How to renovate old factories using steel structures?

By

Canglong Group

How to renovate old factories using steel structures?

In the global wave of industrial upgrading, many old factories face problems such as outdated functions and safety hazards. Compared to demolition and reconstruction, steel structure renovation has become a more economical and environmentally friendly option. Data shows that the global building renovation market reached $12.389 billion in 2024, with steel structures occupying a core position in non-residential renovation projects due to their lightweight, high strength, and recyclability advantages. The market size is projected to exceed $19.6 billion by 2030. This renovation model not only extends the lifespan of factories but also quickly adapts to the needs of modern production and diverse scenarios.

The Core Value of Steel Structure Renovation

The core demands of old factory renovation focus on space expansion, cost control, and safety upgrades, and steel structures precisely match these needs.

• Firstly, the lightweight and high load-bearing capacity of steel structures allows for spatial reconstruction such as mezzanine construction and span widening without the need for large-scale foundation reinforcement. For example, converting a single-story factory building into a two-story production workshop can increase usable area by more than 50%.
• Secondly, steel structure components are mostly prefabricated in factories and assembled on-site, shortening the construction cycle by 30%-50% compared to traditional concrete renovations, reducing disruption to surrounding production. This is especially important for companies needing to quickly resume operations.

More importantly, the sustainability of steel structures aligns with global carbon neutrality goals. Steel recycling rates exceed 90%, and galvanized C-shaped and H-shaped steel components used in the renovation can be recycled through secondary processing. This meets the core indicators of LEED green building certification, such as material reuse and recycling. In European industrial heritage renovations, steel structures have become standard for achieving “zero-carbon transformation.”

Three Core Directions for Renovation

1. Spatial Restructuring

Old factory buildings generally suffer from low space utilization and rigid layouts. Steel structures can optimize space by replacing old beams and columns and adding steel mezzanine floors. For example, replacing the load-bearing system of the original brick-and-wood structure factory building with Q355H steel beams and columns, combined with a loft built with C-shaped steel purlins, can create a combined production and storage space. For large-span requirements, the roof can be modified using a steel truss structure, meeting the load-bearing requirements of automated production lines and heavy equipment installation, with spans extending to over 30 meters.

2. Functional Upgrades

The flexibility of steel structures allows old factory buildings to achieve multi-purpose transformation. In manufacturing plant renovations, ventilation skylights can be built using steel structures, and color steel sandwich panel enclosure systems can be installed to improve insulation and noise reduction performance, adapting to precision machining needs.

In Southeast Asia, many old factory buildings have been converted into auto repair shops using steel structures, adding steel staircases, floor decking mezzanines, and integrating drainage pipes, gutters, and other supporting components to achieve integrated production and office space. Furthermore, steel structures also support the transformation of old factory buildings into new business formats such as cultural and creative parks and shared workshops. By retaining the original structural framework, lightweight steel components can be used to build creative spaces, balancing industrial heritage with modern aesthetics.

3. Enhanced Safety and Quality

The aging structure of old factory buildings poses a significant safety hazard. Steel structure renovation can comprehensively improve building safety. Replacing decaying wooden components with corrosion-resistant galvanized steel structures enhances wind and earthquake resistance. For fire protection, steel components coated with fire-retardant paint, combined with the flame-retardant layer of color-coated steel composite panels, meet building fire codes in most parts of the world. In earthquake-prone Japan, steel structures have become a mandatory material for the seismic retrofitting of old factory buildings.

Technology-Driven Upgrading

Digitalization and greening are two major trends in current steel structure renovation. The deep application of BIM technology has completely changed the renovation process. 3D modeling allows for the simulation of component installation and the detection of collision risks in advance. In a substation renovation project, Zhongnan Steel Structure used BIM technology to avoid 238 component conflicts in advance, reducing rework costs and shortening the construction period by 45 days. This digital solution has been widely adopted in large-scale renovation projects in North America and Europe, achieving full-process visualization of design, production, and installation.

Material innovation is also driving upgrading. The application of new materials such as weathering steel and self-cleaning color steel plates has reduced the later maintenance costs of factory buildings. Photovoltaic integrated steel structure roofs have become a new hot topic, achieving both power generation and shading functions by laying photovoltaic modules on steel purlins, helping factories achieve energy self-sufficiency. In Germany, this type of photovoltaic-storage flexible steel structure renovation of factories already accounts for 27% of new and renovated projects.

Conclusion

From the revitalization of the Rust Belt industrial areas in North America to the upgrading of factories in emerging markets in Southeast Asia, steel structures are becoming a core support for the renovation of old factories due to their advantages of low cost, high adaptability, and sustainability. Whether it’s manufacturing plants that improve production efficiency or mixed-use spaces that transform into diversified business formats, steel structures can revitalize old factories through flexible renovation solutions. With the popularization of BIM technology and the innovation of green materials, steel structure renovation will further break through technical bottlenecks, providing more efficient solutions for global industrial heritage protection and industrial upgrading.