Engineering and Constructor Development and Infrastructure, ThyssenKrupp CSA, Santa Cruz, Rio de Janeiro, Brazil:

T. Schumacher, Chief Executive Officer, torsten.schumacher@thyssenkrupp.com

The following article describes some of the challenges faced by ThyssenKrupp CSA during the construction of the steel mill complex in Brazil, based on the company slab distribution strategy. The article focuses on the personnel recruitment for the project and operational phase, environmental issues, exploitation of the construction site on- and off-shore, piling, foundation and steel construction works as well as the construction of infrastructure and auxiliary buildings. Brazilian market situation in the conditions of passed global financial crisis has been analyzed. A gigantic construction enterprise which finally resulted in a modern steel mill complex. Such a large-scale project demands alot of the people working on it. The logistical challenges can only be overcome by well-organized teams acting with trust, transparency and an open communication. To establish that in a bicultural environment was a major achievement. With the commissioning of the blast furnace and the steel plant, the main project phase ended and the ramp-up of the integrated steel mill began. Four years after the foundations tone was laid, the first slab was produced on 7 September 2010. On 29 September 2010 the first 40 000 t shipment of steel slabs began its journey towards Europe and three weeks later, on 21 October 2010, the second cargo of 70 000 t embarked on its journey to our North American rolling mill in Alabama. Annually, 2 million t of coke, 5.7 million t of sinter, 5.3 milliont of hot metal and 5 million t of slabs, plus 490 MW of power are the new targets to be reached as quickly and safely as possible.

1. Glockner, A.; Igelbüscher, A.; Moormann, C.; Jud, H.; Kunzmann, M.: Bau eines neuen Stahlwerks auf weichen Sedimentböden nahe Rio de Janeiro — Geotechnische Herausforderungen in ungewöhnlichen Dimensionen, Proc. 30. Baugrundtagung 2008, Dortmund, Germany, 24–27 Sept 2008, Deutsche Gesellschaft für Geotechnik, Essen, S. 199/206.

2. http://de.fifa.com/classicfootball/stadiums

3. Average meteorological data (1961—1990) from the Ecologia Agricola weather station: Latitude 22°48’S, Longitude 43° 41’W — 14 km from the construction site.

4. http://wasser-wissen.de