1.89 tons, that’s the amount of carbon per produced ton of steel according to the World Steel Association. As if that were not enough, a lot of CO2 is even produced for nothing – waste generated within the reinforcement steel manufacturing processes is estimated to be between 4% and 8%.
Steel manufacturers all over the world are facing challenges from the initial design stages to disruptions in schedules that often force them to readapt their production, which leads to higher costs in terms of energy and resources. Existing solutions and processes consist of manual workflows, relying on spreadsheets and costly software that does not handle the complexity of the manufacturing process adequately.
How to make all stages of rebar steel manufacturing greener – from the mill to the bar?
That’s the research question of the project “Re-imagining Design & Planning for Greener Reinforcement Steel Manufacturing” (DPGSM). Optimised planning and designing for off-site modular manufacturing will lead to a new way for how buildings are designed and constructed. The goal: reducing carbon emissions in steel manufacturing.
From left to right: Frode Kjøsnes, Wolfgang Kniejski, Peter Robertson, Richard Jackson, Brian Cooney, Chris Wilson, Ruth Kearney, Rune André Haugland, Caitríona Mordan, Christian Bölling, Miguel Gorriz
To reach this goal, the project partners will introduce a new concept of standardisation, thus facilitating scalable volumes which can be forecast and produced offsite as standardised modular prefabricated sections reducing waste significantly. Moreover, they will use an innovative patented building information modelling (BIM) process as well as artificial Intelligence (AI) to optimise the planning process.
Midland Steel leads the project with industry partners from robotics, software, civil engineering design and research on this two-year project to drive sustainability within the sector. The other project partners are Bastal AS, Kuka, Nightingale HQ, O’Connor, Sutton, Cronin (OCSC) and VTT. EIT Manufacturing supports this activity as part of its innovation projects portfolio.