Case Study - Recovering Steel for Reuse at the Former Honda Factory

Project Summary

This project involves the demolition and recovery of steel from several warehouses at Panattoni Park, one of the largest demolition sites in the UK, covering over 370 acres. The overall redevelopment, valued at £700 million, will see the former Honda UK factory in Swindon transformed by Panattoni Group into industrial logistics space.

Project Information

Project name

Former Honda Factory

Location

Swindon

Project type 

Industrial

Amount of steel recovered for reuse

Estimated to be 3,000 tonnes (10% of 30,000 tonnes total)

Economic uplif of sending steel for reuse vs recycling

Estimated between £40 and £80 per tonne compared to scrap value

Other materials recovered

30,000 tonnes of various metals, 380,000 tonnes of concrete and brick, 500,000 tonnes of aggregates, and 120,000 tonnes of asphalt were sent for recycling

Client

Panattoni Group: Supported steel reuse as part of their sustainability strategy to achieve carbon reduction goals.

Demolition contractor

AR Demolition: Tasked with recovering steel for reuse.

Steel Stockholder

Cleveland Steel and Tubes: Purchased the reclaimed steel for resale and reuse in new projects

Key Drivers for Recovering Steel for Reuse

  • Economic Benefits for the Demolition Contractor: Recovering steel for reuse provided financial benefits for AR Demolition, as the value of the recovered steel exceeded that of scrap, leading to increased returns.
  • Client’s Sustainability Goals: Panattoni Group encouraged steel recovery and reuse to align with their net zero and carbon reduction targets. Carbon calculations and reporting will quantify the environmental benefits of these efforts.

Changes to the Demolition Programme and Impact on Steel Recovery

The commitment to steel recovery was made early in the tender stage, aligning with the client’s sustainability and net zero goals. However, due to planning constraints, the demolition timeline was shortened from two years to just 10 months. Despite this, stakeholders remained committed to steel recovery, seeking an efficient method that allowed for the recovery of steels for reuse while maintaining overall project efficiency.

Demolition and Recovery Approach

Steel sections were cut at the ends using shears and then carefully dropped in a controlled manner. Suitable steel members were recovered, while dented areas were gas-cut around the sections. The additional labour costs for removing ends and cutting damaged areas were estimated at £2,000 per week. However, the shearing approach remained largely similar to standard demolition practices, requiring minimal extra effort.

The recovered steel sections were moved on-site using rotating grab attachments, which gripped the steel by the web rather than the flanges to minimise damage. The use of rottaing grab improved efficiency in loading and transporting the steel on-site and onto lorries, while also preventing further damage to steel when handling on site.

Steel Sections

The steel used in the warehouses was from the 1990s. Some sections were much larger than standard sizes, as Honda had designed all their warehouses globally to be earthquake-proof, requiring heavier and larger steel sections.

Challenges

  • Demolition Programme Changes: The shortened timeline affected the demolition approach and steel recovery rate. Initially, a deconstruction strategy was considered but had to be scaled down due to time constraints.
  • Demand for Recovered Steel: Some steel sections were non-standard sizes, leading to limited market demand. These sections were eventually recycled, while standard-sized sections were sold to the steel stockholder for future reuse.
  • Transport and Logistics: Transporting longer steel sections presented logistical challenges, as they were less stackable, increasing loading times. It was estimated that loading 25 tonnes of steel onto a lorry took around 20 minutes.
  • Estimating Tonnages on Site: Accurately estimating the tonnage of steel on-site before sending it to stockholders was challenging. Steel stockholders typically perform an initial defabrication process, and some losses can occur if the material is deemed unsuitable for reuse and requires much processing.

Lessons Learnt

  • Programme Timing: This project highlighted the importance of having sufficient time in the demolition programme, as it directly affects the approach and efficiency of steel recovery.
  • Compliance and Quality Checks: Unlike typical demolition practices, the demolition contractor had to implement on-site compliance and quality checks for recovered steel before sending it to stockholders. The project provided valuable insights into the ideal types of steel sections suitable for reuse, as well as other aspects, which will be beneficial for the demolition contractor in future projects involving steel reuse.
  • Carbon Calculations and Reporting: Carbon footprint calculations and reporting will be conducted to quantify the environmental benefits of the steel reuse initiative.

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