The challenge
Australian steelmaker InfraBuild has set an objective of becoming a low-emission, carbon-neutral steelmaker by 2030.
The company engaged thinkstep-anz to independently review the carbon footprint of their reinforcing bar and mesh products, which they manufacture using an innovative process known as ‘Warm Charging’. Our brief included understanding whether this process could be recognised as an ‘Energy-Reducing Process’ under the Green Building Council of Australia (GBCA)’s Green Star 'Design & As Built' tool.
Warm Charging
Warm Charging minimises the time between casting billets (long, square semi-finished steel products) and subsequently rolling those billets into finished products. By minimising this time, InfraBuild can use the heat retained in the cast billets to reduce the amount of time the billets spend in the reheat furnace before they are rolled into their final shape. The result: Warm Charging means less energy (natural gas) is used and associated embodied carbon emissions are significantly reduced.
What we did
We assessed four scenarios for steel production, including using Warm Charging to reduce the time that billets spend in the reheat furnace. We used Life Cycle Assessment (LCA) to calculate the reductions in embodied carbon emissions and energy. These scenarios and the resulting report were then independently verified.
Using the results of our LCA, we compared the energy savings with the GBCA’s requirements. We produced a report for GBCA setting out our findings and recommending they recognise InfraBuild’s use of Warm Charging in their Green Star ’Design & As Built’ tool.
Our study built on work we have completed with InfraBuild over several years. This includes Life Cycle Assessments (LCA), studies of product carbon footprints, InfraBuild’s original 2016 and updated 2020 Environmental Product Declarations (EPDs) and developing and publishing Material Circularity Indicators (MCI) for all products covered by their EPDs.
What we found
Warm Charging compares favourably with other processes that have received Green Star recognition. Accordingly, we recommended that the company ask the GBCA to approve the process as a way of reducing the energy needed to produce the reinforcing bar and mesh products, and the embodied carbon associated with them.
How we are enabling InfraBuild to succeed sustainably
Build market share and brand loyalty
Green Star recognition helps InfraBuild promote its reinforcing bar and mesh product’s environmental credentials to projects looking to gain a Green Star rating, and to the wider construction and infrastructure market too. The market increasingly wants to use products with lower embodied carbon footprints.
Reduce emissions – and help others do the same
Our study has confirmed the extent to which the Warm Charging process is helping InfraBuild reduce its Scope 1 (direct) emissions of greenhouse gases associated with its reinforcing products. InfraBuild is using Warm Charging as one of its pathways to reduce these emissions.
Steel is an important component of the built environment and InfraBuild’s Scope 1 emissions contribute to its customers’ Scope 3 (value chain) emissions. Building owners, specifiers and construction companies can use the Green Star recognition to reduce their Scope 3 emissions and the upfront embodied carbon locked into their buildings.
Build reputation and social licence to operate
Our work shows the local communities InfraBuild operates in, and the broader construction and infrastructure market, that the company is measuring its emissions and actively reducing them.
Act on business opportunities, reduce business risks
Our data will help the manufacturer develop future opportunities and manage and mitigate regulatory, brand and financial risks.
Attract, engage and retain employees
People increasingly want to work with and for businesses that have strong sustainability values and foster innovation and learning. InfraBuild’s investment in Warm Charging and GBCA’s recognition show existing and future employees that InfraBuild has those values and is acting on them.
Continue to improve
Our report provides a base for InfraBuild to continue to understand and act on opportunities to reduce the environmental impacts of its product. It will help the business meet its objective of being a low emission, carbon-neutral steelmaker by 2030.
June 2022