Since the mid 19th century the sector of steel construction belongs to the hightech industries. It revolutionized the way of building by its high material efficiency, quick construction processes, the great variety of design and the long service life of steel.
Contemporary amorphous structures of public buildings and infrastructure projects of architects like Frank O. Gehry, Santiago Calatrava, Massimilionao Fuksas and Coop. HIMMELBLAU would be unthinkable without steel. Enormous skyscrapers, huge expanding steel bridges, supportfree designs of large stadiums and halls, and hydraulic steel constructions, such as sluices, weirs, dams, hydroelectric power plants, movable bridges and ferry terminals, demonstrate the innovative strength of the steel branch.
Furthermore, steel is characterized as a particular sustainable product due to its 100 percent rate of recyclability.
Our symposium on 12.-13. September 2019 in the Hotel Kloster Wöltingerode is dedicated to current research and application fields with respect to the purpose and the application of steel regarding building or bridge construction as well as in the maintenance of existing infrastructures. The symposium offerts the opportunity to discus latest development and is an ideal platform to share experience and knowledge among experts.
Welcome of the Management of Ilsenburger Grobblech GmbH
Company Presentation of Ilsenburger Grobblech GmbH
On September 19, 2018, the groundbreaking ceremony for the "New Heat Treatment Line" project took place. This is the largest investment project in the history of Ilsenburger Grobblech GmbH. Its costs will exceed € 150 million. The new heat treatment line is the main project component through which Salzgitter AG concentrates the heavy plate activities in Ilsenburg and positions the company securely for future requirements. Due to its extremely flexible cooling-down strategies, the integrated MultiFlex-Quench® enables the production of a broad portfolio, including particularly sophisticated heavy plate grades.
Steel generally is associated with a lightweight construction and very large spans due to its its own high strength to weight ratio.
Of the roughly 38,000 small and medium-sized bridges in Germany, 95% are located on county and municipal roads, mostly under municipal administration. The need for replacement constructions is estimated to total 16 billion Euros until 2030. It is worth to taking a look at the properties and advantages of composite constructions including the aspects of the area of application, its design as well as corrosion protection and service life, its life cycle assessment, external costs and sustainability.
By using High Frequency Peening Methods (HFH), the fatigue strength of welded steel construction connections can be significantly increased and their service life extended many times over. However, so far the basis for the broad application in practice has not been available in the form of a constitutionally recognized regulatory framework. For this reason, the DAST guideline "Fatigue design using High Frequency Peening Methods" has been prepared, which will be published shortly. It regulates the design of essential structural details of steel construction for steel grades S235 to S700. The lecture will explain the basics of HFH and provide an insight into the development and conception of the new DAST Directive.
In joining technology, both the high welding speed and the good root formation take on an important role. The simultaneity of both properties is difficult to achieve by conventional welding processes, which is why a specially combined process, laser hybrid (LH) welding, is used here. Completely new possibilities and synergetic effects result from the merging of a laser beam with an electric arc. The leading laser process results in a very narrow heat affected zone with a high weld depth to seam width ratio. The connected inert gas metal arc welding process has a much lower energy density and is characterized by a higher deposition efficiency. Especially recently, measurable advantages could be achieved and a significant increase in productivity. In addition, LH welding contributes, in direct comparison with the pure laser, to a significant increase in the quality of the joint connection. The fillet weld will be used as an example to discuss the specific requirements, which are not trivial. The full through-welding in one-sided design, which, however, could perfectly and reproducibly be implemented by the development of a special and fully industrial-suitable LH welding head. Compared to the conventional inert gas metal arc technology, the hybrid process requires a reduced filling volume, which results in savings of additional material and reduction of distortion. Furthermore, practical applications and economic considerations of these new process combinations are presented. As result of the shorter production times, personnel costs and, subsequently, unit costs for machine frames for bending-off presses can be reduced.
The four recently completed new construction projects of the Wasserstraßen-Neubauamt (WNA) Magdeburg are the pumping station Niegripp and the low-water lock in the Rothenseer Verbindungskanal at the waterway junction Magdeburg and the two second locks Wusterwitz and Zerben on the Elbe-Havel-Kanal.
Experiences from planning, production and assembly of steel hydraulic engineering including external monitoring are presented here. The use of new materials, GRP pipeliness and fiberglass podiums at the Niegripp pumping station and the low-pressure lock in the Rothenseer Verbindungskanal, as well as polyoxymethylene rails on the slide protectors of the longitudinal channel locks and longitudinal channel inspection locks of the second lock Wusterwitz and Zerben. Another aspect is the problem of the overall award of all four construction measures. For the construction of the hydraulic steel construction this required the steel water companies of all four new construction projects only to be subcontractors in the respective construction ARGE.
The three working levels for 2,000 employees of the new adidas ARENA, designed by Behnisch Architekten, seem to be floating. The office building resembles a highly flexible organism that can easily react to new work processes and future developments. The office cubicle and, thus, the rigid and permanently assigned workplace are a thing of the past.
The monitoring of large-area steel structures, such as bridges, to a great extent is still carried out visually. It is obvious that the visual inspection of areas of several square meters is very difficult. The same applies to the standard NDT methods. The situation becomes particularly more difficult in case of necessary inspections in areas which cannot easily be inspected, e.g. in case of impossible or difficult access or inspections in a dangerous environment, such as nuclear or chemical reactors or at offshore wind farms. Small cracks - important for fatigue - are simply overlooked, especially if the location of the possible crack is not known.
After a brief presentation of the wave propagation basis, e.g. retroactive accounting of the dispersion in the wavenumber domain, the measuring principle is presented and illustrated by examples. This is followed by a consideration of the application of wave beaming. The basics are presented briefly and explained by theoretical and experimental examples. Dependencies of e.g. of the selected frequency, A- and S-mode, the temperature and the slight shift of the measurement results and consequent errors in repeated measurements before and after, are shown, explained and optimized for the application. If these dependencies are exploited properly, the detection of a disturbance by e.g. an attached magnet or by drilling a small 1 mm hole, is amazingly good and beyond doubt.
Railway bridges are an essential component of the railway infrastructure in the route network of DB Netz AG. In railway bridge construction the massive as well as the composite and steel construction are used. The chosen construction depends significantly on the local conditions. Here it remains to notice that the largest share of railway bridges belongs to small to medium span range.
The construction of steel railway bridges requires a high degree of knowledge in static design, material selection, joining technology and storage. In addition to the building supervisory standards exist a series of railway-specific regulations. Besides the European regulations in Eurocodes also the railway-specific Directive 804 "Railway bridges (and other engineering works) plan, build and maintain" have to be taken into account and to be implemented for the calculation and constructive design of steel railway bridges. Furthermore, the rules and regulations of DB Netz AG include Deutsche Bahn Standards (DBS) with its high-quality standards, which meet the requirements of the rail transport.
Another special feature of railway bridge construction is the work being done while maintaining moving traffic. This is known as "Building under the Rolling Wheel". In this context solutions will be sought which should have as little effects as possible regarding railway operations. Moreover, local conditions such as e.g. a low overall height in urban areas, influence the construction.
Mill Tour in small groups
Dr.-Ing. Christian Boppert
Dr.-Ing. Christian Boppert already was entrusted with executive functions and management positions within the Salzgitter Group since more than 22 years. His very strong technical understanding of technical sales has been shaped by his studies of mechanical engineering and the following doctorate. Since April 2015 he is commercial managing director at Ilsenburger Grobblech GmbH.
Prof. Dr.-Ing. Klaus Thiele
Prof. Dr.-Ing. Klaus Thiele heads the Institute for Steel Construction at the Technical Universitiy of Braunschweig since 2012. His studied of civil engineering at the TH Darmstadt and his master studies at the University of Western Ontario in London, Kanada, were followed by a doctorate at the ETH Zürich. Since 2001 he was employed at the technical office of Max Bögl Stahl- und Anlagenbau GmbH & Co. KG, which he headed since 2002.
Prof. Dr.-Ing. Thomas Ummenhofer
After studying Civil Engineering and a doctorate at the University of Karlsruhe professor Ummenhofer moved from the the practice to the TU Braunschweig as Head of the Institute of Building Preservation and Support Structures, endowed professorship of the Salzgitter AG. Since 2009 he professor for Steel and Lightweight Constructions at the KIT. He also is test engineer for building constructions and registered inspector of the EBA.
Univ.-Prof. a.D. Dr.-Ing. Dr.-Ing.E.h. Udo Peil
Udo Peil studied civil engineering at the Technical University of Braunschweig, where he received his doctorate in 1976. After various professional positions, he took over the professorship of steel and light metal construction at the University of Karlsruhe in 1988. In 1992-2012, he headed the Institute for Steel Construction at the Technical University of Braunschweig. In 2014, the Ruhr-Universität Bochum awarded him an honorary doctorate.
For more than 30 years Martin Juhn is working at Fronius and supported the growth from 500 to 5.000 employees in several positions. His international involvement as application engineer enables him to gain a deep insight in key industries, for which he now is responsible. Since 2018 he is Key Account Manager at Fronius Deutschland GmbH and travels the country throughout working out of Hamburg.
Dr.-Ing. Eckart Koch
Eckart Koch studied civil engineering at the University of Karlsruhe with a specialization in structural engineering. Since 2004 he has been team leader steel, composite and glass construction of DB Netze AG. In addition, he is managing director of Directive 804 "Planning, Building and Maintaining Railway Bridges (and Other Engineering Structures)", Technology Management Railway Construction, Bridge Construction and Noise Protection Technology.
Dipl.-Ing. Arch. Stefan Rappold
Stefan Rappold completed an apprenticeship as a carpenter before studying architecture at the University of Stuttgart and then worked in several German practices. He joined Behnisch Architekten in 2000 and was responsible for the design of the new WIPO headquarter in Geneva. He was project partner for the Harvard University Allston Science Complex in Cambridge, MA, USA. In 2012 he became partner of Behnisch Architekten, Stuttgart, together with Stefan Behnisch and Jörg Usinger. Stefan Rappold is a BDA member.
Dipl.-Ing. Klaus Fiedler
Klaus Fiedler has been working at WNA Magdeburg for more than 25 years, initially 10 years as a senior engineer for the design and construction of the Magdeburg Canal Bridge. He has been the engineer responsible for steel water construction for more than 15 years. After studying mechanical engineering, he was initially responsible for the steel structures of large-scale mining equipment at the Buckau machine factory of the Construction department.
Dipl.-Ing. Andreas Rost
More than 29 years Andreas Rost is working in the Salzgitter Group. His career started 1990 as production engineer at the former Stahlwerke Peine-Salzgitter. At Ilsenburger Grobblech GmbH since 2001 he headed the department of quality managment, product development, and technical support. He is responsible for the order center and support department since 2015.
Dipl. Wirt.-Ing. (FH) Tony Dachner
Tony Dachner completed an apprenticeship as wholesale and international trade specialist before studying industrial engineering in 2002-2006 at the Hochschule Mittweida (FH). 2007 he started his career in the strategic purchase at SAM Stahlturm- und Apparatebau Magdeburg GmbH. 2012 he became head of purchasing and key tasks of Enercon GmbH. 2015 he started as saled director at Ilsenburger Grobblech GmbH.