structural steel reuse - SCI - The Steel Construction ... · PDF filestructural steel reuse 4 conclusions. ... Steel (kt) Structural steel scrap arising from demolitions ... Generic

structural steel reuse

Steel and the circular economyThe Building Centre, London

30 November 2016

Jonathan Cullen [email protected] Drewniok [email protected]

the case for structural steel reuse1

2

3

Contents

the costs of structural steel reuse

the barriers to structural steel reuse

4 conclusions

the case for structural steel reuse

SUSTAINABLE MATERIALS WITH BOTH EYES OPEN

JONATHAN M CULLEN JULIAN ALLWOOD

UNIVERSITY OF CAMBRIDGE

www.withbotheyesopen.com

Blast furnace

Pig iron 928

Steelmaking Casting Rolling / Forming Fabrication End-use productsReduction

Scrap steel 570

Forming scrap 99

Fabrication scrap 186

End-of-life cast iron scrap

Iron ore 1002

DRI 66

Direct reduction

Oxygen blown furnace

Liquid steel 892

Liquid steel 407

Continuouscasting (slab)

Continuous casting (billet)

Continuous casting (bloom)

Ingot

Slab 640

Billet 484

89

68

Bloom 99

Primary mill

Hot strip mill

Cold rolling mill

540

108

12 58

8 8

9

130

33

87

59

26

165

133

84

10 42

38

10

68

125

462

94

Galv. plant

Tin mill

Forming

Extrusion

Cold rolled coil

End-of-lifescrap 290

Electrical

Infrastructure 238

Buildings 358

Electrical 33

Mechanical 143

Cars 88

Trucks 20

Ships/other 31

Other 138

Appliances 31

Food packaging 8

Construction596

Industrial equipment

176

Vehicles139

Metal goods177

Hot rolled coil

CRC coated

CRC galv.

HRC galv.

Reinforcing bar

Wire rod

Hot rolled bar

Seamless tube

Heavy sectionLight sectionRail section

Cast steel

Cast iron

Welded tube

HR narrow strip

Plate

Tin plated

Plate mill

Rod and bar mill

Section mill

Steel product casting

Iron foundry casting

Electric furnace

Scrappreparation

Open hearth furnace

Cullen, Alwood, BambachEnviron Sci Technol

2012 46(24):13048-55.

Global steel flows for 2008 in million tonnes

Global demand for steel goods= 1088 million tonnes

steelglobal flows of steel

steel… and energy inputs

the economic margin

availability of used structural steel

0

200

400

600

800

1000

1200

1400

1945 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020

Stee

l (kt

)

Structural steel scrap arising from demolitions - prediction

Consumption of structural steel (sections, fabricated sections, hollow sections)

Prediction of structural steel scrap arising from demolition (INPUT as sections, hollow sections, plates)

Steel sections sent for recycling or reuse as 40% of metals sent for recycling of reuse - NFDC data - kt

+ 5 years

- 5 years

successful reuse of structural steel

740 Rue Bel-AirMontreal, Quebec

BedZEDLondon


Carrwood Park, Doncaster

Blue Steel Building, Leeds


Kings Science Academy, Bradford

University Technical College, Leeds


9 Cambridge Ave (Segro), Slough

Honda Warehouse, Swindon

why is reuse not happening at scale?

Reuse rates in the UK for structural steel are low and are falling

Year Author Reuse Recycle Landfill Note

2001 Steel Construction Institute 12% 93% 5% Heavy sections

2006 Gorgolewski et al. 10% 90% nil Sections, Canada

2012 EUROFER 7% 96% 2% Heavy sections

Small-scale local reuseReuse happens when the buyer and seller

can easily communicate, or are the same entity

Buyerwants reused steel

for new building

Sellerwants to sell a

property or building

Designs for reused sections

Fabricatorframes incorporate

reused steel sections

Designer(engineer /architect)

designs building

hypothesis : current practice

Requests reused steel for project

Full-scale reuse marketSteel stockist holds certified reused steel

Clients / designers not part of decision-making

Buyerwants reused steel

for new building

Sellerwants to sell a





designs building


Stockistholds new and

cretified reused steel

Demolition contractordeconstructs

building to recover steel

Sees value in extracting old steel

from building

Delivers reused steel to stockist

hypothesis : where we would like to be

Generic design for new or reused steel





Full-scale reuse marketSteel stockist holds certified reused steel

Clients / designers not part of decision-making

Supply—demand websiteLinking demand and supply for reuse steel Regular updates of quantities and timing

Clientwants reused steel

for new building

Developerwants to sell a


Generic design for new or reused steel




designs building

Stockistholds new and

cretified reused steel

Demolition contractordeconstructs

building to recover steel

hypothesis : a step along the way


Sees value in extracting old steel

from building

Delivers reused steel to stockist

the barriers to structural steel reuse

Building lifecycle and supply chain actors

MillStockist

Demolition contractor

Main contractor

FabricatorStructural engineer

ArchitectClient

Use DemolitionConstructionDesignConcept

Fabrication

Structural steel section

Recyclingroute

Reuseroute

Links between the actors is critcal

barriers identified

• Profit opportunity/cost additional cost and risk of reusing steel

• Programme disruptions causing delays to the project timeline

• Quality/certification/traceabilitycertifying the properties of structural steel

• Availability/Dimensionsdifficulties sourcing the correct section sizes

• Old/New perception concerns that reused steel is inferior

• Trust/Lack of communication issues of trust and liability

• Uncommon practice reluctance to change current practices

• Design for deconstruction challenges in recovering sections from buildings

Barriers to structural steel reuse identified in the literature

38 interviewees from 30 semi-structured interviews 24 respondents to on-line surveys

Experience of steel reuse

Experienceof steel reuse

No experienceof steel reuse

experience of steel reuse

interview and survey results

Similar scores for the survey and interviews gives confidence in the results

Percentage of actors who mentioned a barrier (%)

Design for deconstruction

Old / new perception

Uncommon practice

Trust/lac of communication

Programme

Profit opportunity / cost

Quality / certification / traceability

Availability / dimensions

salience score

A higher salience score indicates that a barrier is particularly important to that actor

Salience is the state or condition of being prominent

ng – number of mentions of barrier in groupNg – number of respondents in group

N – total number of respondentsnb – number of mentions of barrier

Saliencescore x

the importance of the barrier for the

actor group

the inverse of the importance of the barrier across all interviewees

salience : barrier ranking, by actor

Profit opportunity/cost ProgrammeQuality/certification/traceability Availability/DimensionsOld/New perception Trust/Lack of communication

Uncommon practiceDesign for deconstruction

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Architects & Clients

Structural Engineers

Main Contractors

Stockists

Fabricators

Demolition

Contractors

Profit opportunity/cost ProgrammeQuality/certification/traceability Availability/DimensionsOld/New perception Trust/Lack of communication

Uncommon practiceDesign for deconstruction

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Architects & Clients

Structural Engineers

Main Contractors

Stockists

Fabricators

Demolition

Contractors

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e

Salience of barriers from survey

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

eSalience of barriers from interviews

Profit opportunity/cost Programme

Quality/certification/traceability Availability/Dimensions

Old/New perception Trust/Lack of communication

Uncommon practice Design for deconstruction

Arch

itect

s & C

lient

s

Stru

ctur

alEn

ginee

rs

Mai

n Con

tract

ors

Stoc

kists

Fabr

icato

rs

Dem

oliti

onCo

ntra

ctor

s

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e


0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e

Salience of barriers from interviews





Arch

itect

s & C

lient

s

Stru

ctur

alEn

gine

ers

Mai

n Co

ntra

ctor

s

Stoc

kist

s

Fabr

icat

ors

Dem

oliti

onCo

ntra

ctor

s

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e


0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e






Arch

itect

s & C

lient

s

Stru

ctur

alEn

gine

ers

Mai

n Co

ntra

ctor

s

Stoc

kist

s

Fabr

icat

ors

Dem

oliti

onCo

ntra

ctor

s

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e


0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e






Arch

itect

s & C

lient

s

Stru

ctur

alEn

gine

ers

Mai

n Co

ntra

ctor

s

Stoc

kist

s

Fabr

icat

ors

Dem

oliti

onCo

ntra

ctor

s

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e


0.0

0.5

1.0

1.5

2.0

2.5

3.0

Salie

nce

scor

e






Arch

itect

s & C

lient

s

Stru

ctur

alEn

gine

ers

Mai

n Co

ntra

ctor

s

Stoc

kist

s

Fabr

icat

ors

Dem

oliti

onCo

ntra

ctor

s

Salie

nce

scor

e

salience : actor ranking, by barrier

perception of costs and programme

Perceptions taken from the on-line survey

the costs of structural steel reuse

costs considered

• Transport and handling

• Storage/administration

• Price of steel elements

• Premium for uncommon sections

• Connection design

• Profit margin

• Fabrication operationsrecondition costs, cutting, welding, drilling, etc.

• Materialsbolts, primer

• Erection

• Deconstructionas opposed to demolition

• Testing and certification

• Coating and fire protection

Costs were reconstructed from the information given in interviews

the cost structure for reuse

New SteelTypical Price given

Profitability bounds

Examples of successful reuse case studiesReusing steel elements

Whole structure reuse

Reinforcing old structures

Baseline comparison between reuse and new steel

Fabrication Costs

Cutting, drilling, weldin g, Sandblasting

Connexion design

Erection

AdministrationBolts/PrimerRecondition Costs

Removing plates/weldsStrike down

Reuse SteelBaseline Scenario

Testing

Other CostsTransportation/Handling

Steel cost above scrap priceOperating and profit marginsSteel cost

lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

the cost structure for reuse







Fabrication Costs


Connexion design

Erection




Testing



lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

The cost of reusing steel at scale is at least as expensive as new steel

successful reuse case studies?

three types of successful case study

successful reuse case studies

Three types of successful reuse case studies







Fabrication Costs


Connexion design

Erection




Testing



lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

• minimal sourcing or stocking of steel required (grey)• transport costs are minimised (black); testing or engineering judgement• examples: BedZED, Carwood Park, 740 Rue Bel-Air







Fabrication Costs


Connexion design

Erection




Testing



lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

Recovered sections reused in new design









Fabrication Costs


Connexion design

Erection




Testing



lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

• testing costs are eliminated (grey), but onsite fabrication increases (pink)• transport (black) and stocking (light grey) costs are reduced• examples: Blue Steel, Kings Science, UTC







Fabrication Costs


Connexion design

Erection




Testing



lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

Refurbishment of structure in situ (with strengthening)









Fabrication Costs


Connexion design

Erection




Testing



lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

• minimal sourcing or stocking of steel required (grey)• testing required (blue), fabrication costs are reduced (pink) • examples: Segro, Honda Warehouse, Portal Power







Fabrication Costs


Connexion design

Erection




Testing



lowhigh

£ 0 £ 200 £ 400 £600 £800 £1000 £1200 £1400 £1600 £1800

lowhigh

lowhigh

lowhigh

lowhigh

lowhigh

Paint

Shotblasting

Relocation of entire structure to new site

Conclusions

Motivation

• The economic margin and availability of old steel sections appear to favour reuse

• Several successful case studies of structural steel reuse exist

Conclusions

Findings

• Different barriers to reuse affect different actors along the supply chain

• Barriers are most salient for fabricators, stockists and demolition contractors

• Barrier perception and reality are not always aligned

Conclusions

Findings

• The costs of reusing structural steel at scale are at least as high as specifying new steel

• Successful examples of reuse can be explained by the elimination of one or more of the cost components

• Three types of successful case studies are identified:

- Recovered sections reused in new design

- Refurbishment of structure in situ (with strengthening)

- Relocation of entire structure to new site

Conclusions

thank you

Steel and the circular economyThe Building Centre, London

30 November 2016

Jonathan Cullen [email protected] Drewniok [email protected]

Documents

structural steel reuse - SCI - The Steel Construction ... · PDF filestructural steel reuse 4 conclusions. ... Steel (kt) Structural steel scrap arising from demolitions ... Generic