience, check out the entire manufacturing process in the video below. (Korean)

The Pos-H is sent to a secondary processing company before being used on site. Secondary processing companies perform several works, including hole piercing, painting, and attaching small parts so that the manufactured Pos-H can be used at the construction site. The final Pos-H products are used in the framework of various architectures around us, such as bridges, factories, and buildings.

l The Credible Dong Yang S. Tec

The main factor that makes Dong Yang S. Tec different is that all of its raw materials are 100% POSCO steel. This demonstrates the true identity of an INNOVILT Alliance. Haeng-Jea Lee explained that Dong Yang S. Tec doesn’t use steel from other companies, making the company credible among clients. Jin-Young Kwack added, “Dong Yang S. Tec is a POSCO INNOVILT Alliance. The title itself shows how credible the company is. POSCO provides one-stop solutions from the raw material stage to the sales stage. And also follow-up management in case a problem with the product comes up. But as of present, there hasn’t been a single case.”

The visit to Dong Yang S. Tec could be summarized into a single word — Trust. Dong Yang S. Tec was able to gather credibility and trust from clients through the INNOVILT Alliance with POSCO. POSCO and Dong Yang S. Tec could maintain 40 years of cooperation with this trust. The credible Pos-H was a result of the trust-based relationship between the two companies. POSCO Newsroom looks forward to the next 40 years of both companies and wishes the best on their journey towards a new leap forward — INNOVILT Alliance.

▲ Source: Seoul National University Library Kwanjeong White Paper (2016)

The main building of the Central Library, located in the heart of Seoul National University (SNU) Gwanak campus, was completed in 1975 with the design from Seung-woo Lee. Built to reflect modernism, which was at its height at the time, the building has been well used for over 40 years without much change. It is not necessary to give many titles such as “The best” or “Having the largest number of books” to SNU’s library since it is a significant place with history, where countless students have passed. However, as times changed, more was expected from the library, and the need for expansion became apparent. Bookshelves were lacking space, and the reading rooms were also becoming too small to provide for all the flooding students. So, in 2013, SNU decided to construct “Kwanjeong Building” as an extension building of the central library.

▲ Source: Seoul National University Library Kwanjeong White Paper (2016)

A Large Open Indoor Space

SNU Library Kwanjeong faced some challenges in its construction — like in all other buildings — since it had to meet the following conditions: 1. The Kwanjeong Building had to be directly connected to the main building, and 2. the central stairway between the library and the student center, and the pathway to the east of the library had to be preserved in its original state. To achieve this task, SNU had no choice but to select the narrow piece of land between the Central Library and the College of Pharmacy as the construction site for the expansion. Instead of initiating the original plan, which was to build the library higher, an L-shaped design plan was selected, covering the right-hand side and upper part of the Central Library. This was a measure to secure the scenic view that stands behind the library as well as to keep with the height restrictions of Gwanaksan Mountain. The construction method adopted here leaves a gap between the main building’s rooftop and the Kwanjeong Building, giving it an illusion — as if a new floor was added to the main building.

The Kwanjeong Building took a horizontally long-form, reaching 165 meters to secure maximum interior space. The floor plan of the sixth, seventh and eighth floors, shows that there aren’t any columns or walls passing through the middle, other than the pillar located near the elevator. The sixth floor consists of a multimedia plaza and a computer lab, and reading rooms are located on the seventh and eighth floor, so these three floors are where many students are likely to use at all times. Since there aren’t any columns here, the students can feel much comfortable and a sense of openness as well.

A truss — weaving linear frameworks into triangular nets to withstand heavy weight — structure reaching 112.5 meters wide is supported by the two core mega columns standing at both ends of the building. In reality, using a long span truss structure in a large scale building is quite rare. The key to realizing this structure is POSCO’s high performance construction steel called HSA 650(High-performance Steel for Architecture 650). With a yield strength of 650 MPa and tensile strength of 800 MPa, HSA650 is capable of supporting a weight of 80 kg per 1㎟. Simply put, the SNU Library Kwanjeong is an architecture where excellent materials meet construction techniques.

▲ The outer wall of Kwanjeong was made with a trapezoidal module curtain wall. For the purpose, the Steel Curtain Wall was selected, since it enables atypical designs and shows higher structural performance compared to other materials.

A Facade Filled with the Lights of the Mountains and Sky

Besides its structural merits, Kwanjeong Building catches the eye with its shining exterior. Tae-Yong Yoo, the architect in charge of the project, mentioned that the concept of the design was about “light” — something that has been and will be existing in the future as well. He said, “I started designing by setting a small architectural element that projects light. And this element was repeated to make up a whole.” His intentions are well displayed on the building facade, the exterior of the building. The exterior wall was built by applying the steel curtain wall and anodizing panels — a plated panel with a film that is produced while oxidizing aluminum surface — in a repetitive manner. These panels were tilted to 16 degrees considering that they highly reflect the strong summer sun. So this exterior wall is capable of reflecting and letting in sunlight at the same time.

[Architect’s Pick : INNOVILT Steel Curtain Wall]

Curtain walls aren’t new to modern architecture. However, due to structural issues, they need to be used carefully in the case of high buildings like Kwanjeong (4.5 meters). Especially if the exterior wall is to show an atypical design, a curtain wall made of steel would be most appropriate choice. In the case of Kwanjeong, the frames of the curtain wall that hold the glass and anodizing panels are slim and neat-looking. This is possible because they are INNOVILT Steel Curtain Wall made with POSCO’s World Top Premium Product, ‘PosMAC’. PosMAC is a ternary alloy coated steel composed of zinc, magnesium, and aluminum. When exposed, the coating forms a highly stable and dense film layer called “Simonkolleite.” This enables the product to demonstrate an extra protective layer — a ternary alloy layer whose density is much higher than that of conventional galvanized steel sheet. PosMAC is 10 times more corrosion-resistant than conventional steel.

The facade was made to reflect the sunlight from early morning till sunset, and relieve the heaviness it might impose on the overall landscape. The spacious indoor area with cores on each side, and the harmony of glass and anodizing displayed on the exterior with a slim well-finished frame might be considered as key features of SNU Library Kwanjeong. And INNOVILT Steel Curtain Wall plays a hidden role behind the scenes here.

Deep into the details, there was a secret key that enabled this seemingly impossible task — corrugated steel plate. This corrugated steel plate is made with POSCO high-performance hot rolled steel. And ‘ChungAmEnC’, which manufactures and constructs corrugated steel plates, is one of POSCO’s INNOVILT Alliance.

In November last year, POSCO launched ‘INNOVILT,’ a premium brand of steel products for construction. ‘INNOVILT Alliance‘ are the manufacturers of INNOVILT products. POSCO Newsroom visited ChungAmEnC to see the INNOVILT Alliance in live action. Join us in the first story of the INNOVILT Alliance Journal.

l ChungAmEnC, POSCO, and the Third Generation Corrugated Steel Plate

ChungAmEnC’s corrugated steel plate factory is located in Chungbuk province, an hour and a half drive away from POSCO Center, Seoul. The factory stood past massive peach tree farms and was easily recognizable for the steel material piled up at the site. Some corrugated steel plates awaiting the next process and other steel material going under testing were laid out neatly in the yard. In the factory, gigantic steel plates were being bent into wave shapes. Where and how were these strong-looking steel used, and what role did POSCO play in the process?

ChungAmEnC was established in September 2014 and is an SME that manufactures and constructs corrugated steel plates in the domestic and overseas construction markets. The company operates several business units in Korea, and the factory in Chungbuk province produces all three types of corrugated steel plates — from the first to the third generation. All of the corrugated steel plate in ChungAmEnC are made of SS315 and SS450, both POSCO high performance hot-rolled steel.

ChungAmEnC and POSCO came together in 2017 to develop the third generation corrugated steel plate. Despite the material having a history of more than 100 years globally, it has been utilized for less than 30 years in Korea. POSCO, which introduced the technology for the first time in Korea, began an R&D project with ChungAmEnC to develop the third generation corrugated steel plate. POSCO’s Kyung-Jo Youn recalls the past cooperation, “It took a year and a half to successfully develop the third generation corrugated steel plate. Now ChungAmEnC is the sole manufacturer of third generation corrugated steel plate in Korea. Its quality has been recognized as well, and the company has been advancing into the global market. Thanks to this, sales at POSCO has also increased. We have become good partners creating new values!”

l NNVOILT Corrugated Steel Plate: How Strong Is It?

What exactly is a corrugated steel plate? Put simply, a corrugated steel plate is a thin, flat steel plate that has been formed into wave shapes to make it stronger. The pitch and depth of the wave-shaped steel plate maximize its strength. How is it different from a regular flat steel plate? Well, the corrugated steel plate can withstand about 50 times more weight than a regular flat steel plate of the same thickness — it’s much stronger. The fact that it can maintain its strength while reducing thickness makes it the most structurally safe and inexpensive construction material in the modern era.

Inside the factory, we could see the manufacturing process of the corrugated steel plates. Rectangular steel plates were put into a gigantic machine to create wavy shapes and curvature. Next, they were sent into a punching machine to pierce bolt holes. Seeing flat sheets of steel turn into wavy sheets and become stronger was more than enough to understand the true charms of steel: strong yet extremely flexible.

l What’s Better? Corrugated Steel Plates or Reinforced Concrete?

ChungAmEnC’s corrugated steel plates can easily be seen in our daily lives. The ‘ecological tunnel’ built by connecting severed roads to prevent road kills of wild animals can be a good example. Another example is the Suseo SRT and Gimpo City Railway’s evacuation routes. The material also boasts excellent protection performance and is applied to defense facilities such as ammunition storehouses, airplane hangars, and protective walls.

Since reinforced concrete is considered the most common construction method in the construction industry, what difference does it have with corrugated steel plates? ChungAmEnC’s CEO Hui-Jun Son answered, “Reinforced concrete is the most familiar construction method. However, this method takes a long period to complete since it requires a multi-step process that includes reinforcement, formwork, and so on. In places with much traffic, it’s really important to minimize users’ inconvenience by reducing the construction period as much as possible. Since corrugated steel plates are fully manufactured according to required specifications, they don’t need any welding or cutting on arriving at the site. All you have to do is assemble them in order, so you just need a few people to complete the construction. As a result, the overall construction period and cost can be reduced by more than 30%.”

But isn’t safety more important than reducing the construction period? Son replied with confidence, “These corrugated steel plates are made with 100 percent POSCO steel. Of course, it is durable. Tunnels made of corrugated steel plates are built and designed with thorough calculations to withstand approximately 100 years. All of this has been verified through a long period of testing with POSCO. Let me take the recent case of Samae 2 Tunnel restoration as an example.”

▲ Samae 2 Tunnel restoration

“The advantage of corrugated steel plates over the traditional reinforced concrete was clearly demonstrated in the restoration of the Samae 2 Tunnel in February. POSCO and We discussed the restoration plan together and suggested using corrugated steel plates as a solution to the Korea Expressway Corporation. The reinforced concrete construction required more than six months, but we thought we could finish it within 1.5 months by applying INNOVILT corrugated steel plate in the construction.
POSCO visited the site day and night and provided technical support. With 15 workers and three cranes, we completed the construction in 6.5 days. The tunnel reopened on March 24, one week ahead of our original plan. It is a good example showing how POSCO and INNOVILT Alliance work together.

Despite its many advantages, many in the construction industry are still conservative about using corrugated steel plates. So what can do the trick? The answer is POSCO’s INNOVILT Alliance. Son remarked, “Whenever I mention that our corrugated steel plate products are certified by POSCO, people look at our products differently. They all go ‘really?’ and look more interested. In fact, when we deliver INNOVILT Alliance products to the site, we put a certification sticker on them. Since the sticker proves that the product has been acknowledged by POSCO, the credibility of our product quality has been enhanced, and this has increased the repurchase rate as well.”

▲ Products with an INNOVILT Alliance certification sticker!

l INNOVILT Corrugated Steel Plate Advancing into the World

As mentioned above, the third generation large corrugated steel plates have been acknowledged in the global market as well. So where exactly are ChungAmEnC’s products used overseas?

Recently, ChungAmEnC’s products are making their way into Australia and South America, where the mining industry is developed. The first task in developing a mine is to build an entry road leading to the mine. Vehicles that carry the mine minerals have wheels taller than an adult and are capable of loading about 670 tons. The perfect material that can withstand this super-sized vehicle is the third generation corrugated steel plate. In January, ChungAmEnC, POSCO, and POSCO International worked in cooperation and succeeded in exporting corrugated steel plates to Australia.

Three additional features make ChungAmEnC’s corrugated steel plates more special. First, ChungAmEnC is able to respond to the needs of its customers by designing and producing various waveform sections. R&D and facility investment made possible the mass production of the third generation corrugated steel plates, and now, ChungAmEnC has registered for two intellectual property rights in North America, Europe, South America, Australia, and Asian countries.

▲ BIM simulates the design and construction process.

The second feature is the BIM (Building Information Modeling)*, a global design trend. In 2019, ChungAmEnC introduced BIM in the corrugated steel plate industry for the first time and has been providing engineering services to overseas customers. With BIM, it is possible to simulate the design and construction process in advance, thereby minimizing errors in planning and estimating production volume. This method is expected to boost productivity as well. * BIM(Building Information Modeling): The process of virtually modeling a facility with 3D shape information as well as other information, including the amount of material needed.

The third feature is a field construction and maintenance technology using 3D Scan Monitoring technology and drones. This technology utilizes the 3D scan camera on a drone to acquire 10 million four-dimensional coordinates per second. It is capable of capturing elaborate information within a much shorter time than conventional manual methods. Since this technology obtains surrounding information as well as monitors the construction process, real-time communication with customers is facilitated, thus preventing various errors that occur during the construction process.

The half-day spent at ChungAmEnC truly demonstrated a trust-based relationship with POSCO. ChungAmEnC was advancing into domestic and overseas markets with the POSCO INNOVILT Alliance title, and POSCO was offering technical support and realizing the ‘With POSCO’ philosophy. This is the true synergy of being an alliance, and both companies will continue to cooperate successfully in the future as well.