Research and development

Steel re-use has the potential of saving up to 96% of environmental impacts compared to new steel, so it significantly improves construction sustainability.

One of the hypothesised barriers to steel re-use is a concern related to steel properties. To re-use structural steel elements, it must be verified that they have not been subjected to yield stress. To determine this, lab testing is required or conservative re-use assumptions must be made.

Lab testing is intrusive and costly, so it likely to be amongst the most important barriers to structural element re-use.

This research project will investigate the feasibility of non-intrusive, cost-effective approaches to estimate mechanical properties of structural steel to facilitate re-use. This will include:

• development of the required finite element models;
• sensitivity analysis of the numerical simulation results; and
• study of the role of non-intrusive test data, finite element analysis and mathematical frameworks in the estimation of steel mechanical properties.

While efforts are being made by steel mills in the development of “green” steel, we are re-thinking how we use structures. Our steel carbon calculator is assisting designers to consider the embodied carbon during the design of new steel structures.

The purpose of this research is to build upon these efforts and will investigate the current state, latest developments, and potential of:

• wastage management and its reduction for both structural, and non-structural, components;
• the drivers and challenges with reusing and repurposing steel. This includes incorporating our proposal to develop a material passport for structural steel re-use; and reviewing and incorporating where possible – current international guidance such as SCI P427 Structural Steel Reuse;
• re-thinking the standard 50 or 100 years design life to explore questions such as: how long is long enough? How do we balance climate resilience and durability? What do we need to know to design durable long-life structures in a changing climate? What does a 100+ year high rise building or 200+ year bridge look like? And;
• challenging how we design and build steel structures. For example, could we develop more material-efficient steel members and components? And, what constraints are there in our design of modular structures whose use and purpose are easily changed?

A literature review of the current state of the art will be undertaken, including reviewing recent publications issued by the Steel Sustainability Council, that will form the basis for this project.

The project deliverable will be the development and dissemination of guidelines to unlock the sustainability benefits of steel, as well as recommendations for future research as required.

Structural steel members have the potential to be re-used across multiple construction projects over time. In certain circumstances (given the availability of required data), a quick initial review can be conducted to identify the suitability of re-use before demolition.

This research will aim to identify roadblocks and barriers to the re-use of structural steel.

This project will first investigate the role of a data platform in facilitating steel re-use, and development of a material passport decision-making framework.

To meet these aims, the research encompasses four main steps:

1. investigating the status of re-use, recycling and landfill rates of structural steel in New Zealand,
2. identifying all barriers to re-use steel in New Zealand,
3. identifying relevant data that is required to decrease barriers, encourage, or reuse throughout the supply chain, and;
4. developing a material passport framework using the relevant data.

Evaluation in existing composite bridges

This research looks at us evaluating the maximum load capacity of composite bridges through bridge surveys focused on identifying the most widely used shear connector types and their geometries.  This work will allow structural reliability analyses on design provisions to open up existing highway networks to heavier and higher productivity motor vehicles within required safety margins.

First joint harmonised standard between Australia and New Zealand: AS/NZS 5100.6

This work looks to align our standards with international best practice and work opportunities, while significantly improving composite and fatigue design as we seek to drive ingenuity in steel construction.

Welding trials using NDT, mechanical testing and finite element analysis

This research is focused on optimising weld details for seismic connections to help our members confidently select the best performing and most cost-effective weld solutions in critical seismic connections.

Meeting New Zealand structural steel design and fabrication standards

Developing a comprehensive data base to develop statistical models linking inspection with reliability levels for members.  This involves assessment of DR AS/NZS 5131 Structural Steelwork / Fabrication and Erection standard.  Which introduces the concept of ‘construction category’ to link the importance level of a structure and provide minimum levels of workmanship to ensure design assumptions remain valid.  But is yet to be linked to reliability classes.

Development of Standards AS/NZS 5131 and AS/NZS 5100.6

This work will be critical to our SFC Scheme – allowing us to keep our members up to date with technological advances and quality requirements in the market.  The delivery of these standards will provide a competitive edge against increasing imports, the globalisation of construction product sourcing and changes in procurement practices that raise the risk of non-compliance.