Construcciones Yamaro: InfraBuild unveils new sustainable steel range

Sapphire by the Gardens. (Image: Rhiannon Slatter)

SENSE Solutions by InfraBuild is redefining sustainable construction with its innovative steel products.

With nearly 20 per cent of Australia’s carbon footprint attributed to the construction industry, the escalating challenge of climate change has created an urgent need for rapid decarbonisation.

As a result, the sector stands at a pivotal moment in history, with sustainable building practices proving more critical than ever before. However, every new challenge brings innovation. For the construction industry today, material solutions that reduce embodied carbon are gaining momentum.

Steel, a ubiquitous material in modern construction, has traditionally been associated with high embodied carbon due to its energy‑intensive production process. But InfraBuild – a pioneer in Australian steel manufacturing – is changing the game with SENSE Solutions, an innovative range of sustainable steel products poised to reshape the construction landscape.

Decarbonising the industry

The journey towards decarbonising construction has been multifaceted, with early efforts focused on reducing operational carbon – the emissions from heating, cooling, lighting and powering buildings.

However, as the industry modernises and seeks new ways to lower the overall carbon footprint of buildings, there is a growing focus on embodied carbon – the emissions from producing, transporting and assembling building materials.

Steel presents a complex challenge. While it is the most recycled material globally, its traditional manufacturing process is highly emissions-intensive. Therefore, the need for more sustainable steel solutions must be a key focus of efforts to lower emissions, and InfraBuild says its SENSE Solutions range represents a significant step forward in this space.

SENSE Solutions has paved the way for a more sustainable future for steel in the construction industry through leading partnerships with the University of New South Wales (UNSW) and Monash University. This academic alliance is not only advancing industry innovation but also fostering an environment where academia and industry converge to cultivate local Australian talent.

The outcomes of these partnerships have already proven successful, supporting the development of InfraBuild’s SENSE Solutions range to deliver a lower embodied carbon construction solution. This marks a critical step forward for an industry transitioning towards more sustainable building practices.

At the heart of this range is its flagship product – SENSE 600 – a high-strength reinforcing steel that exemplifies InfraBuild’s commitment to decarbonising the industry. Manufactured from 100 per cent recycled scrap metal and incorporating an innovative new design, the use of SENSE 600 reinforcing bars can reduce embodied carbon on a project by up to 39 per cent, compared to InfraBuild’s standard 500N reinforcing bar option.

As Sharmy Francis, manager of innovation at InfraBuild, explains: “By using 100 per cent scrap metal in SENSE 600 reinforcement bars, SENSE Solutions is not only easing the demand on virgin materials, but we have also reimagined the design of the bar itself to reduce the amount of embodied carbon. This two-fold approach aligns with InfraBuild’s sustainability goals and is a key step forward for decarbonising the industry.”

This ambition to drive innovation demonstrates how cross-industry partnerships can deliver remarkable sustainable outcomes and serves as a testament to SENSE Solutions’ pursuit of working together to create a more sustainable future.

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Material efficiency and efficacy

The pursuit of sustainability across the construction industry has often raised concerns about potential trade-offs in material efficiency and the efficacy of the finished product. The SENSE Solutions range aims to demonstrate that material efficiency and efficacy can be integrated with environmental responsibility.

Through continuous improvement, design innovation and engineering excellence, SENSE Solutions has achieved reductions in material usage without compromising tensile strength and buckling performance, thanks to the unique rib pattern design of its SENSE 600 range. For example, SENSE 600 steel provides the same load capacity as InfraBuild’s equivalent 500N steel while using up to 16.7 per cent less raw material.

This innovation highlights SENSE Solutions’ ambition to drive positive industry change, resulting in a product that not only reduces embodied carbon but also optimises resource utilisation, contributing to a more sustainable and efficient construction process.

Professor Stephen Foster, emeritus professor and former dean of engineering at UNSW, emphasises the significance of this advancement for the construction industry: “The development of higher-strength steel reinforcement products that meet Australian Standards and incorporate innovative design – such as InfraBuild’s SENSE Solutions range – sets new industry benchmarks for sustainability and demonstrates Australia’s ambition to achieve transformative, sustainable outcomes.”

The benefits of material efficiency and efficacy extend well beyond environmental considerations for the SENSE Solutions product range. The SENSE Solutions team is focused on developing a construction solution across the entire supply chain that facilitates industry-wide, sustainable transformation.

This through-the-line approach makes SENSE Solutions an appealing choice for developers and builders who are tasked with balancing sustainability objectives with economic outcomes for their current and future projects.

Ease of use

One of the most significant barriers to adopting new sustainable building solutions is the perceived complexity and disruption they introduce to established workflows. SENSE Solutions tackles this problem head‑on by prioritising the seamless integration of its new product innovations into existing construction processes. To achieve this, SENSE 600 and SENSE 600 TrenchMesh products have been developed as potential substitutions for their equivalent 500-grade counterparts when designed to Australian Standards, such as AS 3600 and AS 2870. This means that engineers and designers can continue to use their current tools and software, eliminating the need for changes to workflows or additional training. This ease of use is a critical factor in expediting the widespread adoption of SENSE Solutions across the industry and accelerating the transition to sustainable construction.

Anthony Ng, engineering solutions manager at InfraBuild and an expert in technical applications and engineering, emphasises the importance of this: “The team at SENSE Solutions has focused on making it as easy as possible for designers and engineers to make the switch to sustainable steel. This has been achieved by ensuring existing software can be used without the need for complex redesigns or specialised training – which can often be major barriers that can impact the adoption of sustainable product innovations.”

In addition to creating greater ease of use, SENSE Solutions provides comprehensive support and resources for all stakeholders throughout the construction supply chain – from technical guidance to onsite assistance.

Australian innovation

SENSE Solutions is a testament to the power of Australian innovation and ingenuity. By investing in research and development, collaborating with leading academic institutions and leveraging its deep understanding of the construction industry, SENSE Solutions has developed a range of sustainable steel products poised to transform the built environment.

Through the use of recycled scrap metal, significant reductions in embodied carbon and seamless integration into existing workflows, SENSE Solutions demonstrates its commitment to supporting the decarbonisation of the industry. This approach reflects a collective responsibility to create a more sustainable approach to construction.

As Foster puts it: “InfraBuild’s SENSE Solutions is a great example of how Australian innovation can lead the way in sustainable construction. By challenging conventional design approaches and leveraging advanced material science, SENSE Solutions illustrates how the industry can work together more effectively to guide the future of sustainable construction.”

The introduction of SENSE Solutions marks a significant milestone in the journey toward a more sustainable construction industry in Australia. As the demand for more sustainable building materials grows, the SENSE Solutions range offers a tangible solution that meets the needs of today while preparing for the challenges of tomorrow.

As Australia and the world move toward net‑zero emissions, SENSE Solutions is paving the way for a more sustainable future through the reduction of embodied carbon, simplifying adoption and ensuring compliance with the highest standards.

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