Reclaimed Steel: Cheaper, Easier, and Approved by Building Control

Jim Pritchard Founder of Building Renewable

Jim is an environmental professional with 25 years’ experience in the areas of sustainability, management of natural resources, and environmental projects. He’s passionate about creating a world where people and nature can thrive together.

Reclaimed steel used to conjure up images of rusty old steelwork, riddled with holes and dangerous sharp edges. Not the sort of material you’d immediately think of to use for your home extension project.

Even now, many people don’t seriously consider using reclaimed steel in their building projects because they imagine it coming with a host of problems, from engineering nightmares and clashes with Building Control, to cost overruns.

However, one homeowner’s recent extension project blows these misconceptions out of the water. Rather than facing problems caused by complexity, increased risk or expense, she and her husband found the whole experience to be surprisingly straightforward, cost-effective, and, most tellingly, encountered “no real challenges”.

Most construction projects face their fair share of difficulties, so the absence of any real challenges from one that pushed the boundaries of sustainable practice requires further examination.

We sat down with Flavie Lowres to discuss the extension she and her husband Will had recently completed for their home in London. Here, we uncover how they made reclaimed steel a central part of their project, and how it turned out to be a seamless and even preferable choice to new steel.

Table of Contents

The “Why”: Carbon, Not Just Cost

Reclaimed steel sections painted red with green footprint labelled with "CO2" and a pound symbol in a circle, both with downward pointing arrows to indicate decreases. — The use of reclaimed steel not only has a smaller carbon footprint, but also works out cheaper.

For Flavie and Will, the decision to use reclaimed steel was based upon their commitment to environmental principles rather than any desire to save money. Flavie provides advice on sustainability in the built environment through her company, Green Thinking Ltd, so these issues are close to her heart.

“It was for environmental reasons and also to test the principles that I have been working on, i.e. reuse of construction products,” explained Flavie.

The production of new steel is highly energy-intensive, which makes its embodied carbon footprint commensurately high. Reusing existing steel meant the couple drastically reduced the carbon footprint of the project, aligning perfectly with their values of sustainability and waste minimisation.

They had no interest in simply ticking a box, this was an earnest effort towards a more circular economy in the construction industry.

Design Integrity: Reclaimed Doesn’t Mean Compromised

An open plan kitchen with an island unit. A washing machine is next to a set of steps leading into a living area. — The vision for Flavie and Will’s extension was a large open-plan kitchen area that felt connected to the living room.

A common misconception is that using reclaimed materials puts the cart before the horse in a way that forces design compromises due to the limited availability of suitable materials.

Would the couple’s extension have to be shaped around oddly sized beams? Would aesthetic compromises have to be made? The answer to both these questions was a decisive no!

“We took the decision to use reclaimed steel once the design had been approved and the structural engineer had submitted his calculations,” Flavie clarified. “The use of reclaimed steel did not affect the design or structural calculations as we asked the supplier to meet the brief provided.”

This is a key point. The design came first, and the reclaimed steel supplier was then asked to provide the reclaimed steel beams that met those exact structural and dimensional requirements.

Using reclaimed steel properly isn’t about adapting your design vision to what’s available; it’s about a specialist reclaimed steel supplier providing reclaimed steel sections to meet the specified brief.

Busting the Biggest Myth: Certification and Risk Management

Red painted reclaimed steel sections in the reclamation yard prior to delivery. In the bottom right is a "certified" symbol. — Red-painted reclaimed steel sections in the reclamation yard prior to delivery.

This is perhaps the most surprising aspect of the project, and one that turns the common misconception that salvaged structural steel is difficult to reuse on its head.

You’d be forgiven for thinking that the perceived risk of using reclaimed steel could be a significant barrier for engineers, architects, and contractors. How could you guarantee its strength? Who signs off on it?

At first, the project encountered some caution. “When we started thinking about using reclaimed steel, we contacted the architect and the contractor. The architect did not want to get involved,” Flavie recalled. However, the contractor was open to the idea, leading to a crucial dialogue with the specialist steel fabricator and, ultimately, the reclaimed steel supplier.

The key to unlocking professional buy-in and regulatory approval from Building Control was surprisingly simple: certification and specialist expertise.

“The supplier provided all the required documents and testing certificates to meet the requirements of the fabricator, the structural engineer and Building Control. It was very straightforward from that point of view.”

This illustrates the vital role of a reputable, specialist supplier like Cleveland Steel (one of the only two in the UK at the time, now the sole supplier). They don’t just salvage the steel and call it a day; they assess, test, and certify it to modern structural standards.

This robust, documented process, readily available from the supplier, completely de-risked the use of reclaimed steel for all parties, from the fabricator to the structural engineer and, critically, Building Control, who “were happy with the test certificates provided and it was very easy.”

The Money and Time Surprise: Cheaper, Not Costlier

A view of the skylight above the kitchen area taken from the roof terrace. The savings from using reclaimed steel helped to keep the project budget down without compromising on the quality of the finishes.

Another common misconception is that opting for sustainable, alternative materials means paying a premium or introducing delays. Flavie and Will’s project proved precisely the opposite.

“The reclaimed steel was actually cheaper than the new steel,” Flavie said. While the specific cost savings weren’t directly passed to the couple due to the project budget already being set, the fact remains that using reclaimed steel was not an additional cost.

It’s also worth noting that there were no delays introduced as a result of using reclaimed steel, with no extra time needed for sourcing or installing the material. “Overall it did not impact the project schedule or budget,” confirmed Flavie.

In terms of logistics, the project ran equally smoothly. The steel beams arrived on schedule, and while the supplier was based in Yorkshire, a local fabricator was engaged for minor adjustments, ensuring there were no last-minute issues.

The Converts: Professionals Turn Advocates

A photograph of a steel fabricator wearing hi visibility tabbard, yellow hardhat with arms folded. To his left is a green circle with a white "thumbs up" icon. — It’s smiles all around now the certification process has been taken care of.

I think the most compelling outcome of this project is the ripple effect it has had on the professionals involved, with their initial scepticism giving way to advocacy.

“The contractor was impressed how easy the process was and is going to use more [reclaimed steel] in future projects where appropriate,” Flavie shared enthusiastically. Even the initially hesitant architect is now “keen to promote its use in future projects.”

This 180-degree shift in professional perception is a massive plus. It moves reclaimed structural steel out of its pigeonhole of being a niche, experimental material into the realm of being a viable, recommended option for mainstream projects.

As Flavie noted, “very few people (in the trade or friends/family) knew it could be done and were surprised but interested in the process.”

Advice for Aspiring Reclaimers

The finished kitchen extension with the couple enjoying the space. — After finishing the project, Flavie and Will have some useful advice to share.

Looking back on the successes of the project, the couple would “definitely do it again,” citing the significant reduction in carbon footprint as the biggest benefit.

Their experience offers useful guidance for anyone else considering using reclaimed steel in their own projects. I asked Flavie to sum up her main learnings to share with others.

Find a Specialist Supplier Early: “Find the supplier (Cleveland Steel is now the only supplier in the UK) and put them in touch with the contractor.” A good supplier is your project’s greatest asset.
Trust the Professionals: “I did not force the use of reclaimed steel as it is important to have the professionals to make the decisions.” Provide the options and the certified materials and let the experts approve them.
Timing is Key: “I also think that if we had made a request for reclaimed steel earlier in the process, it might have complicated the process. Best to find out what you need for your project then contact the supplier to know what they have available.” Design your project first, then source reclaimed materials that fit, rather than designing around uncertain stock.
Leverage Case Studies: Flavie and Will used case studies from organisations like ASBP (Alliance for Sustainable Building Products) to help convince stakeholders, demonstrating that precedent and proven examples are powerful tools.

The experience of the Lowres family shows that using certified reclaimed structural steel is a viable way forward in any home improvement project.

There was no need to compromise on any aspects of the design, and the selection of reclaimed steel for the project was a pragmatic choice that turned out to be not only a good choice for the environment, but also much easier and more cost-effective than expected.

The secret is out: reclaimed steel isn’t a challenging material reserved for committed environmentalists – it’s an opportunity that everyone involved in mainstream home improvement projects can take advantage of.