Implemented for the first time in Turkey, the project was carried out over a total area of 192,000 square meters covering both directions along a 6 kilometer stretch of the TEM Highway between the Gebze and Dilovası junctions.
As Tosyalı moves towards fully sustainability focused green steel production at nearly 50 facilities across 3 continents, it is transforming every by product generated during production into tangible business outcomes through R&D efforts aimed at reintegrating them into the economy. In line with this vision, Tosyalı has taken another step toward the circular economy by developing slag by-product of iron and steel production into a material for asphalt.
The project was carried out by Tosyalı Harsco, one of Tosyalı’s recycling specialized companies. The slag was processed using SteelPhalt technology, developed by Harsco’s UK based subsidiary, and transformed into artificial stone mastic asphalt by Simgemat. As a result, the need for natural stone in road construction was significantly reduced, helping to preserve natural resources.
As part of the project, a total of 22,500 tons of steel slag was used, with slag based materials making up 90% of the stone content in the asphalt mixture. Thanks to this innovative approach, the asphalt became more durable and cost effective, while the carbon footprint of road construction was reduced by up to 70%.
Fuat Tosyalı’s Statement
Fuat Tosyalı, Chairman of Tosyalı Holding’s Board of Directors, explained the project’s circular economy vision:“As one of the world’s leading green steel producers, we are committed to revaluing everything within our ecosystem through the circular economy. In this regard, we invest in low-carbon technologies and implement circular economy focused process management in our facilities. With this approach, we do not waste anything whether waste, air, water, energy, or waste heat and through technology and innovation, we turn even the smallest dust particle into a benefit for people, society, and nature.We recycle steel scrap, ensure the continuity of the life cycle by sending process-related dust to licensed companies, and carry out waste separation at the source. We also send harmless waste generated on site to licensed firms for transformation.Additionally, we develop slag one of the by products of iron and steel production into an advanced material usable in asphalt manufacturing, thus contributing to the economy.I hope that this material, used for the first time in road construction in Türkiye, serves as an inspiration to everyone in terms of circular economy. If we want to increase our competitiveness in production as a country, we should not only focus on improving efficiency and quality but also evaluate every kind of material with a circular production approach.”
Technical Specifications of the New Asphalt
The asphalt developed through the collaboration of Tosyalı Harsco and Simgemat stands out as a material with low water permeability, enhanced vehicle safety, and earthquake resistance. Thanks to the machines used in the project and the Bloodhound software, the metallic iron content in the slag is monitored online and minimized. The recycled slag, with cement slurry penetrating its pores and its high abrasion resistance, is used as a far superior material compared to natural aggregates.
The new generation KGM highway pavement was applied over a 6 km stretch between the Gebze and Dilovası junctions on the TEM Highway, resulting in both an extended asphalt lifespan and reduced costs. The project’s carbon footprint was decreased by 70%.
The Role of Tosyalı Harsco in Circular Production
Tosyalı Harsco, established as a partnership between Tosyalı Holding and the U.S.based company Harsco, provides innovative services to iron and steel, aluminum, copper nickel, ferrochrome, and cement plants in Türkiye. Within this scope, slag waste is utilized in various fields such as asphalt, road construction, cement additives, fertilizer production, and railway ballast.
The projects are planned to be implemented in the İskenderun, Osmaniye, and İzmir/Aliağa regions in the upcoming period, thereby expanding asphalt projects based on circular production.
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