Cost and Life‐Cycle Analysis of a Structural Steel System Designed for Reusability

Abstract

This paper presents a quantitative study of a reusable structural steel frame system. The system is based on modular design, where grid dimensions are defined as multiples of a base module length. It introduces innovative joints designed for easy disassembly and reuse. Beams and columns follow standardized modular lengths and fit predefined joint configurations. This creates a flexible structural system with moment‐resisting pinned joints. The system is compared with conventional steel construction in terms of cost and life‐cycle environmental impact. A real reference building is first designed using traditional methods and then redesigned using the modular system. The total frame cost is calculated using a feature‐based costing method that includes workshop activities. Costs are assessed separately for virgin components and reused beams and joints. A life‐cycle assessment is performed to evaluate embedded carbon while accounting for component reuse. Several reuse scenarios are studied, ranging from fully virgin materials to entirely reused structures. In addition, the reusability of the frame is assessed using a dedicated method. This allows the assumption that design for reusability increases costs to be tested and enables a clear comparison between conventional designs and the proposed system.