We are proud to feature Steelworks New Zealand as the recipient of the constructsteel Excellence in Sustainability Award 2024 for their innovative approach in the Hinuera Sheds project. This award celebrates their outstanding contribution to sustainability in the steel construction industry. We caught up with Grier Fuller, Co-Director, to discuss the sustainable practices behind the project, the challenges they overcame, and the role of steel in shaping a more sustainable future for the industry.
Steelworks New Zealand is a family-owned business with a strong emphasis on sustainability. Can you tell us a bit more about the company and the team behind the Hinuera Sheds project?
Steelworks New Zealand is a family-owned enterprise dedicated to the fabrication and erection of structural steelwork. Located in Tauranga, our company focuses on large-scale commercial and industrial projects while also offering services for earthquake strengthening initiatives. Our commitment lies not only in delivering high-quality work but also in pioneering innovative and sustainable practices within the industry. A key aspect of this approach is maximising resource efficiency by repurposing steel whenever feasible, thereby reducing waste and embracing a circular economy model for our projects’ lifecycle management.
For the Hinuera Sheds project, we had an amazing team behind the scenes. Mike Aldridge, our detailer, worked closely with the engineers and the client to create the fabrication and construction drawings. Our site team, led by Nic Taituma, assembled the structure over three months, working through some tight logistics and time constraints. And of course, the entire Steelworks crew, from the workshop and QA to the site team, who worked tirelessly to ensure the project was a success. This project really was a team effort, and we’re incredibly proud of what we accomplished.
Could you tell us a little about what inspired this award winning project and how it came to life?
Thank you! We’re incredibly honoured to receive recognition and awards for the Hinuera Sheds project around innovative reuse and repurposing of steel in sustainable construction practices.
We came into this project as the fabricator to work with the builder, Sabre Construction and CHS Engineering to come up with the process of how the recycled material was going to be used and designed on the proposed site. The client, Pete Barker acquired the steel from a shed from the Port of Tauranga, originally built in the 1990’s, when it was being demolished with the idea of reusing it.
From there we were engaged in the process of how the building was going to be designed around the available recycled steel working on the same span, same knee heights etc and working with the builder and engineer on how that process was going to happen. So, a lot of moving parts in terms of getting everyone to connect, getting the tape measure out and selecting the material that was fit for purpose and able to be used in the new structure.
It took a fair bit of courage from the client to take on a project like this – it could have been a big mistake had the engineer rejected the material (e.g. around compliance or damaged steel from demolition) and you’re left with 400 tonnes of steel sitting on the ground that would have been scrapped and probably at a huge cost. I think when it comes to any sort of sustainable project, there is a certain amount of risk around the unknown in terms of how it will play out and if it will be in fact reusable.
One of the big things that we took out of the trip to the United States to receive the award was that the industry talks about this reuse and repurposing and recycling, but it’s easier said than done – and we did it. It’s the unknown factors around compliance and working through the processes to incorporate demolished steel into a new structure rather than turning it into scrap and melting it; and actually reducing the carbon outputs.
What were some of the key challenges you faced while repurposing the steel beams?
Working with material salvaged from a demolished building required careful design, inspection and management. The beams, stored in an open yard and exposed to the elements, had rust, dirt, and old welds that needed attention. We had to conduct thorough inspections, including ultrasonic testing, to ensure that it met the required engineering standards. Our Quality Manager, Workshop Manager and Welding Supervisor was tasked with visually identifying inadequate joints and welds and organising a reworking and testing regime to comply with the NZ Standards. Ultimately, it was a highly rewarding process that demonstrated just how effectively steel can be reused.
Hinuera Sheds - drone aerial view
Hinuera Sheds - drone aerial view
It’s impressive how the project minimised environmental impact. How did you ensure sustainability throughout the construction process?
Minimising environmental impact was one of our top priorities, which was reflected in the five key project phases. First, in Material Acquisition, we reused steel, significantly reducing the need for new raw materials and lowering energy consumption and carbon emissions. Second, in Transportation and On-Site Logistics, we streamlined logistics into a cyclic flow to minimise transportation between the workshop for fabrication, blast and painting, and on to site for installation. Third, in Modification and Fabrication, we designed the building for easy disassembly, ensuring future material reuse and supporting the circular economy. Lastly, a closed-loop approach by the design and fabrication team to ensure the end quality of reused materials is same as new and deliver the project successfully.
There are ways in which we can go about validating and understanding what we can do around reusing steel to make it fit for purpose and achievable. You can look at it on different fronts. From a Commercial front I think was still commercially better off for the client to opt for repurposing steel rather than purchasing raw material. Environmentally, we haven’t created or used new steel so there’s a huge environmental benefit from avoided shipping steel from overseas. So yeah, absolutely I really love it. I really commend the efforts from all involved on this project and it’s the environment that’s won out of the whole entire process.
Steel is often considered a “superhero material” in construction. How does the Hinuera Sheds project highlight steel’s potential for the future of sustainable building?
Steel truly is a superhero when it comes to sustainability. This project shows how steel can be reused in future construction projects to reduce waste, save energy, and cut carbon emissions. By extending the life cycle of steel, we’re not only reducing the need for new materials but also making the most of what we already have. The Hinuera Sheds project is a great example of how steel can be repurposed into something new and strong, contributing to a more sustainable construction industry.
Steelworks New Zealand has long emphasised quality, culture, and sustainability. How do these values influence your day-to-day operations and long-term goals?
From the beginning, my brother, Elliott Fuller, and I wanted to build a company that didn’t just focus on delivering high-quality products but also made a positive impact on our people, the environment and our community. Sustainability is woven into everything we do, and we’ve made it a core part of our business model. We’re always looking for ways to improve, innovate, and reduce our environmental impact. Being one of the first fabricators in New Zealand to join the Sustainable Steel Charter was an important milestone, and we’re committed to continuing to lead by example. In this sustainable era we have a commitment to the future where we need to think about the benefits of reusing and recovery.
Learn more: https://steelworksnz.co.nz/