Case Study: ARUP – Catalysing a new supply chain for sustainable concrete
In response to the urgent need for Scope 3 decarbonisation within construction and infrastructure, Arup has taken a leading role in addressing one of the most challenging contributors to greenhouse gas emissions – concrete. Concrete accounts for approximately 9% of global emissions within the 40% contribution the construction industry makes globally. It is key to creating and maintaining Australia’s infrastructure due to its unique strength and potential 100-year design life. Making cement also requires quarrying limestone, transporting it, and heating it to extreme temperatures. The carbon-intensive nature of its primary binder, cement, necessitates innovative approaches to reduce emissions without compromising the material's inherent strength and durability. Yet for organisations, it is the hardest contributor to their carbon footprint to abate.
At Arup, we’ve focused on developing sustainable alternatives to traditional concrete by replacing cement with locally sourced, low-carbon materials. These innovations are not just theoretical but actively implemented in major infrastructure projects across Australia. We collaborate closely with materials suppliers, road authorities, project delivery authorities, and academics to re-design supply chains, enabling the widespread adoption of sustainable concrete. By leveraging our position at the intersection of research, standards setting, and project delivery, we ensure that these alternative materials are not only researched and developed but also put into practice on live projects.
One of the key strategies we've employed is substituting cement with waste products such as soft plastics, demolished waste, slag from steelmaking, stockpiled clay from quarrying, and by-products from excavated soil. These materials offer significant greenhouse gas (GHG) reductions - up to 60-80% compared to Ordinary Portland Cement. As Australia transitions to renewable electricity, traditional substitutes like coal ash are becoming less available, making these innovations even more critical.
Arup’s unique position allows us to catalyse industry-wide change. Arup adopts a collaborative approach, working closely with the supply chain, government agencies, design teams and project teams to establish a framework to unite and coordinate our initiative more efficiently. We harnessed our in-house research capabilities, strong links to universities and academia, and technical expertise to drive forward sustainable concrete solutions. With this vantage point we convened the right stakeholders so that alternative concrete is not simply theorised, but is delivered in major infrastructure projects, making a tangible, immediate impact on emissions reduction. These innovative materials are already being used in approximately AUD$5 billion worth of Australian infrastructure projects. This demonstrates that sustainable concrete is not merely a concept but a viable, scalable solution that can drive significant reductions in carbon emissions.
Outcomes:
Arup's pioneering efforts in sustainable concrete have yielded significant outcomes across multiple dimensions, impacting not only the projects directly involved but also influencing broader industry practices and regulatory frameworks.
To date, Arup has successfully facilitated the use of sustainable concrete on nine major infrastructure projects across Australia, with a combined construction value exceeding AUD $5 billion. These projects have included various forms of sustainable concrete, incorporating high levels of supplementary cementitious materials, recycled soft plastics, and recycled concrete aggregates.
The impact of these innovations on greenhouse gas (GHG) emissions is substantial. By achieving a 50% reduction in cement usage, Arup has been able to reduce GHG emissions by approximately 30% across these projects. In addition to emissions reductions, our sustainable concrete initiatives have also assisted resource use reduction. Approximately 200-400 kg of landfill material were re-utilised and sequestered per cubic meter of concrete, further enhancing the sustainability profile of the projects. Through the delivered 50% cement reduction, 10-20% were from recycled materials, reducing the demand for virgin resources, and contributing to a more circular economy. One standout example is within the Level Crossing Removal Program in Victoria, where 60,351 tonnes of concrete were used, resulting in emissions savings of 1,935 tonnes of CO₂ equivalent.
The outcomes of Arup’s sustainable concrete innovations extend beyond environmental impact; they also create new sources of business value for the company itself. The introduction of sustainable concrete as a new product has strengthened Arup's corporate portfolio, enhanced brand equity and loyalty, and allowed penetration into new markets. As clients increasingly seek to achieve their emissions reduction targets, Arup’s ability to offer tangible emissions reductions and cost savings provides a competitive advantage, positively influencing both revenue and cost structures. With government bodies like Infrastructure Australia and Infrastructure NSW recommending carbon valuations of $123 per tonne in business cases, Arup's innovations are well-positioned to drive financial value by aligning with these emerging economic drivers.
In this respect, Arup's innovation has also catalysed change across its ecosystem. Clients now have heightened expectations and are increasingly demanding sustainable alternatives in their projects. This shift has prompted at least six different cement/concrete suppliers (Alex Fraser, Boral, Delta Group, Hanson, Holcim, and Renex) to rethink their approaches to concrete. For instance, Boral has begun promoting its reduced carbon concrete, while Alex Fraser emphasises its contributions to the circular economy.
Arup’s pioneering approach positions us as a leader in decarbonising concrete on major Australian infrastructure projects. Our influence extends to regulatory frameworks, standards and specifications setting as well as implementation frameworks. Arup has been actively involved in concrete standard-setting for projects including the Western Program Alliance, Waurn Ponds Duplication, and through collaborations with Austroads, NSW DCCEEW, and the ACT Government. With Infrastructure Australia forecasting a 5-year pipeline of public infrastructure projects valued at $237 billion, and the potential for 27% of conventional materials used in roads to be replaced with recycled materials, Arup's innovations are poised to scale rapidly, influencing both industry practices and regulatory frameworks.
To date, our sustainable concrete has been used and is proposed to be used in numerous major infrastructure projects, including:
In progress:
- Victorian Level crossing removals with Western Program Alliance (WPA), Mt Derrimut Road, Old Geelong Road, Werribee Street, $589.5M
- South Geelong to Waurn Ponds Duplication, Victoria $750M
- Ovingham, South Australia level crossing removal, $196M
- South Australia Tram Grade Separation Projects, $400M
- Operations and Maintenance (SSTOM) package, $3.83B
Proposed:
- Suburban Rail Loop Work Package D
Primary Beneficiaries:
Arup’s clients, including public and private infrastructure developers, have benefited from our first mover advantage in sustainable concrete. In the low-carbon economy, our extensively tested sustainable concrete innovations will enable the continued development and maintenance of social infrastructure such as rural and regional roads and bridges, offices, hospitals, water pipelines, and more. Such infrastructure is a foundation for economic productivity and far-reaching impacts including providing equitable access to jobs, services and networks that support quality of life and the wellbeing of communities.
At least 9 government agencies have directly benefited from Arup's innovations in sustainable concrete. These agencies including Greater Metropolitan Cemeteries Trust, and the NSW Department of Climate Change Energy the Environment and Water (DCCEEW), have engaged Arup to develop and implement low carbon emissions materials use specifications and policies. The initiative has had a profound impact on the construction industry, particularly in creating and supporting new supply chains. To date, 25 organisations and circa 200 jobs have been created, opening a new supply chain to support its implementation on $5 billion of infrastructure projects. Suppliers such as Hanson, Holcim, and Alex Frazer have rethought their approach to concrete, incorporating sustainable practices into their operations. This shift is fostering a greener economy, reducing GHG emissions, and encouraging waste reduction throughout the industry.
Arup has partnered with leading academic institutions, including the University of Melbourne, RMIT, Victoria University, and Deakin University, to advance research and development in sustainable concrete. These collaborations not only enhance the technical knowledge base but also provide practical applications for world class research. Through collaborations with organisations such as MECLA and Standards Australia and providing guidance to government bodies such as the Department of Transport and Planning Victoria, Arup has played a key role in setting new benchmarks for sustainable concrete. This leadership ensures that the benefits of sustainable concrete are not limited to individual projects but are embedded within industry wide practices, driving broad, long-term environmental and economic benefits. We are currently conducting pilots with the Western Program Alliance and have a Memoranda of Understanding (MOUs) in place with another major infrastructure delivery agency. We also have a MOU in place with major concrete suppliers including Hanson, Holcim, and universities such as RMIT and the University of Melbourne. These partnerships are valued at over half a million dollars.
Leaving a Legacy:
Arup’s sustainable concrete innovations have contributed to the UNSDGs while reshaping the future of infrastructure development in Australia and beyond. The initiative directly aligns with UNSDG 9 (Industry, Innovation, and Infrastructure), as Arup’s work in sustainable concrete embodies commitment to building resilient infrastructure, promoting sustainable industrialisation, and fostering innovation. Arup is also driving transformation by developing and implementing alternative materials that reduce cement usage by up to 80% and incorporating up to 50% recycled content. This innovation not only addresses the immediate need for more sustainable materials but also sets a new standard for the industry, ensuring that infrastructure projects are both environmentally responsible and economically viable. The anticipated $200 billion, 5-year infrastructure pipeline will benefit from these advancements.
Moreover, Arup’s sustainable concrete initiative contributes significantly to UNSDG 11 (Sustainable Cities and Communities). The use of sustainable concrete is a crucial element in making cities more inclusive, safe, resilient, and sustainable. Arup’s innovation ensures essential infrastructure (roads, bridges, hospitals, and water pipelines) can be developed with a significantly reduced environmental footprint. By targeting a 70% reduction in GHG emissions from concrete elements across all Australian projects by 2035, Arup is actively contributing to the creation of sustainable cities that are better prepared to face the challenges of climate change in the present and near future. This work enhances the sustainability of urban environments but also promotes the wellbeing and quality of life for communities and Australians.
Arup’s approach also aligns with UNSDG 12 (Responsible Consumption and Production). By integrating waste materials such as slag, ash, and soft plastics into concrete production, Arup is not only reducing reliance on virgin resources but also contributing to significant waste reduction - ensuring sustainable consumption and production patterns. This approach demonstrates circular economy, minimising environmental impact through re-using and recycling materials. Furthermore, Arup’s collaboration with government agencies to develop low-carbon materials specifications and policies is fostering public-private partnerships that are essential for scaling these sustainable practices across the industry.
The success of this initiative is underpinned by strong partnerships, a key component of UNSDG 17 (Partnerships for the Goals). Arup’s sustainable concrete innovation received support by universities, suppliers, public and private infrastructure clients, road authorities, and industry associations. Arup has created a collaborative ecosystem that accelerates the adoption of sustainable concrete. These partnerships enhance policy consistency for sustainable development, ensuring that these innovations pioneered by Arup are integrated into broader industry practices.
In addition, Arup’s innovation in sustainable concrete also supports UNSDG 8 (Decent Work and Economic Growth). By fostering a market for low carbon materials, Arup is helping to create jobs and economic opportunities while ensuring that infrastructure development is aligned with the principles of sustainability. The creation of new supply chains and the involvement of 25 organisations and 200 jobs in projects is driving economic activity. Scaling is also vital for meeting the industry’s broader purpose of delivering innovative, sustainable, and socially beneficial infrastructure.
The reduction of upfront embodied carbon emissions through Arup’s innovative concrete applications embeds a lasting legacy into our infrastructure’s design life, as the materials, in most cases, cannot be altered once the structure is built. The legacy of Arup’s sustainable concrete initiative extends beyond immediate environmental benefits. It highlights a shift in perspective of sustainability in the infrastructure industry, where sustainability is no longer a secondary consideration but a core principle to be considered in all stages of a project. This is reflected in continual changes to government infrastructure standards and the adoption of greener supply chains. As Arup continues to scale this initiative, the long-term impact on GHG emissions, resource use, and economic growth will be exponential.