Welcome to our project showcase - Hinuera Sheds: Recycling fabricated steel Beams for Hinuera Storage Sheds 2023!
This project showcases our evolution into the sustainability era and highlights how innovative solutions to recycling material can position steel as a key player in the circular economy. Hinuera Sheds is a prime example of how repurposed steel can reduce carbon footprints, promote sustainability, and position steel as a ‘superhero’ material of choice in construction.
Key Project Statistics:
- Material Used: 380 tons of structural steel, including nearly 200 tons of recycled fabricated beams.
- Purlins: 11.5 km in total
Project Overview:
Client Background: Working closely with Sabre Construction, the client acquired fabricated beams from a demolished building at the port with the aim of repurposing them for storage sheds. Facing time constraints, plans immediately transpired for designing sustainable storage sheds aptly named ‘Hinuera Sheds’ and the engineering and design team kicked into action.
Project Phases:
- Material Acquisition and Transportation:
- Procured fabricated beams from a demolished port building transported from Hinuera to Steelworks for fabrication and painting then back to Hinuera every few days during the course of the project.
- Maintaining a timely flow of material was critical due to time constraints, and essential in minimising transport requirements, costs and environmental impact to deliver the project successfully.
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- On-Site Design and Modification:
- Engineers finalised the shed design based on available fabricated beams on site at Hinuera.
- Steelworks detailer Mike Aldridge worked with the Engineers and client to create construction drawings for fabrication and installation.
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- Fabrication:
- Fabrication included UT ultrasonic examination of original (old) welds, removing & gauging out old non-compliant welds; rewelding; and removing old connections. All areas affected were repaired and reinspected with a final UT inspection to reveal that welds comply with the NZ Standards.
- Adjustments involved shortening and modifying fabricated beams to fit the new design requirements.
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- Painting and Finishing:
- Fabricated steel components underwent a blasting and painting process for durability then transported back to Hinuera for installation.
- Final Installation:
- Our site team, led by Nic Taituma, assembled the 380ton structure over a 3-month period, which included 11.5km of purlins.
- The installation was sequenced bay by bay to erect the 5-ton beams, which included operating two cranes for tandem lifts.
Challenges Overcome:
- Time constraints and on-site design based on availability of usable recycled material.
- Weld testing, removal, and replacement of non-compliant welds for structural integrity.
- Transportation of beams from Hinuera to Steelworks over the Kaimais in sequence.
- Size of fabricated beams and safely fabricating in the workshop, loading and transporting and installing on them on site.
Sustainability Impact:
- By recycling Fabricated beams, the project contributes to environmental sustainability saving costs in recycling, using raw materials, energy, and decarbonisation.
- Major carbon savings in the building due to reusing materials from a demolished building.
- Endorses the lifecycle of steel as a product of choice in construction.
- Demonstrates the viability and environmental benefits of repurposing structural steel into new builds.
Conclusion: In conclusion, this project shows our commitment to innovative and sustainable construction practices. The journey from salvaging steel beams to their transformation showcases our expertise in working with clients wanting to recycle material for their unique project. We are proud to have contributed to environmental sustainability, cost savings and the efficient use of existing resources.
Steelworks NZ Ltd is committed to a sustainable vision where we provide steel products as a critical enabler in New Zealand’s journey to a low emission economy. Part of this journey includes achieving our circular economy programme, which involves reusing or recycling steel for your upcoming project with us.
Working closely with Sabre Construction and the client, SH29 Limited, reusing and repurposing fabricated beams is a major component of the structural integrity of Hinuera Sheds...and the result is AWESOME! Economical, efficient, aesthetic and playing a huge part in reducing its carbon footprint, this building is a showcase for how effective the use of steel is in sustainability of the construction industry.
Click here to see video footage of the building in construction: