structural steel reuse Jonathan Cullen [email protected] Michal Drewniok [email protected] Steel and the circular economy The Building Centre, London 30 November 2016 Contents the case for 1 structural steel reuse the barriers to 2 structural steel reuse 4 conclusions the costs of structural 3 steel reuse the case for structural steel reuse SUSTAINABLE MATERIALS WITH BOTH EYES OPEN JONATHAN M CULLEN JULIAN ALLWOOD UNIVERSITY OF CAMBRIDGE www.withbotheyesopen.com global flows of steel steel Reduction Steelmaking Casting Rolling / Forming Fabrication End-use products Global demand for steel goods Oxygen Continuous Hot Cold Blast furnace blown furnace casting (slab) strip mill rolling mill = 1088 million tonnes Cold rolled coil 108 Galv. plant Cars 88 CRC coated 12 Vehicles Slab 640 540 139 Trucks 20 Iron ore Pig iron 928 Liquid steel 892 CRC galv. 58 Ships/other 31 1002 Tin mill Tin plated 8 Electrical 8 Mechanical 143 9 HRC galv. Industrial Primary Plate mill Hot rolled coil 130 equipment Ingot mill 176 125 Electrical 33 Direct 89 HR narrow strip 33 reduction Open hearth DRI 66 furnace Plate 87 Continuous Rod and Forming casting (billet) bar mill Scrap Welded tube 59 preparation Extrusion Electric Seamless tube 26 furnace Buildings 358 End-of-life Billet 484 462 scrap 290 Construction 596 Scrap steel 570 Liquid steel 407 Reinforcing bar 165 Infrastructure 238 Wire rod 133 Continuous casting (bloom) Section mill Hot rolled bar 84 Bloom 99 94 Rail section 10 Light section 42 Food packaging 8 Steel product casting Heavy section 38 Metal Appliances 31 goods 177 Cast steel 10 Other 138 Iron foundry casting 68 Cast iron 68 End-of-life Global steel flows for cast iron scrap 2008 in million tonnes Cullen, Alwood, Bambach Environ Sci Technol Forming scrap 99 2012 46(24):13048-55. Fabrication scrap 186 … and energy inputs steel the economic margin availability of used structural steel Structural steel scrap arising from demolitions - prediction 1400 1200 1000 800 600 + 5 years Steel (kt) 400 200 - 5 years 0 1945 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 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 successful reuse of structural steel 740 Rue Bel-Air Montreal, Quebec BedZED London successful reuse of structural steel Carrwood Park, Doncaster Blue Steel Building, Leeds successful reuse of structural steel Kings Science Academy, Bradford University Technical College, Leeds successful reuse of structural steel 9 Cambridge Ave (Segro), Slough Honda Warehouse, Swindon why is reuse not happening at scale? Year Author Reuse Recycle Landfill Note Steel Construction 2001 12% 93% 5% Heavy sections Institute 2006 Gorgolewski et al. 10% 90% nil Sections, Canada 2012 EUROFER 7% 96% 2% Heavy sections Reuse rates in the UK for structural steel are low and are falling hypothesis : current practice Buyer Small-scale local reuse Seller wants reused steel Reuse happens when the buyer and seller wants to sell a for new building can easily communicate, or are the same entity property or building Requests reused steel for project Designer (engineer /architect) designs building Designs for reused sections Fabricator frames incorporate reused steel sections hypothesis : where we would like to be Buyer Small-scale local reuse Seller wants reused steel Reuse happens when the buyer and seller wants to sell a for new building can easily communicate, or are the same entity property or building Requests reused Sees value in extracting old steel steel for project from building Demolition Designer contractor (engineer /architect) deconstructs designs building building to recover steel Generic design for Delivers reused new or reused steel steel to stockist Fabricator Full-scale reuse market Stockist frames incorporate Steel stockist holds certified reused steel holds new and reused steel sections Clients / designers not part of decision-making cretified reused steel hypothesis : a step along the way Client Small-scale local reuse Developer wants reused steel Reuse happens when the buyer and seller wants to sell a for new building can easily communicate, or are the same entity property or building Requests reused Sees value in extracting old steel steel for project from building Demolition Designer Supply—demand website contractor (engineer /architect) Linking demand and supply for reuse steel deconstructs designs building Regular updates of quantities and timing building to recover steel Generic design for Delivers reused new or reused steel steel to stockist Fabricator Full-scale reuse market Stockist frames incorporate Steel stockist holds certified reused steel holds new and reused steel sections Clients / designers not part of decision-making cretified reused steel the barriers to structural steel reuse Building lifecycle and supply chain actors Main Demolition Client Architect contractor contractor Concept Design Construction Use Demolition Structural Fabrication engineer Fabricator Recycling route Structural steel section Reuse route Links between the actors is critcal Stockist Mill barriers identified • Profit opportunity/cost additional cost and risk of reusing steel • Programme disruptions causing delays to the project timeline • Quality/certification/traceability certifying the properties of structural steel • Availability/Dimensions difficulties 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 Barriers to structural reluctance to change current practices steel reuse identified in the literature • Design for deconstruction challenges in recovering sections from buildings experience of steel reuse Experience of steel reuse No experience of steel reuse Experience of steel reuse 38 interviewees from 30 semi-structured interviews 24 respondents to on-line surveys interview and survey results Design for deconstruction Old / new perception Uncommon practice Trust/lac of communication Programme Profit opportunity / cost Quality / certification / traceability Availability / dimensions Percentage of actors who mentioned a barrier (%) Similar scores for the survey and interviews gives confidence in the results salience score Salience is the state or condition of being prominent ng – number of mentions of barrier in group Salience x Ng – number of respondents in group score N – total number of respondents nb – number of mentions of barrier the importance of the inverse of the the barrier for the importance of the barrier actor group across all interviewees A higher salience score indicates that a barrier is particularly important to that actor Salience of barriers fromSalience survey of barriers from survey 3.0 3.0 Salience of barriers from survey 3.0 2.5 2.5 Salience of barriers from survey 2.5 2.0 3.0 2.0 Salience of barriers from survey 2.0 1.5 3.0 2.5 1.5 1.5Saliencescore 1.0 2.5 2.0Saliencescore 1.0 Saliencescore 1.0 0.5 1.5 2.0 0.5 0.5 0.0 Saliencescore 1.0 1.5 0.0 salienceSaliencescore 0.0 : barrier ranking,Salience by of actorbarriers from interviews 0.5 1.0 3.0 Salience of barriers from interviews Salience of barriers from interviews 0.0 0.5 3.0 3.0 2.5 3.0 0.0 Salience of barriers from interviews 2.5 2.5 2.0 3.0 2.5 Salience of barriers from interviews 2.0 1.5 3.02.0 2.5 2.0 1.5 1.0 2.0 2.51.5 1.5 Saliencescore 1.0 0.5 1.5 2.0 1.01.0 Saliencescore 0.5 Salience score Salience 0.0 1.0 1.5 Saliencescore 0.5 0.0 Saliencescore 3.00.5 0.5 1.0 Stockists Engineers Saliencescore Demolition 0.0 Fabricators 0.0 0.52.50.0 Contractors Stockists Engineers Engineers Stockists Demolition Fabricators Fabricators Demolition Contractors 0.0 MainContractors ArcHitects & Clients & ArcHitects 2.0 Structural Contractors Architects & Clients Main Contractors Structural MainContractors Stockists Stockists ArcHitects & Clients & ArcHitects Engineers Structural Engineers Demolition Fabricators Demolition Contractors Profit opportunity/cost Programme Fabricators Uncommon practice 1.5 Profit opportunity/cost ProgrammeContractors Quality/certification/traceability Availability/DimensionsStockists Design for deconstruction Engineers Demolition Fabricators MainContractors Old/New perception ProfitTrust/LackQuality/certification/traceability opportunity/cost of communicationContractors ProgrammeAvailability/Dimensions MainContractors ArcHitects & Clients & ArcHitects Structural 1.0 Clients & ArcHitects Structural MainContractors Quality/certification/traceabilityOld/New perception Availability/DimensionsTrust/Lack of communication ArcHitects & Clients & ArcHitects Structural Profit0.5 opportunity/cost Old/NewProgrammeUncommon perception practice Trust/LackDesign of for communication deconstruction Profit opportunity/cost Programme Quality/certification/traceabilityProfit opportunity/cost UncommonAvailability/DimensionsProgramme practice Design for deconstruction 0.0 Old/NewQuality/certification/traceability perception Trust/Lack of communicationAvailability/Dimensions Quality/certification/traceability Availability/Dimensions Stockists Engineers Fabricators Demolition UncommonOld/New practice perception Design for deconstructionTrust/Lack of communication Old/New perception MainTrust/Lack Contractors of communication Contractors Architects & ClientsStructural UncommonUncommon practice practice