Advancing Circularity in the Metal Building Industry

by tristan_marks | July 31, 2025 12:53 pm

Regulations, customer and public expectations, and the imperative to act on climate change are increasing the pressure on the construction industry to reduce its environmental footprint. Circularity is becoming a central strategy for minimizing waste, conserving resources, and extending the life of buildings and building materials. For the metal building industry—where steel and aluminum are primary materials—the principles of circularity are especially relevant. Metals are among the most recyclable materials, yet realizing the full potential of circular practices requires a holistic approach that begins with design and extends through manufacturing, construction, operation and maintenance, and ultimately deconstruction and reuse.

Circularity is focused on effectively remaking rather than just efficiently making things and is centered on creating new resources rather than accepting waste as inevitable. From current best practices, like waste reduction and recycling, to promising innovations, such as advanced manufacturing and digital twins, circularity is reshaping how architects, engineers, contractors, and manufacturers approach metal building projects. By adopting best practices today and investing in future innovations, the industry can significantly lower its environmental impact while creating long-term value.

 

Current best practices—waste reduction, recycling, and reuse

Waste reduction is central to circularity, and the metal building industry has made significant progress by improving efficiency from the design phase forward. Designing for minimal waste starts with careful planning. Architects and engineers are adopting digital design tools to optimize material use, ensuring that structural members and cladding materials are used as efficiently as possible. Off-site fabrication of modular and panelized building systems also contributes to minimizing waste, as components are precision-fabricated in controlled environments with careful management and optimized use of materials.

In manufacturing, lean production techniques help eliminate inefficiencies. Metal fabricators can automate production and adopt just-in-time production and continuous improvement strategies to reduce off-cuts and scrap. On construction sites, contractors can implement smart material ordering systems to avoid surplus inventory and improve storage and handling practices to prevent damage and waste.

Recycling is a well-established practice in the metal building sector. Steel and aluminum boast some of the highest recycling rates of any building materials (70 to 90 percent), with steel in particular enjoying a robust infrastructure for collection and remanufacturing, but there is still room for improvement. Organizations like the Steel Recycling Institute and the Aluminum Association have developed guidelines to support consistent recycling practices across the industry.

Some manufacturers have implemented closed-loop recycling systems that capture scrap generated during fabrication and reintroduce it directly into production. This not only reduces material costs but also cuts emissions by lowering the demand for virgin materials.

On the job site, best practices include carefully sorting scrap metal during construction and demolition to ensure clean, high-quality material streams for recyclers. Deconstruction planning, rather than traditional demolition, is gaining traction as a strategy to preserve the value of metal components and maximize recycling rates. Beyond recycling, extending the life of metal components through reuse is an increasingly important part of the circular economy. This requires buildings to be designed with disassembly and future adaptability in mind.

Due to their modular nature, metal building systems are ideal for disassembly. Panels, framing systems, fasteners, and structural supports can often be removed and reused with minimal reprocessing. Designing for disassembly involves selecting reversible connections, standardizing component sizes, and planning for future access to connections. These strategies make it easier to deconstruct buildings at the end of their service life and repurpose components in new projects.

A number of case studies demonstrate successful reuse. For example, some industrial facilities, including a warehouse at U.S. Army/Air Force Joint Base Lewis-McChord in Washington state, have been carefully dismantled, with their steel framing and cladding repurposed in other structures. However, barriers persist, including concerns about structural warranties, compliance with modern building codes, and logistical challenges in transporting reused materials.

A recent project illustrates the potential for deconstruction. The 23,225 m² (250,000 sf) steel-framed Boulder Community Hospital in Boulder, Colorado, was successfully deconstructed in 2023, achieving an overall 93.5 percent diversion rate (98 percent for structure and enclosure). The City of Boulder stockpiled 584 structural steel members, many of which have already been reused in a new fire station and other projects. The as-built drawings provided a useful inventory of the type and size of components available, allowing advanced planning for reuse.

 

Future circularity innovation

While today’s best practices provide a strong foundation, technical innovation will drive the next generation of circularity in the metal building industry. One of the most promising developments is the use of digital twins—virtual replications of the physical and functional characteristics of buildings throughout their lifecycles.

When digital twins are integrated into the design phase, architects and engineers can model how buildings will be constructed, maintained, and eventually disassembled, informing material choices, configurations, and connection details that facilitate future reuse. Digital twins can also catalog the source, specifications, and usage history of materials and components, supporting future deconstruction and reuse planning and ensuring that reused materials meet safety and performance standards. During operation, these models can guide maintenance practices, extending the useful life of building systems and components.

Advanced material science is another frontier for circularity. Researchers are developing new metal alloys that enhance durability and recyclability and coatings that extend the lifespan of building elements, reducing the need for replacement.

On the logistics side, AI-powered inventory management platforms can connect surplus materials from one project to new applications elsewhere, creating digital marketplaces for reclaimed building components. Take-back programs coordinated through these platforms could allow manufacturers to reclaim materials at the end of a building’s life, reintroducing them into production with minimal processing, a big step toward circularity.

 

Conclusion

As circularity moves from concept to practice, the metal building industry is uniquely positioned to lead. With metals like steel and aluminum offering inherent recyclability, the challenge is not the material itself but how we design, build, and manage materials, assemblies, and whole buildings to maximize reuse and minimize waste.

For architects, engineers, contractors, and manufacturers, embracing circularity means adopting today’s best practices in waste reduction, recycling, and design for disassembly. Looking ahead, it also means investing in innovations like digital twins, advanced materials, and smart logistics that will redefine what’s possible in sustainable construction. By working collaboratively across the supply chain, the industry can close material loops, reduce environmental impacts, and deliver buildings that are as resilient as they are resource-efficient.

Alan Scott[1], FAIA, LEED Fellow, LEED AP BD+C, O+M, WELL AP, CEM, is an architect and consultant with over 36 years of experience in sustainable building design. He is the director of sustainability with Intertek Building Science Solutions in Portland, Ore. To learn more, follow him on LinkedIn[2].

Source URL: https://www.metalarchitecture.com/articles/columns/constructive-insights-circularity/

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