When Colemans were engaged by one of the world’s biggest technology companies to demolish a 90,000m2 portal frame building in South Wales, we saw it as the perfect opportunity to showcase our circular economy commitment and demonstrate the viability of our pioneering Emerald Steel approach – repurposing and reusing steel from demolition works into new construction projects.
We were appointed to manage site security, above ground demolition, below ground structure removal and a comprehensive earthworks and civil engineering package of works. More than that, we wanted to showcase to our client and the wider industry in the UK and overseas that steel repurposing and reuse can be radically improved, streamlined and developed to help contribute significantly to global carbon reduction targets.
The building was made of 4,500 tonnes of primary structural steel, of which 600 tonnes (13%) were repurposed and reused in the design of the new build structure on site.
In total, 89% of the steel removed from the original structure was deemed suitable for reuse and put back into the circular economy thanks to our pioneering approach, saving 6,774 tonnes of carbon compared with new steel.
The project was only made possible thanks to a unique proof of concept project from the Colemans team.
The cautious client was initially hesitant to proceed based on risk modelling, but we alleviated those concerns and showed the viability of our approach by applying the same techniques to another demolition project in London.
Colemans scanned and scheduled steel before it was dismantled to ensure best suitability for reuse. Once removed safely and carefully, working with key supply chain partners, we tested, designed, prepared and fabricated the steelwork before galvanising. During these key work stages, evidence was collated, learning events captured, documented, and shared.
The repurposed steel now stands erected proudly in Ireland as part of Colemans’ development of a wellbeing retreat, Skelligs Retreat, and put back into the London project – repurposed to demonstrate we could develop our procedures and follow accordingly.
With documented evidence of this success our client had the confidence to proceed with what we believe is the world’s largest steel repurposing initiative based on scale and complexity.
Applying learnings from previous steel reuse projects, we digitally mapped the South Wales structure using our latest scanning technology, replacement engineering software and suitability analysis. With these insights, we established that 4000 tonnes (89%) of the steel was suitable for repurposing and reuse, of which 600 tonnes would be required for the new structure on site, a data centre.
Colemans specified several cranes, specialist deconstruction equipment and longstanding key partners, supported by our own engineers to progress internal deconstruction in a way that allowed 89% of steel work to be reused as ‘Emerald’ steel, which is our patent pending rebranding of Green Steel.
Applying a phased approach to ensure client confidence at each individual step, we progressed the project through our proven method of testing, preparing, fabricating and galvanising steel once it had been carefully removed, ensuring it is suitable for reuse.
All members of our team had to be trained in new techniques, which represent a step up above conventional deconstruction for demolition purposes.
For example, it was critical that the materials were not damaged in the process and that high quality materials passport procedures were applied. Due to the lack of British standards relating to steel reuse in the UK, Colemans continued to develop and finalise our own quality assured systems and procedures that capture all key stages of the steel process, aligned with key recognised trusted information sources such as the Steel Construction Institute (SCI), of which we are members.
For every one tonne of steel reused in this way, it saves 1.69 tonnes of carbon when compared with using new steel members.
The project was made more complex due to the onerous planning conditions, which ensured an incredibly tight timescale to complete demolition due to a fixed start date.
The only way to achieve this timescale would have been through traditional demolition shearing methods, which would not have enabled us to demonstrate our commitment to steel reuse and the circular economy. Instead, we engaged closely with the local authority and showcased the environmental benefits of our proposed approach, before agreeing on an alternative schedule. .
This allowed us to design a complex façade retention system that allowed the roof, all internal steels and majority of slab and below ground obstructions to be deconstructed for reuse, whilst satisfying the planning team.
Overall, this project has positioned Colemans as a world leader in green, sustainable, engineered deconstruction and demolition contracting.
