VALUE BENEFITS

OF STEEL

Speed keeps Derby on track The most valued structural material In-depth Service and Support

VALUE BENEFITS OF STEEL CONTENTS

Contents
3 WELCOME Alan Todd of Corus and Derek Tordoff of the BCSA commend the value case for steel INTRODUCTION No other construction material delivers as much value throughout the supply chain as steel SAFETY Steel construction is inherently safer than alternatives and the sector has a long track record of putting safety first SPEED OF CONSTRUCTION A speedy construction programme helped ensure the historic Derby could be run at Epsom 4

10 QUALITY Selecting steel as a framing material is the best assurance that a quality end product will be delivered 12 VALUE BENEFITS OF STEEL Steel delivers even more value benefits than might be immediately apparent 14 EFFICIENCY Clear, open spaces were crucial for the steel-framed, world-class, Museum of Liverpool 16 SUSTAINABILITY The worlds most multicycled construction material produces sustainably excellent projects 18 INNOVATION Continuous advances are made in technology and design related knowledge 20 OFFSITE Potential construction sites can have no worth at all if they cant be accessed, but offsite produced steel can release the value 22 SERVICE AND SUPPORT All the back-up that could help make designing and constructing in steel as straightforward as possible is provided without charge

Cover Image: The roof of the City Point building in London

WELCOME VALUE BENEFITS OF STEEL

Steel delivers wide ranging value benefits

Welcome to this review, from Corus and the British Constructional Steelwork Association (BCSA), covering the range of value benefits achievable on construction projects using structural steelwork. Corus and the BCSA have worked in partnership for many years to promote the effective use of structural steelwork and support the construction sector in achieving the highest quality in contemporary architecture and engineering. Working together we aim to ensure that the benefits of using steel are shared with those who most need to know. Steel is, by some margin, the most popular framing material for multi-storey buildings in the UK. Some might assume this is entirely due to the long established cost advantages of steel over other framing materials. The articles in this supplement aim to demonstrate the wider benefits of steel and how its use delivers significant further value whilst maintaining the cost advantage. The wider benefits of steel are examined under a number of headings such as safety, speed of construction, quality, efficiency, sustainability, innovation, offsite manufacture and service and support. The articles each tell a different value in steel story supported by real project examples: from the high quality corporate headquarters of Unilever House and the time critical completion of a new grandstand at Epsom racecourse, to the delivery of a project that is a benchmark in sustainability for the Home Office. Very different projects they may be, but they have in common that they were built safely, on time and to budget, and would have been more difficult if not impossible to deliver if steel was not the chosen framing material.

ALAN TODD Construction Services and Development General Manager, Corus

DEREK TORDOFF Director General, BCSA

Published April 2009 on behalf of: Corus Tel: 01724 405060 Fax: 01724 404224 Email: construction@corusgroup.com Web: www.corusconstruction.com and The British Constructional Steelwork Association Ltd (BCSA) Tel: 020 7839 8566 Fax: 020 7976 1634 Email: postroom@SteelConstruction.org Web: www.steelconstruction.org Produced by: Barrett, Byrd Associates Tel: 01892 524455 Designer: Alastair Lloyd Printed by: Pureprint Group

Views expressed in this publication are not necessarily those of Corus, the BCSA or Barrett, Byrd Associates. Although care has been taken to ensure that all information contained herein is accurate with relation to either matters of fact or accepted practice at the time of publication, Corus, the BCSA and Barrett, Byrd Associates assume no responsibility for any errors or misinterpretations of such information or any loss or damage arising from or related to its use. No part of this publication may be reproduced in any form without the permission of the Publishers. All rights reserved 2009

VALUE BENEFITS OF STEEL INTRODUCTION

Shared values of steel

No other construction material offers as much value throughout the supply chain as steel. The major benefits that flow from the decision to use steel are enjoyed throughout a buildings life, and more are delivered even when a buildings useful life ends as virtually all structural steel is multicycled.

teel is multicycled, it is continually re-used or recovered and fed back into the production of new steel, without any loss of properties. The speed of erection achieved with steel itself creates a lot of value, allowing projects to start generating returns faster than otherwise could be the case. The inherent benefits start to be delivered as soon as the decision is made to build in steel. Wide ranging technical support and guidance is provided to clients, designers and contractors by the best developed steel supply chain in the world. The articles in this publication show the categories under which some of the value benefits of steel can be sub-divided; all of these benefits, and more, are delivered whatever the reason that steel

was selected. Safety, speed, economy and quality are probably the most often cited reasons why steel is the preferred choice for the widest range of structures, including the overwhelming bulk of multistorey and industrial buildings, long span and increasingly short span road and rail bridges. But the other benefits, if they were calculated for each project, would significantly boost the already overwhelming case for steel. The steel sector is constantly seeking new and innovative ways of working and has supported the development of a range of cost and time saving and safety enhancing initiatives page 6. One recent development, Structural Fire Engineering, based on Finite Element Analysis, means that fire protection can now be eliminated on

most secondary steelwork on multi-storey commercial buildings. Sometimes speed alone is enough to make steel the only practical choice. For example, building a new grandstand for Epsom Racecourse page 8 had to be done in record time so that The Derby could be held. Slippage in the construction programme was not an option and steel helped make the project, as well as the race, a success. Speed is always crucial to developers and offsite fabricated steelwork proves time and time again that its construction programmes are considerably shorter than with concrete, cutting out much time consuming preliminary works, enabling an earlier start on site, and allowing project revenues to start flowing sooner especially important in todays tougher economic climate.

INTRODUCTION VALUE BENEFITS OF STEEL

Steel has irresistibly robust sustainability strengths, as can be seen at Vulcan House in Sheffield page 16 which achieved a BREEAM Excellent rating without the use of bolt-on features. Steel-framed buildings with the highest BREEAM ratings are routinely being delivered across the public and private sectors. Offsite manufacture delivers a string of benefits, boosting safety, shortening construction times, improving quality and accuracy and minimising waste. Trial erections also mean that site assembly is safer, faster and more speedily erected by teams of highly skilled operatives, as with the Snowdon Visitor Centre page 20. Steel proves its value on a daily basis and is maintaining its commitment to improving the value delivered to the construction industry and its clients through all phases of the business cycle. Sharing the productivity and other benefits of this commitment has earned steel the confidence of a construction industry that has to continuously seek value for its clients.

The competitive gap widens

Comparison of Steel and Concrete Frame and Floor Costs Buildings A and B - Average of All Schemes

Two buildings are analysed for the study:

Building A: a regional office block located in Manchester Building B: a prestige company headquarters located in London

Gazeleys G Park Blue Planet logistics warehouse at Chatterley Valley, Staffordshire, became the first building to achieve the new highest BREEAM Outstanding rating. Steel is the sustainable preference for 97% of the single storey industrial buildings market

The competitive cost gap between steel and concrete building frames is widening. Steel frames are consistently shown to be the fastest and most cost effective choice for frames for commercial multi-storey buildings by the annual series of independently produced Cost Comparison studies. The latest study for the fourth quarter of 2008, shows steel gaining in competitive advantage since 1995. The average building options in 1995 showed a 12.10 per square metre advantage for steel this had grown to 22.22 in 2008. The study showed concrete frame and floor options costing an average of 190.56 per square metre against only 168.34 per square metre for steel. The Department for Business, Enterprise and Regulatory Reform (BERR), formerly the DTi, produces monthly statistics tracking material costs against GDP inflation to provide

a comparison in real terms. These figures show that since 1995, the cost of steel has increased by 43%, the cost of concrete has increased by 25% and reinforcement bar has increased by 87%. Constructed component costs over the same period show that the relative costs of fire protection and metal decking have fallen below or remain very close to 1995 levels, which has helped maintain steels competitive position over concrete. Although the cost of a frame and floor is a relatively small part of the total cost of a development, selecting a steel frame reduces timescales and has a beneficial effect on other major variable cost items such as foundations, cladding and services, leading to significant cost savings for the overall project. For details of the cost study visit www.corusconstruction.com/ coststudy

VALUE BENEFITS OF STEEL SAFETY

Edge protection systems are now standard safety features on steel construction projects

SAFETY VALUE BENEFITS OF STEEL

Safety first approach pays off

Steel construction is inherently safer than alternatives and the sector has a long track record of putting safety first, which is reflected in a commendable safety record.
n 2000 the Health & Safety Executive (HSE) set a target of 10% improvement to accident rates within a ten year period since then the steel construction sector has achieved over a 50% improvement to the reportable injury rate. A positive approach to health and safety brings together expertise within the steel sector to continuously revise practices and procedures, creating an environment that reduces risk, but never at an impracticable cost to production or quality. It is this positive attitude towards health and safety that has produced the sectors improved safety performance, says BCSA Health and Safety Manager Pete Walker. The steel sector continuously drives health and safety, with a number of successful new initiatives launched recently. To help smaller and medium sized steelwork contractors a health and safety service called Safety in Steel Construction has been launched, giving access to direct and regular monitoring and advice. A number of good practice guides have been published; some of these are to fill the gap where the Health and Safety Executives guidance has been withdrawn and others are to help compliance with new or changing legislation. One particular guide, Steel the Safe Solution, was published to increase awareness of good practices to people in a position to influence the activities of the industry. The guide explains that when undertaking structural design, steel construction is the safest choice for the structural frame. Steel is inherently safer than alternative structural solutions as it is pre-engineered in a way that makes

pre-planning of operations easier and more certain, explains Mr Walker. A virtual reality model of the steel frame can be built in three dimensions in the computer, thus facilitating detailed planning of the erection procedure. Steelwork is pre-fabricated offsite, which makes it accurate and less liable to errors that would generate site hazards. The development and introduction of the Safe Site Handover Certificate (SSHC) by the BCSA was supported by the HSEs concerns regarding on-site safety. Many of these concerns arose as a result of the parties involved not being aware of the importance of proper access for trailers, safe areas for turning and unloading, etc. Mr Walker says: The SSHC has improved the communication between all involved and can also be used as a monitoring aid during the programme of work. This reduces the risks arising from poor site conditions and provides a mutual basis for improved productivity, efficient working and reduced delay and, hence, reduced overall total cost. The SSHC helps to establish criteria for safe site conditions as an inherent part of the steelwork tender offer, and as a mutually agreed basis for the commencement of delivery to site and of steelwork erection. Having fewer people working on site itself increases safety. Virtually all steel construction is offsite manufactured, which means most of the work is carried out in safer, factory controlled conditions. There are fewer deliveries of materials and equipment which means fewer potentially hazardous activities. Using steel means shorter building programmes, hence less pressure on workforces to reach completion targets.

VALUE BENEFITS OF STEEL SPEED

New approach wins at Epsom

Construction programmes can sometimes be allowed to slip, but few deadlines are less capable of being shifted than those imposed by major sporting events that is one reason why steel is proving to be so popular a framing solution on delivery of the 2012 London Olympics venues.
ew sporting events are more high profile than the world famous Derby Stakes, or the Epsom Derby, better known to most of us as simply The Derby. It is a Group 1 race, one of the five British classic horse races, steeped in the tradition of racing. The Derby was inaugurated in 1780, although racing on the Epsom site has been recorded as far back as 1661. The Derby Festival is recognised as one of the last of the great British folk festivals. With the weight of all that tradition behind it, some things just cant be changed it is a flat race for threeyear-old thoroughbreds only, it must be held on the first weekend in June, and crucially, it must be held at Epsom Racecourse. Demolishing the old concrete grandstand and replacing it with a modern steel structure would have been easier if the construction team could have taken possession of the course for two years or so. But that would have meant moving the race elsewhere in 2008 but The Derby would not be The Derby if it were held anywhere else. A new approach was needed, taking advantage of the speed and flexibility of steel

construction. Standing spectators were able to see the 2008 race from the 4,000 capacity terrace of the new 80m long grandstand, made possible by careful planning and the selection of a steel frame.

Speed was of the essence

The construction team led by main contractor Willmott Dixon had only a narrow window of opportunity between the 2007 and 2008 Derby Festivals to get the grandstand ready once other preliminary works had been completed, including demolition of the old concrete grandstand, there was only six months to erect steel and get ready for the race. Speed was of the essence, said John Cutlack, Director of structural engineer Capita Bobrowski. The new grandstand has a flexible design to allow for various uses, with internal columns kept to a minimum. Steel trusses to accommodate the spans for a 960m2 open area behind the terracing were brought to site already assembled. It is planned that during exhibitions heavy items like cars will be able to be hung from these two-metre

deep trusses, which explains why the hall has a clear floor to ceiling height of 8m. Above this hall is a first floor reception area with bars and catering facilities that had to be ready for the 2008 Derby. This open plan area required large elements incorporated into the first floor slab, with steelwork contractor Graham Wood Structural erecting a series of 18m long fabricated trusses, each weighing some 14t.

Configuration can be changed

An upper floor housing private facilities and a Super Box able to hold 100 spectators has inbuilt flexibility thanks to the use of steel. The grandstands barrel vaulted roof was partially erected and left for completion after the 2008 race. This structure is formed by long tapering rafters, each weighing six tonnes. Pairs of rafters were bolted together on the ground and lifted into position in 30m sections to form the roof and the stands 15m cantilever. The complete steel frame was erected in plenty of time for The Derby won by a horse appropriately named New Approach.

SPEED VALUE BENEFITS OF STEEL

Left: The Derby wouldnt be The Derby if it was not at Epsom Below: The new grandstand takes shape Bottom: Racegoers were able to use the new grandstand in record time

Project team
Client: Jockey Club Racecourses Architect: Limbrick Structural engineer: Capita Bobrowski Main contractor: Willmott Dixon Steel contractor: Graham Wood Structural Steel tonnage: 825t Project value: 27.5M

Speed benefits of steel

Steel construction is the fastest way of

erecting a quality frame or bridge

Offsite fabrication in factory

conditions means right-first-time, accurately produced sections, so no time is wasted re-doing work Steel allows the earliest possible start on site Fabricated steel is delivered to site only when needed Skilled and trained erection teams ensure speedy erection, making way for other critical path operations Trial erections can be staged to ensure even the most complex operations will go as planned Design changes can be accommodated at any time Steel structures can be easily extended, even during construction Speed is achieved without jeopardising safety steel construction is inherently safer than alternatives The entire construction programme benefits significantly when steel is used Speed means that the pay back period of investments starts earlier

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VALUE BENEFITS OF STEEL QUALITY

Steel sets the quality standard at Unilever House

The steel flying carpets are a major feature of this high quality headquarters building

Overlooking the River Thames and occupying a prominent City of London site along Victoria Embankment, the steel-framed Unilever House was a landmark structure from completion in 1931. A new steel-framed building continues the tradition.

he building houses Unilevers main UK headquarters and in early 2007 a complete redevelopment of this famous 43,000m2 office block was completed. This extensive work, which included retaining the Grade II listed faade, resulted in the high quality, flexible accommodation suited to a modern office occupier. The works programme followed an extensive consultation process between Unilever, the City of London and English Heritage. Proposals were developed which achieved a balance between retaining the faade as well as providing the improved and enlarged internal work areas. The architect, Kohn Pedersen Fox and the structural engineer, Arup, designed a modern eight storey office and an adjacent five storey gatehouse building, with a structural form consisting of a combination of reinforced concrete stability cores, steelwork bracing and approximately 2,000t of structural steelwork and decking. Around 50% of the building was demolished, but as the faade was acting as the structures main source of stability, it was heavily propped during the works programme and a 9m deep adjoining bay was also kept. Sustainability played a role in the decision to use steel for the buildings new innards. The original foundations as well as the original steel tubular piles which were discovered to be in pristine condition after 76 years buried in London clay were all re-used. We had to do some load balancing for the new structure and a concrete frame would have been too heavy for the original foundations, explains Ben Tricklebank, Arup Project Engineer. The building was originally steel-framed and marrying new steel to old turned out to be the easiest option. The new steel frame also includes a new central atrium that has four levels of suspended structures that are known as flying carpets. Designed as break-out and meeting areas for the office workers, these

QUALITY VALUE BENEFITS OF STEEL

11

platforms are supported by a series of spiraling rods hanging from a diagrid roof system.

Offsite fire protection

Each of the four flying carpets is a different shape and they were all pre-fabricated at steelwork contractor William Hares workshops and then transported to site in two pieces before being welded together. Intumescent fire protection was applied offsite, with a site applied topcoat on the visible members. Offsite application greatly reduced the build time as well as ensuring a high quality application with a minimum 12 years to first maintenance. Due to the complexity of the hanger system, the design of the rods necessitated precise calculations to determine the tension in each so that the final positioning of the platforms could be achieved. Close monitoring of their installation was specified and controlled by Arup to ensure that the design criteria was met.

The completed Unilever House is an excellent example of a sustainable project delivery that has made extensive use of steel construction. The job achieved a BREEAM Excellent rating and carbon emissions were reduced by 25%, which is far greater than regulations currently require. From the start the project team was tasked with delivering the most sustainable project possible and the targets set were more than achieved. Detailed lists of all elements of the existing building identified what could be re-used or recycled.

Project team
Client: Unilever Architect: Kohn Pedersen Fox Associates Structural engineer: Arup Main contractor: Bovis Lend Lease Steel contractor: William Hare Steel tonnage: 2,000t

Choosing the quality option

The creation of new, modern buildings brings many challenges that continually push building design. Whether the need is for an open structure, a curved faade, or long open spans, steel offers far more precision than any other material and provides the best guarantee that a high quality building will be achieved. Corus and the BCSA have worked in partnership for many years to promote the effective use of structural steelwork. All steel construction products and systems are produced offsite, so all are manufactured in factory conditions to the same unrivalled high standard. This delivers many quality enhancing benefits to buildings, including:
All structural steel from Corus is Steelwork contractors signing up to

Steel was the only option

The flying carpets are accessed by a series of opaque glass walkways that are formed from box sections and fabricated T-sections that taper into the adjacent floors. These were also pre-fabricated and transported and erected in single lifts. In addition to the usual benefits of steel construction, the concept of pre-assembled units helped reduce the overall programme duration to achieve effective completion in 25 weeks. Steel was the only option for the atrium, says Mr Tricklebank. The design is so complex and intricate that we couldnt have done it in any other material. The project also includes a series of lozenge columns, which were formed by the welding of two continuous side plates between two CHS sections. These members support the highly architectural lift guide arms, which were fabricated from plate and hollow sections. The tolerance requirements for these lift guides required them to be site welded after the erection and plumbing of all support columns.

CE marked, providing assurance that the material is compliant with the Construction Products Directive Steelwork is fully tested and certified before it arrives on site, unlike concrete whose test results are only known days or weeks after it is placed Corus has a long track record of investment in its processes to ensure a high quality product, such as the new state-of-the-art Automated Distribution Centre at Corus Scunthorpe site (see Page 23)

the Steel Construction Certification Scheme (SCCS) commit to a wide range of annual audits on quality, environmental and safety performance. Audits are now being carried out on factory production control and welding quality management in readiness for the start of CE marking of steelwork next year There is an extensive choice of steelwork contractors, ensuring a competitive tender list. All BCSA members are assessed regularly and identified in terms of type and value of steelwork contract they can undertake. To find a steelwork contractor or product supplier visit www.steelconstruction.org The quality assured fabrication process is driven by 3D modelling and numerically controlled fabrication machinery, resulting in high accuracy of offsite manufactured steelwork, and few defects or on site problems compared to other materials Steelwork is erected to tight tolerances and trial erections can be arranged for especially demanding fabrications Erected steelwork never gives rise to problems like creeping or shrinkage

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VALUE BENEFITS OF STEEL

The value option

Steel has many benefits that deliver value to designers, contractors, developers and building users. Most arise automatically once the decision to build in steel is made, and at no extra cost.
SAFETY Steels use reduces the number of people needed on site and therefore

reduces the risk of accidents

Accurate offsite fabrication reduces the amount and handling of waste On site pre-assembly can further reduce the number of lifting

operations and reduce the need to work at height

Minimum use of temporary work is required Steel can be easily modified if changes are needed when erection is underway

SPEED Offsite fabrication means no time wasting quality issues on site Steel construction is fast Speed comes with a safety focus Earliest possible pay back on investments Earliest start on site Speedy erection by skilled teams

QUALITY Steel provides the surest guarantee of a high quality

VAL

finished building Steel is tested and certified before it arrives on site Corus structural steel is CE marked All Steelwork is produced in factory conditions to high tolerances steel production and fabrication processes are fully quality The assured Fabrication is driven by 3D modelling and numerically controlled fabrication machinery BCSA steelwork contractors are regularly checked for their All technical capabilities and financial standing

EFFICIENCY Efficient steel designs take advantage of the high strength

to-weight ratio of steel

Foundations can be lighter and cheaper as a result Superior use of space and longer flexible internal column

free spaces can be achieved

Lean manufacture within an integrated supply chain gives a

more predictable construction programme

Just-in-time deliveries can be sequenced and synchronised

with the construction programme Steel is fabricated offsite to tight tolerances and brought to site for erection with virtually no waste

VALUE BENEFITS OF STEEL

13

SUSTAINABILITY Steel is the worlds most recycled material 99% of structural steel used in the UK is re-used

or recyled
Steel is multicycled again and again without loss

of quality Waste is minimal to non-existent Offsite production is inherently safer than on site construction Steel buildings are adaptable and flexible Signatory companies to the BCSAs Sustainability Charter agree to their sustainability credentials being assessed and monitored
INNOVATION The competitive nature of the steel construction

sector drives innovation

Additional value has been provided for customers Productivity gains have been shared Safety has benefited from new approaches and

systems
Extensive research and development investment

underpins the focus on innovation

New knowledge is widely disseminated OFFSITE A wide range of types of projects have enjoyed the

LUE

benefits of offsite construction

Overcomes congested and hard to access site

challenges
Local communities appreciate reduced dust and

noise
Building programmes are shorter Offsite construction is inherently safer More accurate workmanship is achieved site assembly is faster and safer On SERVICE & SUPPORT The steel sector provides the most comprehensive

and in-depth technical support and guidance Everything is done to allow designers to keep up-to-date on the latest design and construction thinking and techniques comprehensive range of design guides covering A all aspects of steel construction is freely available The BCSA has approximately 130 steelwork contractors, ensuring competitive bids steel sector works closely with designers to The develop new approaches and working methods steel sector has been involved in developing The the Eurocodes for over 20 years

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VALUE BENEFITS OF STEEL EFFICIENCY

Steel graces Liverpool World Heritage Site

Liverpool taking shape on historic Pier Head.
iverpool is getting a long desired Fourth Grace to stand alongside the world renowned Three Graces the Liver and Cunard Buildings and the old Mersey Docks and Harbour Board offices - in the shape of an iconic steel-framed building housing what will be one of the leading City history museums in the world. Turning the complex and challenging design of Danish architect 3XN into reality at the centre of this Merseyside World Heritage Site could hardly have been envisaged without steel, and the project has accrued many benefits from the choice of steel along the way, including a value engineering exercise that cut down the originally designed need for four large plate girders to two, creating a lighter roof structure.

Main photo: The museum will be an iconic steel addition to the Mersey waterfront Inset above: Artists impression of the completed museum

The efficiency of steel construction is clearly exhibited at the new landmark Museum of

Manchester based executive architect AEW took responsibility for delivering the design and a joint venture of Danish company Pihl and Galliford Try took on the construction of the 65M project. It is a striking design, a partially closed X on plan, symmetrical about the diagonal axis, with sweeping wing roofs and large glass picture windows at each end. Three levels of exhibition space are built around a full height central atrium dominated by an elliptical spiral staircase. Cladding is a mix of stone and glass, with natural light allowed to flood in from a large skylight above the atrium and from the glazed elevations on the second floor. Clear, open spaces were a key requirement of the client, which were easily provided by the load bearing capability

of structural steel. Buro Happold had the task of turning the architects vision into a workable structure. Its a very complex, unconventional form, explains Buro Happolds David Taylor. The client was looking for large, open spaces, and the architect has come up with a scheme which provides this, and within a very unusual form. A total of 2,100 tonnes of steel is used in the buildings main structure, the load taken into the ground via a 4m deep reinforced concrete raft. The benefits of the clear spans will be felt most on the second floor, where there are two 40m long, columnfree main galleries one at either end -with the beams above spanning 28m across the width of the structure. The roof above the second floor galleries

EFFICIENCY VALUE BENEFITS OF STEEL

15

is supported by Westok cellular beams spanning 28m, and there are also two 2.3m deep x 26.5m long plate girders in the central section of the building. They sit very close to the movements joints, and carry loads from the plant room roof and also from the roofs of the two outer sections, explains steelwork contractor Caunton Engineering Director Allan Younger. The girders are supported at one end by the circular concrete lift cores and at the other by articulated columns that are held in place by 80mm diameter pins. Originally there were to be four of these massive plate girders, but two were taken out of the design after a value engineering exercise introduced four columns into the central atrium. That allowed us to take out two of the plate girders and create a lighter structure in the roof, explains Mr Taylor. A wide range of steel sections were used but, explains Mr Younger, the lack of

repetition was not a problem.We operate a just in time system of making erectable loads of steelwork, so we dont batch manufacture too much. On this job weve broken it down into the three phases, and then broken those into bite sized chunks, which are then designed, drawn and manufactured in the same sequence. The new Museum of Liverpool is due to open at the end of 2010.

Above: Clear spans and a complex geometry are the main features of the steel frame

Efficiencies
Efficient designs take advantage of the

Project team
Client: National Museum Liverpool Architect: 3XN and AEW Structural engineer: Buro Happold Management contractor: Pihl Galliford Try Steel contractor: Caunton Engineering Steel tonnage: 2,100t Project Value: 65M

high strength-to-weight ratio of steel, allowing better utilisation of space and longer flexible internal column free spaces, as well as foundations that are lighter and cheaper Lean manufacture leads to more predictable construction programmes Just-in-time deliveries can be synchronised with the construction programme, saving on site space and reducing damage during storage Highly visible strategies ensure that waste is minimised throughout the supply chain, so offsite fabricated steel will be erected with virtually no waste at any stage in the process

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VALUE BENEFITS OF STEEL SUSTAINABILITY

Left: Vulcan House is contributing to the regeneration of this area of Sheffield Below: The buildings orientation takes account of solar gain

Sustainability forged in Sheffield

There is increasing recognition that a sustainable building is a cost effective one. That was proven at Vulcan House where a speculative development achieved the highest environmental performance without the use of bolt-on features such as photovoltaic panels and wind turbines.
teel construction scores high on any sustainability measure for a host of reasons. Vulcan House in Sheffield is a recent project that demonstrates sustainable construction practices. A major challenge for the construction team derived from a Home Office aim to meet the governments environmental target of carbon neutrality in its estate ahead of the target year of 2012. The new building was to provide quality accommodation for the staff of the UK Border Agency (UKBA), as well as providing much needed public space in a developing quarter of Sheffield. Vulcan House, a seven-storey, steel-framed office development designed by architect Hadfield Cawkwell Davidson, provided a test bed for the Home Office in its sustainability drive and lessons learned there are being applied on other projects. The Home Office was so pleased with the project one of the UKs greenest buildings that it awarded its property consultant Drivers Jonas its

Supplier of the Year Award 2008 for the Most Beneficial Contribution to Sustainability. Vulcan House achieved a BREEAM Excellent rating, the highest score given to any building in Sheffield up to that time.

A state-of-the-art building
There are two buildings in this development, on a site believed to be one of the first integrated iron and steel works. Here we focus on one of them, known as Vulcan House Steel; the other is called Vulcan House Iron. Because of the procurement route chosen by the Home Office, Vulcan House was built by a speculative developer, Wilson Bowden, which proves that speculatively built offices can achieve the highest sustainability credentials, without any add-ons. Consulting engineer Mott MacDonald, as Clients Engineer and Representative, scoped the buildings services. The intention from the outset was to create a building as environmentally efficient as possible at the

same time as being user-friendly for the UKBA staff who would use it. The UKBA aimed to minimise its ecological footprint, measuring CO2 emissions through construction, operation and ultimately demolition. The building sets a benchmark for future Government construction projects. BREEAM ratings are won or lost in the first 10% of the design phase, says Mott MacDonald Technical Director Eddie Murphy. We asked bidders to look at integrating building services with the fabric. Its not enough to put up a building and slot services in afterwards. You have to treat the building as a whole from the moment you start. The UKBA recognised the major role played by a buildings users in optimising its environmental performance, so a design manual and guided tours were used to explain things such as how the building takes in fresh air at each floor level rather than from a centralised unit, which means

SUSTAINABILITY VALUE BENEFITS OF STEEL

17

The worlds most multicycled material

Sustainability is top of the construction agenda, and steel is unrivalled in proving its value for meeting the challenges ahead. Sustainability is a balance between economic, environmental and social issues, and steel delivers on all three without compromising future generations. Steel has always had a sound sustainability case:
Steel is the worlds most multicycled

material, with almost 500M tonnes of steel recycled globally every year 99% of structural steel is recovered in the UK for re-use or recycling Steel can be repeatedly re-used or recycled without any degradation in the quality of the material All steel construction products are pre-engineered, so site activity is safe, fast and predictable Offsite work is carried out in a factory

controlled environment which allows hazards to be reduced or eliminated Waste is minimal to non-existent and construction programmes are controlled and predictable Steel buildings are among the most adaptable and flexible assets in which a business can invest Long span column free spaces help keep buildings modern looking throughout their lifetimes Buildings can be easily adapted, avoiding costly and environmentally harmful demolition and redevelopment Steelwork contractors demonstrate their commitment to operating in a sustainable and responsible way by signing up to the BCSAs Sustainability Charter. Members are assessed and can achieve Gold, Silver or Member Charter status The BCSA has introduced a carbon

footprinting tool so its members can accurately assess the carbon footprint of all their operations Steel has a higher embodied carbon value per tonne than concrete, but a tonne of steel goes a lot further so steel structures generally have a lower carbon footprint than concrete ones There are far fewer deliveries required to construct a steel frame than a concrete one, which reduces the emissions associated with transport Maximum fabric energy storage in buildings thermal mass can be mobilised from a 100mm thickness of concrete floor slab. This mass is available in standard steel-framed construction. The extra mass associated with heavyweight concrete construction is a waste - in every sense www.sustainablesteel.co.uk

it is more hygienic as it travels only short distances rather than down long and dusty ducts. Energy is saved by not having to pump air long distances. Ways of capitalising on the buildings design to conserve energy use were also explained.

Virtual thermal models

The design was informed by virtual thermal models using local weather data over a year, which led designers to change the orientation of the building, locating UKBA staff in the north and east sides of the building where solar gain is least. Local ventilation is combined with heat reclaim systems, heating incoming air with warmth from extracted air. Although Vulcan House is fully air conditioned the energy this will use is far below the good practice level for this type of building. The chillers use ammonia which has no global warming impact rather than HFCs which are powerful greenhouse gases. Structurally the building is straightforward,

with a steel frame built on CFA piles with composite floors of 150mm concrete over metal decking. It is a cube shaped block as this offers the best ratio of external area per internal square metre for regulating internal temperature. A central lightwell punctuating the block lets in plenty of daylight. Steel was used for speed of construction the frame went up in 12 weeks, comments Wilson Bowden Developments Senior Construction Manager David Wragg. It makes the building lightweight, though there is still enough thermal mass to help stabilise the buildings temperature. Steelwork contractor Robinson Construction erected more than 980t of structural steel. Cellular beams were used throughout, minimising the structural void and giving the building maximum possible floor to ceiling heights. The cellular beams span up to 15m in places, and keeping all services within their depth allowed for column free zones

between the structures perimeter faade and the internal lightwell. By using long span steel beams the buildings configuration can be changed, said Mr Murphy. Bearing in mind that its a speculative building, the Home Office could end its tenancy in 15 years and then it could be easily divided into a multi tenant block in the future.

Project team
Client: Home Office Property General project consultant and advisor: Mott MacDonald Architect: Hadfield Cawkwell Davidson Structural engineer: White Young Green Main contractor: Wilson Bowden Developments Steel contractor: Robinson Construction Steel tonnage: 1,000t

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VALUE BENEFITS OF STEEL INNOVATION

Innovation comes as standard

Manufacturing techniques and traditional ways of working have been transformed by a steel supply chain dedicated to continuous innovation to meet and exceed the demands of modern building owners and users.
teel construction and innovation go hand in hand. The competitive nature of the steel construction sector drives innovation within all areas of construction. The search for improvements in all aspects of the construction of buildings, bridges and other structures in steel is a continuous process. The systems and products that have been developed in recent years have not only provided additional value for customers, but have made construction safer, faster, more sustainable and more accurate. Steel is at the forefront of modern and efficient construction and all key areas are under continual scrutiny for better ways of working. No other construction material supply chain supports such a wide range of specialist sector groups dedicated to meeting the needs of the construction industry. These steel sector groups are dedicated to specific issues such as health and safety, sustainability, connections, fasteners, industrial buildings, steel homes, steel bridges and fire performance. As well as looking for improvements in

steel and the fabrication process, the steel supply chain has proven dedication to working collaboratively with other members of integrated construction teams. This has benefitted a wide range of projects, including Heathrow Terminal 5 where close co-operation extended to early involvement in the design process and trial erections at steelwork contractor Severfield-Rowens workshop. Steelwork contractors are themselves engineers, which helps create the marriage of minds that underpins collaborative developments in construction. They understand the needs of designers and contractors. The nature of steel construction itself promotes collaborative design approaches, with computer modelling easily passed between steel contractors and others in the construction team. This sort of close co-operation fosters innovation as well as delivering best value to clients. The steel sector can point to a wide range of leading edge innovations that resulted in regular advances in health and safety, productivity and sustainability. Steelwork contractors have a long track
Cellular and fabricated beams with web

Innovations

openings Areas where technical innovations have Shallow floor solutions Deep decking for composite construction been introduced: Wind-moment frame design methods Safety advances such as fall protection Standard connections Structural fire engineering and edge protection systems Long span solutions that create highly Understanding of floor dynamics for valued column free spaces vibration critical applications, such as Asymmetric beams hospitals

record of introducing innovative safety products and procedures; examples include pre-fixed edge protection systems whose use is now standard, and more recently safe loading and unloading systems. Bridge sections can now be sub-assembled to include access systems which significantly reduces work at height risks. Highly optimised cellular beams and plate girders have been developed. Environment friendly water-based protective systems are now available. Structural Fire Engineering, based on the use of Finite Element Analysis, has been developed with the support of Corus to enable fire protection to be eliminated on most secondary steelwork on major projects. Thanks to innovation architects enjoy greater freedom to express their vision. Steel can be shaped in any dimension that their designs require. Tubular steel features on most stadiums, shopping centres, and commercial developments of all types. Steel based cladding systems adorn iconic and landmark structures worldwide. Building owners value the flexibility of steel buildings, as the light open airy spaces provided can be modernised, extended or otherwise adapted with minimal disruption to existing building users. The commitment to searching for innovation and developing more efficient ways of working together has been backed by extensive research and development investment. This has produced a wide range of detailed advisory publications on topics such as the performance of steel in fire, and the acoustic and vibration performance of steel buildings.

INNOVATION VALUE BENEFITS OF STEEL

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Towers of London
Two steel-framed office blocks have replaced an earlier design for one large structure on Londons Isle of Dogs. The development at Canary Wharf comprises two 16 storey office blocks provisionally known as DS3 East and West, rising up on a plot between the existing Barclays and HSBC towers. Steelwork contractor Cleveland Bridge erected 8,000t of structural steel, 3,500t for the East tower and 4,500t for the slightly larger West tower. The project takes advantage of the new sections sizes from the Corus Advance sections range. All primary steelwork erected on site by Cleveland bridge is Corus Advance sections. This new range includes 21 section sizes that are ideal for long span floors, with over 1,600t of the new Advance 610 x 178 UKB used on the project. Dr Sam Wong, WSP Project Director, says this new section was specified because of the weight saving. We are saving nearly 20kg per beam, and that is a very significant figure when you take the whole project into account. Although both towers are unconnected above ground level, they share a concrete substructure and slab, which incorporates a shared four level basement. Both towers have concrete cores (three in the West and two in the East tower) and from ground floor up the entire project is steel-framed. The foundation work and the concrete sub-structure were completed in 2003 when the plan was for a single structure, but this design was eventually shelved and the site lay dormant for a couple of years before the current, two tower scheme was given the go ahead. The original design had one structure covering the entire sites footprint, but the new scheme includes a large central courtyard area taking up nearly a third of the site. Constructing two separate towers on the site instead of one large structure involved some major modifications to the concrete sub-structure prior to steelwork erection. Part of the West tower comprises a large 14 storey high atrium and including it in the design required addition of a new core. Each of the towers two main cores are in the same position as the original scheme but the area to the west of the atrium required a new satellite core. The longest spans, from core to perimeter, are 13.5m while the perimeter columns are set at 9m spacings. For the West tower the main steelwork challenge was the atrium area, which is mostly a column-free area all the way up to the 14th floor, with some 25m long beams spanning the atrium void. Steelwork for both towers incorporates large plate girders on the second floor which span over a double height entrance foyer. These large 15.5t sections were installed to accommodate differing column locations. On the East tower Cleveland Bridge installed a series of large A-frame transfer structures below the ground floor slab to support the differing column lines. To pick up the loading from the steel columns above, the A-frames were installed to transfer load to the existing concrete columns and piled foundation in the basement.

Project team
DS3 East and West Towers, Canada Square, London Client: Canary Wharf Group Architect: Kohn Pedersen Fox Assoc. Structural engineer: WSP Cantor Seinuk Main contractor: Canary Wharf Contractors Steel contractor: Cleveland Bridge Steel tonnage: 8,000t

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VALUE BENEFITS OF STEEL OFFSITE

Modern methods maximise value

Offsite construction is growing in popularity for many good reasons, not least because of the benefits it brings to sustainable construction and health and safety.

he widest range of projects have always taken advantage of offsite produced steelwork, from schools, hospitals and large City commercial developments, to some in inaccessible locations that could have hardly been envisaged if it wasnt for offsite manufacture, such as visitor centres on top of mountains (see box below). Construction is increasingly on brownfield sites, which usually means the inner city, which almost always demands using modern

methods of building to overcome the challenges of working in heavily congested and restricted areas. A proven way of avoiding much of this nuisance is to opt for the offsite construction benefits of steel frames. Local communities gain from offsite manufacture and work carried out away from the congested construction site means less of an impact on the surrounding areas, as well as shorter build programmes that in return leads to steel construction that is dry and dust free and relatively quiet.

Offsite construction is valued for delivering other key benefits. It is inherently safer since most of the work is carried out in controlled operations. Far more accurate workmanship is achieved in these factory controlled conditions, and the pre-engineered steel is safely and speedily assembled on site by small, well-trained teams of skilled, specialist erectors. Using steel as the framing solution has been proven to reduce construction programmes on commercial buildings by up

Reaching the summit

All projects benefit from maximising offsite construction, but for some it is an essential choice. For the construction team on the new visitor centre on the summit of Mount Snowdon in North Wales, getting the materials and even themselves to the often inhospitable site was a challenge. The centre, which houses a caf, washrooms, information area, medical centre and overnight shelter, comprises a structural steel frame and a Kalzip Hi-Point roof. Dense fog, low clouds and high winds were everyday occurrences at the site 1,085m above sea level. The site is only accessible by a mountain railway, and the team was able to take advantage of the trains flat bed carriage. As there was a strict limit on how much could be transported that way, all offsite engineered steelwork elements were packaged up to fit in 14m long packages onto the carriage. The main structure, 30m long x 13.5m wide, was a challenge to fabricate and design because of its unusual sloping shape, dictated by the need to fit into the environment without impairing the spectacular views. To make sure the elements of the fabricated structure fitted together steelwork contractor EvadX did a complete trial erection of the building at Corus Shotton facility on Deeside. At the summit there was very little storage space, which decreased as the building rose. We marked up all of the individual members which ensured that the steel was taken up the mountain in the desired sequence, which helped with final erection on the summit on the same day, explains EvadX Project Manager Andrew Roberts. Welding of members was carried out at the Corus facility during the trial erection, and included 154 brackets that are attached to the roof perimeter to hold granite roof sections in place. The brackets fit to a 300mm x 300mm box section that effectively holds the structure together at eaves level.

For final erection, EvadX used two cherrypickers and one 8t capacity mini mobile crane. The cherrypickers were small enough to fit onto the trains flat bed trailer, and the crane was specially sourced as the largest available that could be transported by rail to the summit. With limited space and a strict schedule, pre-engineering the component parts offsite saw the frame and roof delivered safely, on time and accurately.

OFFSITE VALUE BENEFITS OF STEEL

21

to 15%. Construction programmes benefit hugely from the certainty that steel will be brought to site when required, but only when the programme demands it. Applying corrosion or fire protection coatings at the fabrication stage further reduces predictable construction programmes. This modern method of construction does not need an army of carpenters and steelfixers, or space to store expensive and fragile, bulky formwork. Once delivered to site, offsite fabricated steelwork assures a high quality, defect free product and minimal waste of resources any waste arising at the fabrication stage is 100% recycled and there will be no on site waste or packaging to dispose of. Steels provenance is easy to demonstrate as it is easily standardised, tested and certified.

Pre-assembled Adey Steel support truss sections are craned into position at Gloucester Quays retail development

Competitive bids assured

The steel construction sector is one of the most transparently competitive in the construction market. The BCSA has approximately 130 members, ensuring that there will always be a healthily competitive response to invitations to tender. Most BCSA members have comprehensive certification of their operations through schemes such as the Steel Construction Certification Scheme. The BCSAs membership assessment criteria allows confident selection of a steelwork contractor that is properly qualified to undertake particular types of project. Steelwork produced in line with the National Structural Steelwork Specification helps ensure that steelwork will be accurately, economically and safely built. Membership of the BCSAs Sustainability Charter signifies that a steelwork contractor has an independently assessed commitment to the highest sustainability practices.

Project team
Client: Snowdonia National Park Authority Architect: RH Architects Structural engineer: Arup Main contractor: Carillion Steel contractor: EvadX Steel tonnage: 120t

PHOTOGRAPH: ADEY STEEL

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VALUE BENEFITS OF STEEL SERVICE AND SUPPORT

Strength from in-depth support

Designing and building in steel has never been as straightforward as it is today. The steel sector provides comprehensive and in-depth technical back up to ensure that those using steel have all the guidance and support they could need at their fingertips.

he steel sectors long-term investment in research and development is shared with industry members, ensuring that up-to-date and reliable advice on relevant issues and regulatory change, is always to hand. The sector works closely with designers and others to develop new approaches and methods of working. For example, advances in the area of structural fire engineering has been spearheaded by UK designers with support from Corus, creating a world-class design approach that means most secondary steelwork can be safely left unprotected on major structures.

Contacts:
Support is available through the Corus telephone hotline and from technical experts at the BCSA and SCI.

Corus Hotline: 01724 405060 BCSA: 020 7839 8566 SCI: 01344 636555
Many technical resources including design guides and software are available on-line at: www.corusconstruction.com www.steelconstruction.org www.steelbiz.org

Co-ordinated and comprehensive support is provided free of charge to specifiers, clients and designers. Detailed technical advice can be accessed from Corus telephone Hotline or website, and direct support is also available from technical experts at the British Constructional Steelwork Association (BCSA) and the Steel Construction Institute (SCI), in area such as acoustics and floor vibration where knowledge is being continuously developed. Since the early 1980s Corus has operated a network of Regional Technical Managers, who are on hand to offer guidance and support to all designers in steel. The needs of the construction industry are widely represented via a range of steel sector groups dedicated to specific issues such as health and safety, sustainability, connections, fasteners, industrial

Other useful sites include: www.new-steel-construction.com

(New Steel Constructions searchable article archive)

www.steel-sci.org (SCI News)

www.steelcal.org (Computer aided learning)

www.architecturalresources.info
(Basic information on construction)

www.access-steel.com
(Technical support for Eurocodes)

www.sustainablesteel.co.uk

buildings, steel homes, steel bridges and fire performance. Significant resources have been devoted over the past 20 years or more by the steel sector to the preparation of design guides covering all aspects of steel construction. With the Eurocodes introduction now imminent, the time and effort dedicated to developing new design guidance, training aids and web-based learning packages will help designers and structural engineers make the transition smoothly. Keeping abreast of developments is aided by an extensive programme of popular technical courses and seminars provided by Corus, the BCSA and the SCI, on issues such as CE Marking, Responsible Welding, Composite Design, and of course Preparation for Eurocodes. The free seminars run by Corus provide delegates with in-depth technical knowledge on specific issues, with leading edge projects showcased in the popular Framed in Steel series, helping designers keep up-to-date on the latest design and construction thinking and techniques. The industry has worked closely with educational institutions for many years. As well as the extensive teaching resources and bursaries that are provided, the sector also supports the annual Student Awards aimed at young architects and engineers. These awards allow undergraduates to demonstrate their design skills in innovative and effective ways in the three categories of structural steel, bridges and architecture.

SERVICE AND SUPPORT VALUE BENEFITS OF STEEL

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Extensive design advice free

Neil Tilley, Manager, Constuction Advisory Service, heads a network of Regional Techical Managers that is the current version of what was the Structural Advisory Service which was formed over 20 years ago. Neil says: Extensive back up advice has always been offered to designers by Corus. Since the 1980s we have had a team of experienced engineers organised regionally who visit designers at their offices to offer whatever design support and advice they can. Our presence means that there is always someone to turn to for whatever technical advice is needed, and there is no charge for this service. The existence of this service has provided an advisory resource that can be easily tapped into, and over the years has saved many designers time and money. Neil adds: Keeping design guidance relevant is vital. Regular contact with designers helps identify any gaps, possibly due to changes in legislation and codes, or simply by engineers being more adventurous. This will lead to research and publications of new design guidance. Corus operates a Hotline service, manned by an experienced team who are trained to deal with technical telephone enquiries, many requesting advice and support. Their experience means they can deal with queries efficiently and speedily, ensuring that any questions are directed to our team of qualified engineers with extensive experience or elsewhere within the steel supply chain. This support means designers can draw on the expertise of specialists in structures, tubular steel, plates, bridges, corrosion, structural fire engineering and any other topic relevant to good design in steel. Senior Advisory Engineer Paul Windsor, who heads the sections Advisory Desk, says he is expecting a rise in Eurocode related questions. Most designers are pretty well up on the existing codes, although brittle fracture still produces a regular stream of enquiries. There are a lot of requests for advice about using the free software that we provide for our Slimflor and Slimdek flooring products, and about our decking system, ComFlor. Some people just want advice on general topics. We receive questions on whether a particular approach is suitable for the loads to be imposed, or if a particular grid is suitable. Although we dont provide full designs, we can do quick design calculations that will provide a general answer so the designer can then either proceed with the full design or have a rethink. The BCSA also invests considerable resources in ensuring that designers and others are kept up-to-date with the latest advice and guidance on the full range of fabrication and erection related technical issues. Director of Engineering David Moore promises that any questions that come in are answered promptly and in detail. Whatever you need to know we will find out, even if we dont have the answer immediately to hand, says David. BCSA mostly receives enquiries about the selection of steelwork contractors and product suppliers together with enquires relating to the extensive guidance that it publishes, which is by definition on the most important technical issues. A full technical service on all standards and associated documents relevant to steel construction is offered. The Eurocodes are not a major source of questions at the moment but that will change as we get nearer their introduction. Fortunately we have a long involvement in the relevant committees that have drafted the Eurocodes so we are well placed to explain what the codes mean, says David.

The Automated Distribution Centre at Scunthorpe (pictured left under construction): can store up to 17,000t of steel sections under cover and protected from the elements. The facility not only enhances Corus end product quality for sections, but the automated stacking system minimises handling-time and increases load flexibility, as well as improving safety standards. Its existence ensures that all products are despatched speedily and in the best possible condition

Steel. The sustainable facts

VALUE. No solution is sustainable unless it is also economically valid. The environmental and social benefits will be short lived without a solid economic case. Steel construction is the competitive choice, and offers numerous sustainability advantages that are easy to realise. Steel retains its value from cradle to cradle, and the major environmental gains arising from multicycling and re-use provide a guaranteed future for the structures we are building now.

To find out more about the material of the future visit www.sustainablesteel.co.uk