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ThyssenKrupp Steel Europe is growing and investing globally. The key project for the capacity development is the integrated steel plant in Brazil, ThyssenKrupp Companhia Siderurgica do Atlantico (TK CSA). This paper is reporting on a selection of challenges that ThyssenKrupp CSA faced during its formation and during the erection of an integrated Steel Mill complex in Brazil. The main focus is on simultaneous personnel recruitment for the operation phase and project phase, environmental aspects as well as construction related challenges and the frame conditions given by the market influenced by the financial world crisis. With the commissioning of the Blast Furnace in June and the Steel Plant in September 2010 the main project phase ended and the ramp up of the plant started. Four years after the foundation stone the first slab has been produced at the 7th of September 2010. At the 29th of September 2010 the first steel slab cargo of 40.000 tons started its shipment towards Europe and three weeks later, 21st of October 2010, the second cargo of 70.000 tons gathered its way to the North American Rolling Mill in Alabama. 2.000.000 tons of coke, 5.700.000 tons of sinter, 5.300.000 tons of hot metal and 5.000.000 tons of slabs plus 490MW power production are the new challenges to be reached as soon and safe as possible.