• Architect/original membrane Engineers
Schlaich Bergermann & Partners
• Project manager
Jabatan Kerja Raya Malaysia
• Fabrication / Installation
Catonic (M) Sdn. Bhd
• Seating capacity
100 000 seats
• New Membrane Engineer
TK Abdul Sathar (Catonic - Technospan)
• Composite material
Précontraint 1202 S2
• Material area
44 000 m²
Built in 1997 for the 1998 Commonwealth Games, the Malaysian Government is rightly proud of Bukit Jalil National Stadium because it remains the ninth largest stadium in the world and the second largest in Asia.
The stadium’s 44,000 m² initial roof (covered with a composite material of German origin) had suffered irreversible premature aging and its canopy required total replacement.
50 tonnes of end-of-life materials has been recycled through Texyloop, the new roof made of Précontraint 1201 S2 has been installed.
New roof contractor Catonic (M) Sdn. Bhd. and its CEO Fadzullah Hassan were required to meet a highly demanding contract specification from both technical and environmental standpoints. Panels needed to be identically replaced on existing structural members and an end-of-life solution had to be found to avoid landfill disposal of the original defective material.
The Malaysian authorities, which remain closely involved in the destiny of this emblematic stadium and its environmental footprint, endorsed their requirements by opting for the Texyloop recycling process: to date, the only technology enabling production of new raw materials and significant reduction of environmental impacts.
A spectacular operation
The replacement exercise required operators specialized in high level access work for dismantling the 36 roof panels (each with an area of approximately 1250 m²) and replacing them, fitting a new PRECONTRAINT 1202 S2 flexible composite material: the same material which has already been in place on the roof of the neighbouring station, which forms part of the 1997 infrastructures and still in service today.
Recycling: a positive environmental balance
The 50 tonnes of material repatriated to France from Malaysia were inspected, weighed and shredded before being reshipped to Italy for recycling to give birth to new raw materials. These new, so-called 2nd generation resources will be used in new products such as PVC granule-based hoses or polyester-based growing mats for green roofs. Despite the long return journey in containers, the additional impacts generated by marine transport operation remain very minor compared with the overall reduction in environmental impacts ensured by Texyloop. These positive conclusion are exhibited by the Life Cycle Assessments (LCA) conducted by environmental consultant EVEA in compliance with ISO 14040, which compared impacts generated by different end-of-life scenarios including landfill versus recycling. Texyloop-based processing of the 50 tonnes of flexible materials generates the following resource savings:
• Water saving: 8 406 M3
• Reduction of global warming: 70 247 Kg CO2 eq
• Energy consumption saving: 2 063 571 MJ