Connections - November 2017

Vol 16 | Issue 2 | November 2017

| www.asa-inc.org.au

17

Editorial

In this edition, we profile Natasha Porteous, Senior Environmental Advisor for Services and Manufacturing Excellence at Bluescope who is an active member of ASA Technical Committee. As someone who has worked within the construction materials industry continuously over 20 years, her comical Member Profile is a testament to her diverse and long-standing interest in ISS.

TH I S I SS U E

Later in this edition, we hear from new member SLN, as well as a report from Global Cement and Thomas Reiche, Managing Director of the FEhS Institute for Construction Materials Research. Reiche shares how Global Cement has developed to meet the needs of today’s industry, both in Germany and further afield.

1. Editorial 2. Concrete 2017 - Advances in Concrete Materials and Structures 3. SLN - The Newest Member of the ASA 4. Member Employee Profile - Natasha Porteous 5. FEHS Institute - Evin Zozan 7.

Membership Survey Results 8. Table 1 9. 99th NSA Annual General Meeting 10. 9th Euroslag Conference 11. #GLOBALSLAG 12. Quick Reference Guide 4 16. New ASA Headquarters

Annually, the ASA conducts a survey for information regarding ISS production and sales by members and non-members for each calendar year. For your convenience, the Association has provided a brief overview and commentary on the statistics and figures returned by our survey participants in regards to their annual production and sales of ISS. In terms of industry events, the ASA team and exhibition attended the Concrete 2017 Conference in late October, providing important networking and member generation opportunities. Craig Heidrich also took to the skies to attend EuroSlag 2017, in Metz France. Looking forward, there are a number of conferences on the horizon with World of Concrete, Las Vegas in January 2018, and the Global Slag Conference in April 2018.

On a final note, the Association will be moving to a new office over the next month. Please note the change of address to Unit 5, 41-47 Five Islands Road, Port Kembla, 2505 NSW. The ASA team would like to wish its members and their families a safe and happy Christmas. We look forward to working with you in 2018.

CONTENTS

2017 has been a fast year of positive developments for members of the Australasian (iron & steel) Slag Association (ASA). With a number of key member projects taking place including the finishing of the Berry/ Foxground Bypass, installation of new slag facilities in Melbourne, VIC, numerous road upgrades, coupled with major progress on multiple projects within the Cooperative Research Centre for Low Carbon Living. The ASA’s involvement highlights a continued investment and demonstrates a commitment to furthering the beneficial outcomes associated with the use of iron and steel slags (ISS).

CONNECTIONS EDITORIAL TEAM | November 2017 Edition Connections is published by the ASA The Australasian (Iron & Steel) Slag Association Wollongong NSW 2500 Phone: 02 4258 0160 Fax: 02 4258 0169 Email: info@asa-inc.org.au Web: www.asa-inc.org.au Executive Director: Craig Heidrich Editor: Aiden Chilcott Design: 101 Design Contributors: Evin Zozan, Natasha Porteous, Robert McCaffery, Aiden Chilcott, Carol Wilson, Craig Heidrich, Eliza Elliott, Thibault de Saint-Vaulry Connections is a biannual publication with an online circulation of 1500 copies

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@asa_info

CONCRETE 2017

ADVANCES IN CONCRETE MATERIALS AND STRUCTURES The Concrete Institute of Australia has just held their 28th biennial conference, Concrete 2017 with over 530 industry delegates travelling to Adelaide to attend the largest concrete conference in the southern hemisphere, surpassing Concrete 2015 in Melbourne.

The conference was filled with a range of activities for delegates, including 160 technical presentations, 2 supplementary workshops, 3 social events, 5 keynote speakers, 2 invited speakers and 45 exhibitors. HBM Group occupied three positions, showcasing the CPAA, ADAA and ASA. Concrete 2017 began with a welcome address, and first keynote speaker, Louise Adams (Aurecon) delivering her presentation on innovation within the industry. Both keynote and invited speakers delivered a range of relevant industry topics from both a local and international perspective.

The Concrete Institute of Australia and ICDC were able to assemble an excellent lineup of industry leaders - Professor Des Bull, Professor Doug Hooton, Professor Tim Ibell, Professor Karen Scrivener, Mr Peter McBean, Dr Stuart Matthews, and Mr Mike Schneider.

The 2017 Gala Dinner was well attended by approximately 450 delegates, who joined in the festivities to welcome several significant Concrete Institute Members to the growing list of Life and Honorary Members, and to celebrate the National Awards for Excellence in Concrete and National Engineering Bursary Winners. The following individuals and projects took home Medallions and were each worthy of the recognition bestowed upon them, including HBM Group’s Mr Craig Heidrich, receiving Life Membership to the Concrete Institute of Australia.

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At the Concrete 2017 Gala Dinner, Craig Heidrich (CEO) and Dr Liza O’Moore – University of Queensland were awarded life membership of the Concrete Institute of Australia. The Council of the Concrete Institute of Australia makes Awards for Life and Honorary Membership to recognise people who have made significant contributions to the Concrete Industry.

Concrete Institute Life Members • Dr Liza O’Moore – University of Queensland • Mr Craig Heidrich – HBM Group Concrete Institute Honorary Members • Professor Jay Sanjayan – Swinburne University of Technology • Professor Priyan Mendis – University of Melbourne • Mr Tony Thomas – Formerly Boral Concrete The full album of Concrete 2017 images can be found on the Concrete Institute’s Facebook Page. The Institute will also be covering project profiles of the National Award Winners across their social channels and website.

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SLN - THE NEWEST MEMBER OF THE ASA GROUPE ERAMET

Based in New Caledonia and part of the ERAMET Group, SLN is the largest ferronickel producer in the world with an output of 55 to 66kt Nickel per year. Operating for more than a century, its product which is an alloy of Iron and Nickel is widely acknowledged by the stainless steel industry for its quality and consistency (ISO 14001 & 9001 compliant).

The ore containing around 2.5 Nickel is stacked and homogenized to ensure consistent input in the process. After going through pre-heating and calcination, it is then processed in an Electrical Arc Furnace (EAF).

Ferronickel slag (FNS) is generated at this stage. Being lighter than liquid metal, it is poured through a dedicated tapping channel and immediately granulated with sea water to be stockpiled on a monitored stocking area.

FNS has been used for decades in various applications: • Land reclaiming: around 20% of Nouméa city has been reclaimed using FNS. • Nonstructural concrete: blockworks using 100% of FNS as a sand, footpath, breakwaters… many applications are using FNS as a sand substitute • Structural concrete: More recently, SLN has conducted the construction of a complex switch room to demonstrate the quality of its product when used as a natural sand replacement in concrete.

• Road base: New Caledonia has used Ferronickel slag for many years as a road base. SLN itself used it for a road followed by 100 tons trucks within its plant. After several years of intense usage, no cracks or deformation can be observed.

The above applications consume around 100 to 150kt of slag every year in New Caledonia. However, SLN generates approximately 1.6 to 2 million tons per year of FNS. This represents a unique opportunity for Australia to source a robust and quality aggregate just 1,200 miles away from its Eastern Coast.

In order to commercialize this product in Australia, SLN has branded its FNS “Le Sland” and conducted extensive tests for several years with reputed entities such as Perth University and UNSW. Drs. Prabir Sarker (Perth University) and Arnaud Castel have demonstrated the excellent properties of this product:

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• As a sand replacement: due to its low absorption ratio and binding properties, the use of SLN as a sand replacement allows to substantially reduce cement introduction in concrete mixes. It is compliant with the AS 2758.1 • As an SCM: when ground, Le Sland represents a credible alternative to GG BFS and fly ash.

As it is the case in New Caledonia, Le Sland can also be used as a road base (raw or ground) and for land reclaiming.

SLN has also invested in a ship loader in order to optimize upstream logistics. Moreover, New Caledonia is importing more than 900kt of coal every year. SLN can, therefore, take advantage of competitive freight rate from handysize ships normally returning to Australia empty.

While sand supply is becoming an increasing challenge in Australia, quarries being always further away from consuming areas, Le Sland is widely available due to a historical stockpile of over 20 million tonnes which is closely monitored. Favoring the principles of the circular economy model, SLN is now commercializing its product in Australia, setting up a sales office in Sydney.

For more information on our material please click here: http://www.sln.nc/le-sland Sydney: Thibault de Saint-Vaulry Thibault.de-saint-vaulry@erametgroup.com 0426 171 831 Office: 25 Burton St, Glebe NSW 2037 New Caledonia: Frederic Martin F.MARTIN@eramet-sln.nc +687 793171

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NATASHA PORTEOUS MEMBER EMPLOYEE PROFILE

Best advice you have ever been given?

“Don’t sweat the small stuff.” It’s not advice that I take, but it is the best I have been given!

Climate change is definitely one that will not go away, but the broader issues of creating a sustainable business, not only environmentally, but economically and socially, raises many concerns.

Why is slag important to BlueScope?

For many years BlueScope has been committed to turning what has traditionally been seen as a “waste” into a useful and valued resource.

Slag is a great example where we have been able to find applications for a material that creates significant value for BlueScope, our partners and the end users.

What is your favourite quote/saying?

My kids answered this one for me…apparently it is “Seriously??!!?”

I work closely with Australian Steel Mill Services (ASMS), who are contracted to manage the slag produced at Port Kembla Steelworks, to ensure we comply with our legal environmental obligations. Recently, with the assistance of the ASA, BlueScope and ASMS, were successful in negotiating changes to the Steel Furnace Slag Order and the Steel Furnace Slag Exemption with the Environmental Protection Authority.

These changes involved adjusting the chemical limits written into legislation to protect our ability to handle and utilise BOS furnace slag into the future. It was an excellent outcome.

What’s the funniest thing that has ever happened to you at work?

Well, there was that time when I was 60m up the old Sinter Plant stack and had to go to the bathroom…but maybe we better not go there!

Pretend you’re the Bluescope CEO. What two concerns about the firm’s future would keep you up at night?

There are so many challenges facing Australian manufacturing at the moment that there must be many sleepless nights for our leaders!

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What are your current roles and responsibilities at BlueScope?

I am the Senior Environmental Advisor for Services and Manufacturing Excellence, which basically means I support this part of the business in achieving its environmental goals and obligations. It’s such a diverse role, which means I am never bored and always challenged. Maintaining a good relationship with our environmental regulator (EPA) is a priority.

How did you become interested in the slag industry?

Well, as they say “you don’t choose the slag industry, the slag industry chooses you!”. Actually, they don’t say that but they should!

What do you work toward in your free time?

After work and motherhood, there’s not a lot of time left but I love to cook, take the kids camping and skiing, and then plan the next holiday!

The ASA would like to thank Natasha for her assistance in creating this edition of Connections, and the comical Member Profile.

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FEHS INSTITUTE - EVIN NOVAN The FEhS-Institute for Construction Materials Research, based in Duisburg, Germany was formed in the 1950s to develop sustainable solutions and marketable co-products from iron and steel manufacturing, namely iron and steel slags. In this brief interview with Thomas Reiche, Managing Director of the Institute, Thomas provides an insight into how FEhS has developed to meet the needs of today’s circular economy needs, both in Germany and further afield.

Please tell us about the genesis of the FEhS - how did it come to be formed?

The manufacturing of iron and steel at the beginning of the 1950s included a booming production of slags. At this time the leading steel industry companies in Germany were aware of the necessity to develop sustainable market products out of slag. As a result, they came up with the idea to build up a technical and scientific association focused on slag research and development. Consequently, the FEhS-Institute for Construction Materials Research was established in 1954. Today, it is a registered association supported by European steel manufacturing companies, slag processing companies and cement manufacturers as members.

How has the FEhS changed over the years?

The FEhS-Institute has changed from a traditional research association to a consultancy, with partners in research and development as well as in the coordination of standardisation, legislation and regulatory activities.

The tasks of the FEhS-Institute in its three focal areas of research, services and advocacy include the testing and monitoring of industrial co-products of the iron and steel industry and other construction products. We certify the manufacturer, we research opportunities for utilising ferrous slag and smelting works co-products, we provide consulting services for construction clients and we dispatch experts to national and international committees for standardisation.

Today, the FEhS-Institute generates an annual turnover of $5m Euro.

The Institute runs six (6) laboratories with state-of-the-art technical equipment for chemistry, cement, concrete, road construction, metallurgy and physics. Each has worked in accordance with ISO/IEC 17025 and ISO 9001 since 1996. Accreditation of the labs by Germany’s Accreditation Body Dakks was finalised in 2016. About 45 highly motivated employees with a wide variety of professional backgrounds provide customer-oriented and result-driven services.

How does the FEhS fit into the landscape of industrial and academic research in Germany and in the wider world?

We speak our industry’s language as we closely cooperate with our member companies. This is different to most other research facilities.

Consequently, application relevant and output driven work is crucial to us.

The FEhS-Institute is the only organisation of its kind in the world that is primarily concerned with research and development in the field of slag and its various applications, for example as a sustainable construction material.

In the scientific sector, close cooperation with universities and other private and public research institutes based on mutuality is well established. The FEhS-Institute was focused on research and consulting services to customers in Central Europe. By implementing its ‘FEhS 2020 Strategy’ in 2015, the institute has started to internationalise its business model. First steps have already been made. The construction materials department has established cooperation with a company focused on commodity trading in the US and we cooperate with a big steel manufacturer based in Asia on studies regarding slag utilisation opportunities.

How did you personally come to be involved in the FEhS-Institute?

Three years ago, the FEhS-Institute was looking for a successor to the Managing Director. I was asked whether I would be interested to take over the job and started in March 2015. With a background in the paper sector (among others), the steel industry and especially the slag issues were new to me. I was fascinated by the FEhS-Institute, its research and consulting capabilities and the motivated and well-educated staff.

Slags and its various applications are a real-world example for the preservation of our natural resources, which is now a major political topic. Resource efficiency is now high on the agenda here at the FEhSInstitute in Duisburg. My aim is that we more actively communicate the good story we can tell about slags and their contribution to a resourceefficient world.

What is the role of the FEhS today, particularly with regards to the cement industry?

The question of how to use ground granulated blast-furnace slag (GGBFS) slag for cementitious purposes, to evaluate the properties of concretes made with slag cements and to accompany the development of suitable test methods has been one of the most important tasks of the FEhS-Institute since 1954. About 80 funded research projects regarding the different aspects of slag use for binders and concretes have been organised.

The themes cover production (wet or dry granulation or pelletization) and the chemical, mineralogical, physical and cementitious slag properties as well as the cement and concrete properties, for example with respect to strength development, durability and environmental aspects. While most of the projects are related to GBS and its use, some projects have also been conducted into use steel slags as aggregates or as a constituent in binders. Besides this technical work, the traditional tasks of the building materials department include participation in national and international standardisation and scientific committees.

Image: UNSW

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These main activities have basically remained unchanged since 1954.

The most important change results from the fundamental decision of the European steel industry to transfer its slag cement production to the cement industry. Based on this decision, which was taken in the 1970s, the technical discussion on slag cement or concrete properties is no longer restrained by the competitive situation of two industries.

Today the FEhS-Institute acts as a link between the steel and the cement industry when it comes to slag research and development.

What resources can you bring to services for the cement industry?

Referring to the activities mentioned, the FEhS-Institute is not only able to test most of the relevant slag, cement and concrete properties in own labs but also to evaluate the results against the background of more than 60 years experience and the knowledge on current developments and framework conditions.

In addition, both the close contact to the slag producers and the knowledge on their needs and possibilities form a solid basis for consulting work. As a consequence, many slag and cement producing companies as well as plant engineering companies have already become partners in bilateral consulting activities.

What are the main challenges for the organisation today?

The FEhS-Institute is in a good position being the only Institute specializing in iron and steel slag research and evaluation. It has highlyskilled staff members both at the scientific and operational level. One of our main challenges will be to internationalise our business model, as we perceive that know-how about slags and its utilisation are not at the same level in the world. We see this as a challenging opportunity to extend our business model.

Another challenge will be the rebranding and acceptance of slag as a valuable and sustainable by-product of the steel industry. We see a need to achieve a change of perception in the (political) public sphere.

Especially in comparison to natural resources, we must build a positive perception and communicate our contribution to resource efficiency.

Where do you see the FEhS in 10 years’ time?

Currently, we are running the ‘FEhS-Strategy 2020.’ Our aim is to become the number one service provider for slag producers in Europe and worldwide. Firstly, we will grow our business through co-operations in research and development by internationalising our business model.

Secondly, the FEhS-Institute will customise its laboratory services as a result of the new information obtained internationally. This will allow us to demonstrate that slags provide a major contribution to resource efficiency in the global slag and global cement industries.

To learn more about the FEhS-Institute head to the website: http://www.fehs.de/en/fehs-institute/

www.asa-inc.org.au

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MEMBERSHIP

SURVEY RESULTS

The ASA conducts an annual survey for information regarding iron & steel slag production and sales by members and non-members for each calendar year. For your convenience, the Association has committed to publishing an annual membership survey report, providing a brief overview and commentary on the statistics and figures returned by our survey participants in regards to their annual production and sales of iron & steel slags.

Information provided by members and non-members is reviewed, compared, collated and aggregated into a national set of results and include ISS production levels, and nominated uses for all slag products.

For the calendar period January to December 2016, some 2.587 million tonnes (Mt) ISS was generated by steel makers nationally or imported from overseas sources and used within various industry sectors.

Compared with 2015, there was an increase of approximately 90,000 metric tonnes of total slag available within the market.

This increase in the volume of ISS and slag utilisation correlates well with current demand for steel and the increased road and infrastructure spending by the Australian Government, in particular within the streams of steel production for BOS and EAF processes. However, the reduced demand for granulated blast furnace slag (GBFS) within the cement and concrete sectors has meant that GBFS use has decreased some 63,000 tonnes over the period. For the reported period, GBFS was from either domestic sources or imported mainly from Japan.

From the 2.587 Mt available, 2.447 Mt or 95% of ISS produced was effectively utilised within various value-added civil and construction material applications throughout Australasia.

The survey results include all generators, (iron & steel plants) marketers, (processing and marketing companies) and users for the total production and resulting sales for each end use. Where required, data is supplemented with importation data and other secondary data sources for accuracy purposes.

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The key results for the calendar period 2016 survey were: • Approximately 2.587 Mt (million tonnes) of iron and steel slag products were produced within Australasia (Australia and New Zealand).

• From the ISS produced, some 2.447 Mt or 95% has been effectively utilised (sold or reused for some beneficial use).

• On per capita basis, this equates to 107 kgs per person recycled or reused for 2016.

• 77% or 1.88 Mt was used in cementitious applications - “high value add” (HVA) Note: approx 1.1 Mt of GBFS was imported.

• 13% or 0.322 Mt was used in non-cementitious or road construction applications - medium value add (MVA).

• 9% or 0.236 Mt was in general civil or fill applications – low value add (LVA).

In summary, the longer-term trend of ISS materials end use applications continues its movement towards HVA away from LVA applications. To this end, the active recovery and use of ISS continues to provide significant positive environmental impacts, including resource conservation and in this case, the reduction of greenhouse gas emissions from the processing of virgin resources.

Table 1 provides more detail for individual category sales of ISS for the period 2016 with comparisons against 2015, 2014, 2013, 2012, 2011, 2010, 2009 and 2008.

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0

0

C2. Agricultural Applications

C2. Water Treatment/Filtration Products

D1. Total of all sold in 2015 (Auto Calc)

SECTION D Summary Results

1,685,480

106.67%

63.84%

GBFS

38,575

0

0

0

0

0

0

0

21,790

0

0

37,429

1,587,686

343,837

BFS

33,580

0

C3. Waste Stabilisation/Solidification

C3. Miscellaneous/Other

0

C3. Mining Applications

190,999

0

C2. Mineral Fillers (e.g. Asphalt)

C2. Asphalt & Concrete Aggregates

0

0

C2. Structural Fills/Embankments

C2. Rockwool Products

0

C2. Grit Blasting Products

119,258

0

C2. Feed Stock for Clinker/Glass Products

C2. Road Base/Sub Base

0

C1. Cement or Binder Products

GBFS

76.69%

292,669

SFS

145,153

0

0

79,330

0

0

0

0

3,379

13,317

0

51,490

0

SFS

78.44%

100,151

EAFS

0

0

0

31,100

0

0

0

0

68,051

1,000

0

0

0

EAFS

0.00%

0

KOBM

0

0

0

0

0

0

0

0

0

0

0

0

0

KOBM

50,000

9.62%

25,844

Other

18,890

0

0

0

0

0

0

0

6,954

0

0

0

0

Other

268,579

25,800

83.08%

2,447,981

Combined

236,198

0

0

301,429

0

0

0

0

219,432

14,317

0

88,919

1,587,686

Combined

BFS

127,674

25,800

25,800

1,101,099

1,845,481

2016 Combined

SECTION C Slag Use (mt)

381,627

0

25,800

268,579

Other

2,946,580

1,580,149

0

0

50,000

KOBM

538,551

0

0

127,674

EAFS

B2. Total Used in 2015 (Auto Calc)

0

0

381,627

SFS

Combined

0

A4. Total Removed from Storage during 2014

0

1,101,099

479,050

GBFS

SECTION B Auto Calculations

0

538,551

BFS

A3. Total Stored (not used)

A2. Total Imported in 2015 (Jan-Dec)

A1. Total Produced in 2015 (Jan-Dec)

SECTION A Slag Beneficial Use Calculations (mt)

95.06%

2,372,982

Combined

294,965

0

0

335,347

0

275

0

0

122,728

13,260

0

126,645

1,479,762

Combined

2,496,226

Combined

0

0

1,006,980

1,489,246

2015 Combined

89.70%

2,344,225

Combined

294,965

0

0

335,347

0

275

0

0

122,728

13,260

0

56,154

1,521,496

Combined

2,613,547

Combined

100,020

382,746

968,585

1,927,688

2014 Combined

Australasian (iron & steel) Slag Association 2016 Slag Production & Sales Survey

86.00%

2,476,983

Combined

259,700

0

0

407,776

0

421

0

0

203,245

0

0

114,105

1,491,736

Combined

2,880,090

Combined

51,933

421,041

820,049

2,429,150

2013 Combined

92.29%

2,789,080

Combined

241,838

0

0

428,385

56

0

4,291

1,430

241,475

689,215

0

46,820

1,135,569

Combined

3,022,216

Combined

426,349

617,707

684,033

2,529,541

2012 Combined

93.46%

3,184,195

Combined

476,947

3,758

0

630,277

29,317

115

22,012

3,505

409,822

524,242

0

28,538

1,055,662

Combined

3,406,912

Combined

167,879

235,547

612,662

2,861,918

2011 Combined

87.74%

2,346,451

Combined

234,097

3,758

22,484

710,014

29,205

0

28,199

2,766

405,636

22,119

0

16,778

871,394

Combined

2,674,354

Combined

295,814

470,472

449,129

2,399,883

2010 Combined

75.30%

2,570,669

Combined

235,370

7,137

53,384

677,585

25,643

611

38,730

2,000

522,967

388,443

0

57,270

561,529

Combined

3,414,107

Combined

0

843,438

384,250

2,941,079

2009 Combined

79.57%

2,710,556

Combined

355,965

7,137

35,493

887,092

25,793

611

31,182

11,719

604,421

14,443

0

65,547

671,153

Combined

3,406,322

Combined

0

695,766

249,100

3,157,222

2008 Combined

99TH

NSA ANNUAL GENERAL MEETING

In 1990, various members representing producers, processors, marketers, customers and suppliers of iron and steel slags founded the Australasian (iron & steel) Slag Association (ASA). Adopting a similar operating model used by the National Slag Association the based in the USA, the ASA has since forged its own operating model and governance structure to meet the needs of an evolving and complex operating environment in Australia. The ASA & the NSA have maintained a strong partnership over the years and in September, Craig Heidrich, CEO, attended the NSA’s 99th AGM and spoke to the board regarding Australia’s current standing with the slag industry compared to the global economy of ISS. Craig’s presentation covered: • The progressive idea of a Circular Economy: Alternative to a traditional linear economy in which we keep resources in use for as long as possible, extract maximum value from them whilst in use, then recover and repeat the process.

• Classification Systems: Of ISS are dislocated throughout regions, dominated by inter-jurisdictional inconsistencies based on various methods of assessment.

• Redefining “Waste”: as a recourse, by-product and co-product.

• Review of WoISS: World of Iron and Steel Slag • Spoke on Blast Furnace Iron and Crude Oil Steel Production Download Craig’s full presentation at: https://issuu.com/hbmgroup/docs/2017_heidrich_etal?e=29494037/55278884

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9TH EUROSLAG CONFERENCE The 9th European Slag Conference took place in Metz, France, from October 11th to 13th, 2017, organised by EUROSLAG with the local support of AFOCO, the French Industrial Co-Products Operators Association.

EuroSlag, created in 2000 deals with the promotion of slag as a product, enables the exchange of information and research and facilitates the interaction with governing bodies. About 45 million tons of ferrous slags are generated annually in Europe by iron and steel plants.

The purpose of the 9th European Slag Conference was the exchange of knowledge related to technical applications, environmental and legal subjects for all kinds of iron and steel slags. More than 200 attendees from 29 countries attended the event, which Craig Heidrich (CEO) noted was a highly successful and enjoyable event.

A full report of EuroSlag will be published on the ASA Blog Page in the coming months.

Learn more: http://www.euroslag.com

www.asa-inc.org.au

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#GLOBALSLAG The organisers are pleased to announce that the 13th Global Slag Conference and Exhibition will take place in Prague, Czech Republic (Czechia), on 24 - 25 April 2018.

The conference will allow all attendees to maximise their profits from slag - both ferrous and non-ferrous, will keep them up-to-date with the industry state-of-the-art and will provide extensive networking and business opportunities for both producers and users of slag and slag-based products. If your business is slag, make it your business to attend the 13th Global Slag Conference in 2018!

The registration fee includes attendance at the conference and exhibition, conference proceedings book including delegate names/ company/country and all available powerpoint slides, CD or memory stick including all available presentations in pdf or powerpoint format, participation in networking/speed-dating sessions, delegate name badge, special distribution magazine, conference briefcase, coffee breaks and snacks, lunches, welcome reception and farewell reception.

The conference early-bird registration is open until 19 February 2018 Employees of members of the conference association partners (Euroslag, National Slag Association, Slag Cement Association, Australasian (iron and steel) Slag Association, Nippon Slag Association and the Brazil Steel Institute) benefit from a large discount on registration prices.

Conference themes · · · · · · ·

Slag and slag cement market trends Non-ferrous slags Slag product trends Beneficiation of slag and slag products Slag cement production and use Case studies New applications for slag and slag products

Who should attend? · · · · · ·

Slag producers Slag-product users Cement producers and users Equipment vendors Traders and shippers Academics and researchers

To learn more or register visit: http://www.globalslag.com/conferences/global-slag/introduction

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QUICK REFERENCE GUIDE 4 - 2015 QUICK REFERENCE GUIDE 4 - 2015

Electric Arc Arc Furnace Furnace Slag Slag Electric

INTRODUCTION INTRODUCTION

TYPICAL PHYSICAL PHYSICAL PROPERTIES PROPERTIES TYPICAL

Electric ElectricArc ArcFurnace FurnaceSlag Slag(EAFS) (EAFS)is isaa co-product co-product of of the the steel steel making makingprocess. process.The Theproduction productionof ofEAFS EAFS involves involves steel steel scrap scrapand andfluxes fluxeswhich whichare areadded addedto to aa refractory refractory lined lined cupcupshaped shapedvessel. vessel.This Thisvessel vesselhas hasaalid lid through through which which carbon carbon electrodes electrodesare arepassed. passed.An Anarc arcis isinduced induced between between the the scrap scrap and andelectrodes electrodesand andthe theresultant resultantheat heat generated generated melts melts scrap scrap 1 and andfluxes fluxesproducing producingmolten moltensteel steeland and slag slag1..

Table 11 -- Typical Typical Physical Physical Properties Propertiesof ofEAFS EAFS2.2.

Table Typical Physical Physical Properties Properties- -Aggregate Aggregate Typical

ElectricArc Arc Electric FurnaceSlag Slag Furnace

Bulk Density Density (t/m (t/m33)(loose) )(loose) Bulk

1.60- -2.10 2.10 1.60

Particle Density Density (t/m (t/m33)) Particle

3.30- -3.45 3.45 3.30

Dry Strength Strength (kN) (kN)

220- -270 270 220

Strength (kN) (kN) Wet Strength

200- -250 250 200

Wet/Dry Variation Variation (%) (%) Wet/Dry

15 55- -15

Water Absorption Absorption (%) (%) Water

(coarseaggregate) aggregate) 11- -22(coarse (fineaggregate) aggregate) 22- -44(fine

LA Abrasion Abrasion (%) (%)

15 15- -20 20

Polished Polished Aggregate Aggregate Friction FrictionValue Value(PAFV) (PAFV)

58 58- -62 62

Sodium Sodium Sulfate Sulfate Soundness Soundness(%) (%)

<<44

Flakiness Flakiness Index Index (%) (%)

<<55

Free Free Lime Lime (%) (%)

<<33

Physical Physical PropertyProperty- 20 20 mm mmRoad Roadbase base 3 1 Maximum Maximum Dry Dry Density Density(kg/m (kg/m3) )1 2 Optimum Optimum Moisture Moisture Content Content(%) (%)2

2,300 2,300- -2,600 2,600 88- -12 12

Notes: Notes: 1 1 MDD based on 100% standard compaction.

MDD based on 100% standard compaction.

2 2 OMC OMC depends on the particle size distribution of the mix.

OMC OMC depends on the particle size distribution of the mix.

Figure 1 - Electric Arc Furnace Figure 1 - Electric Arc Furnace Typical physical properties of EAFS aggregates, after Typical physical properties of EAFS aggregates, after processing to remove metallicâ&#x20AC;&#x2122;s are shown in Table 1. processing to remove metallicâ&#x20AC;&#x2122;s are shown in Table 1.

Through its research activities between relevant stakeholders, Through its research activities between relevant stakeholders, the Australasian (iron & steel) Slag Association continues to the Australasian (iron & steel) Slag Association continues to increase the recognition and understanding of the beneficial increase the recognition and understanding of the beneficial use of iron and steel slags amongst industry members, use of iron and steel slags amongst industry members, government and the community though projects such as the government and the community though projects such as the Quick Reference Guide (QRG) Update.

Quick Reference Guide (QRG) Update.

This QRG updates the Guide to the use of Iron and Steel slag This QRG focusing updates the Guide to theaspects use of Iron andtoSteel slagof in roads, on the specific related the use inElectric roads, Arc focusing on the specific aspects related to the use Furnace Slag (EAFS) in terms of its physical and of Electric Arc Furnace Slag (EAFS) in terms its physical chemical characteristics, applications andofcase studies. and chemical characteristics, applications and case studies.

Quick Reference Guide 4 2015 | Electric Arc Furnace Slag

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Quick Reference Guide 4 2015 | Electric Arc Furnace Slag

EAFS EAFS is is dark dark grey grey in in colour colourand andcharacteristically characteristicallyharder harderthan than natural aggregates. It has a density about 20 - 25% greater natural aggregates. It has a density about 20 - 25% greater than basalt. It crushes to a cubical shape. than basalt. It crushes to a cubical shape.

EAFS may contain small amounts of potentially expansive EAFS may contain small amounts of potentially expansive products such as burnt lime and dolomite. Sufficient moisture products such as burnt lime and dolomite. Sufficient moisture and time must be provided to enable hydration of these and time must be provided to enable hydration of these materials, commonly known as weathering. Weathering is materials, commonly known as weathering. Weathering is typically achieved by periodic watering, monitoring and internal typically achieved by periodic watering, monitoring and internal stockpile management procedures before releasing for use. stockpile management procedures before releasing for use.

TYPICAL APPLICATIONS TYPICAL APPLICATIONS EAFS is similar to Steel Furnace Slag (SFS) with self-cementing EAFS is similar to Steel Furnace Slag (SFS) with self-cementing properties for heavy duty pavement applications. Unconfined properties forstrength heavy duty pavement Unconfined compressive (UCS) > 5 MPaapplications. has been achieved at compressive strength (UCS) o > 5 MPa has been achieved at 28 days bench cured at 23 oC. As a tough, durable material, 28 days cured at resistance 23 C. As a comparable tough, durable material, EAFS hasbench excellent skid to rhyolite.

EAFS has excellent skid resistance comparable to rhyolite.

Resistance to rutting also makes EAFS particularly applicable Resistance to rutting also makes EAFS particularly for heavily trafficked corners and stopping zones. applicable for heavily trafficked corners and stopping zones.

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Slag asphalt was laid in the northbound direction with granite asphalt in the southbound direction.

Typical applications for EAFS include: • Sealing aggregate (skid resistant) • Asphalt aggregate • Road Base, Sub-base (bound and unbound) • Construction fill Typical applications for the use of EAFS are referenced in various State Road Authority specifications as shown in Table 2.

Table 2 - Specifications for the use of EAFS. EAFS Type

RMS3

VicRoads4

Unbound

R71

304

Bound

R73

815

Select Fill

R44

812

Aggregate

3152

404 - 407

Asphalt

The types of asphalt commonly used that could incorporate EAF slag aggregates5 are: • Dense Graded Asphalt (DGA) (or Asphaltic Concrete • Open Graded Asphalt (OGA) • Stone Mastic Asphalt (SMA) • Fine Gap Graded Asphalt (FGGA) • Ultra-Thin Asphalt (UTA) Surfacings including Thin Open Graded Asphalt EAF slag aggregates can be incorporated into any of the above mix types as an alternative to natural aggregates or to take advantage of the unique properties.

The pH value of the aggregate product leads to a natural affinity to bitumen and binders, leading to reduced stripping and lowers the requirement for lime additions during the production process.

One of the main benefits of EAF slag it’s skid resistance performance combined with its ability to maintain properties for significantly longer than most natural aggregates. In place SMA mix designs have shown the SFC of slags has maintained a 15% increase over natural aggregates over time.

This leads to the consideration for the use of EAF slag sealing aggregates in applications where increased and maintained skid resistance can help lead to improved safety and reduced accidents.

Case Study 1: Emerald-Monbulk Road, Victoria

Using a VicRoads SCRIM machine, assessment of skid resistance properties between EAFS and natural materials was conducted. Results of the testing showed that the average skid resistance was 6.5% higher for the EAFS asphalt compared to granite.

A 2013 independent University report then used these results as part of a study into the beneficial impact of skid resistance on pedestrian injuries over the life of the road. This report recognised that EAFS asphalt exhibits superior skid resistance properties which last for long periods as the new frictional surfaces are regenerated on the surface of the material6.

EAFS asphalt aggregates have subsequently been specified and used at numerous sites throughout Melbourne.

SUB-BASE & BASE COURSE EAFS has been successfully used as a sub-base by: (a) Using a minus 40mm crusher run material; (b) Blending minus 20 mm or minus 40 mm material; or (c) Blending with granulated blast furnace slag.

EAFS has been used in two main applications as a base course.

The material has been blended at a rate of about 40% with existing base materials to rehabilitate existing pavements where the EAFS increased the wet/dry strength value, decreased the Plasticity Index and modified the pavement materials such that it now conforms to a DGB20 specification in accordance with RMS Specification 3051.

EAFS has also been blended with granulated blast furnace slag (GBFS) to form a bound base material. These blended materials offer slower setting due to the lower free lime content, but UCS values over 4 MPa can be achieved, ensuring the material meets the heavily bound criteria.

CONSTRUCTION CONSIDERATIONS Construction joints occur where bound material is placed against previously placed bound material which is outside the bound material’s working time. Where this occurs, a clean, compacted, vertical perpendicular surface should be cut to the full depth of the pavement layer thickness for both transverse and longitudinal construction joints. This will reduce the risk of plating effects on the pavement. All spoil material should be discarded and not incorporated back into the works.

As with all rigid pavements, the correct management and placement techniques should be considered such as: • • •

Figure 2 - Emerald-Monbulk Road, Victoria using EAFS Quick Reference Guide 4 2015 | Electric Arc Furnace Slag

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Correct location of joints limiting the overall pavement widths; Ensuring the joints are not in wheel paths; and Ensuring joints in sub-base layers are offset to joints in the base layer.

Suppliers product data and handling recommendation should be consulted for guidance where appropriate.

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Case Study 2: Wyong Rd Tuggerah 2014 Heavily bound pavement material produced using a blend of EAFS with other resource recovered materials was chosen by the New South Wales Roads and Maritime Services (RMS) for the purpose of pavement rehabilitation in sections of Wyong Road at Tuggerah.

Figure 4 shows another section ready for placement of the EAFS based heavily bound pavement material.

The material was also placed during light rain with no effect to the final product quality or compaction process.

Due to the high density results, RMS were able to reduce the time required for compaction (compared to their standard practices) whilst achieving the relative density on a single thick layer.

This enabled RMS to expedite placement of the material and progress construction faster than expected. A 70mm asphalt wearing course was placed over the pavement layer, opening within hours of completion.

ENVIRONMENTAL CONSIDERATIONS Several comprehensive studies of EAFS have shown this material and laboratory generated leachates contains trace amounts of metal well below trigger levels for environmental investigation

Figure 3 - Wyong Rd Tuggerah The above figure 3 shows a section of existing road boxed out and ready for placement of EAFS based heavily bound pavement material.

The works required a pavement material to be placed, compacted (reaching required specified relative densities), then sealed and opened to traffic all within a 10 hour construction window.

NSW Environment Protection Authority (EPA), have issued resource recovery orders and resource recovery exemptions for generators, processors and consumers of EAFS within a range of applications7.

The primary environmental risk when utilising EAFS in road making applications is the potential for alkaline leachate to enter local waterways. This risk is minimal when EAFS is incorporated into well-designed and constructed roads with adequate drainage. Alkalinity decreases over time as the material gains strength.

The EAFS based heavily bound pavement material was placed in 1 layer (up to 400mm deep) and sealed once compaction targets were achieved. The road was opened for traffic within hours of the final seal being placed. Performance of the material was critical for RMS.

Water sheeting off a road or hardstand area is not in contact with EAFS for a long enough period to produce high pH run-off. Hours to days of direct stagnant contact with EAFS are required for the pH of the water to reach environmentally significant levels.

Using standard placement methodologies the material was placed over a number of different subgrade types from weathered sandstone to poor quality clay based materials.

CONCLUSION EAFS being a co-product of the steel making process is produced using controlled inputs. These controlled inputs ensure a homogeneous output where the physical and elemental properties can be relied on for consistency. This can provide benefits over naturally occurring aggregates and pavement materials where variability within natural deposits related to geological weathering and alterations can occur.

Along with the above, environmental benefits are significant for a reduced carbon footprint along with conservation of natural resources.

Figure 4 - Wyong Rd Tuggerah Quick Reference Guide 4 2015 | Electric Arc Furnace Slag

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REFERENCES 1

http://www.asa-inc.org.au/products/electric-arc-furnace-slag

[accessed 2015] REFERENCES

http://www.asa-inc.org.au/products/electric-arc-furnace-slag ASA (2002). A Guide to the Use of Slag in Roads. Revision 2. [accessed 2015] Wollongong, Australasian (iron & steel) Slag Association Inc. with amendments 2 ASA (2002). A Guide to the Use of Slag in Roads. Revision 2.

Wollongong, Australasian (iron & steel) Slag Association Inc. with 3 http://www.rms.nsw.gov.au/business-industry/partnersamendments suppliers/specifications/index.html [accessed 2015] 1 2

Find technical notes, case studies, reports, data sheets and more under the Knowledge tab on the ASA Website or visit: http://www. asa-inc.org.au/ knowledge

http://www.rms.nsw.gov.au/business-industry/partnershttps://www.vicroads.vic.gov.au/business-and-industry/tenderssuppliers/specifications/index.html [accessed 2015] and-suppliers/contractors-and-consultants/standard-documents [accessed 2015] 4 https://www.vicroads.vic.gov.au/business-and-industry/tendersand-suppliers/contractors-and-consultants/standard-documents 5 ASA (2001). A Guide to the Use of Steel Furnace Slag in Asphalt [accessed 2015] and Thin Bituminous Surfacings. Wollongong, Australasian (iron & steel) Slag Association Inc. 5 ASA (2001). A Guide to the Use of Steel Furnace Slag in Asphalt and Thin Bituminous Surfacings. Wollongong, Australasian (iron & 6 Jones, N 2010, ‘Paper 22 The regenerative frictional properties steel) Slag Association Inc. of slag aggregate’, Harsco Metals Group Limited 3 4

Jones, N 2010, ‘Paper 22 The regenerative frictional properties http://www.epa.nsw.gov.au/wasteregulation/orders-exemptions. of slag aggregate’, Harsco Metals Group Limited htm [accessed 2015]

6 7

http://www.epa.nsw.gov.au/wasteregulation/orders-exemptions. htm [accessed 2015]

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AUSTRALASIAN (IRON & STEEL) SLAG ASSOCIATION AUSTRALASIAN (IRON & STEEL) Suite 2, Level 1, 336 Keira Street, SLAG ASSOCIATION Wollongong NSW 2500 Australia Suite 2, Level 1, 336 Keira Street, PO Box 1194 Wollongong NSW 2500 Australia Wollongong NSW 2500 Australia

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PO Box 1194 Telephone: +61 2 4258 0160 Wollongong NSW 2500 Australia Fax: +61 2 4258 0169 Email: info@asa-inc.org.au Telephone: +61 2 4258 0160 Fax: +61 2 4258 0169 Email: info@asa-inc.org.au4 connections November 17 | 15 4

ASA

NEW HEADQUARTERS

Itâ&#x20AC;&#x2122;s with great anticipation and pleasure to let you know that in November 2017, the ASA will move offices. The new location is Unit 5, 41-47 Five Islands Road, Port Kembla, 2505 NSW. The phone numbers and email addresses will remain the same at 02 4258 0160 and info@asa-inc.org.au.

The new location is close to the Wollongong CBD and will provide you with plenty of convenient parking.

Feel free to contact us with any questions you may have concerning the new location or our services. We look forward to hearing from you.

NEW ADDRESS: UNIT 5, 41-47 FIVE ISLANDS ROAD, PORT KEMBLA, 2505, NSW.

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