SENSE 600®: A World-Leading Sustainable Reinforcing Steel

The challenge was to produce a reinforcing bar for use in concrete buildings that would be more sustainable, cost neutral or less, and easy for all players in the construction industry to adopt. Any two of these challenges are arguably readily achievable, however achieving all of them simultaneously is a considerably greater challenge, particularly when the product passes through a relatively long construction supply chain. Furthermore, there was the challenge to make a unique, internationally competitive bar that conforms to an Australian Product Standard and Australian Design Standards for building construction.

The solution was to use scrap steel exclusively to produce a higher strength bar with smaller diameters compared with conventional bars. The equivalent capacity bar with a ‘square’ cross-section and bold deformation pattern facilities its one-for-one substitution for conventional bars ensuring the mass savings are realised. Using SENSE 600® bars mean less steel is needed to carry the same load giving a reduction in a building’s carbon footprint with no cost penalty. Conformance to Australian Standards means it can be used in the same way by the construction supply chain, making the switch to SENSE 600® bars easy.

SENSE 600® being made exclusively from scrap steel and in sizes 16.7% smaller in area than conventional product results in a 39% reduction in embodied carbon when substituted for InfraBuild's conventional bars. Another measure of its sustainability is the 16.7% saving in material to carry the same load which results in the same percentage reduction in raw materials and energy consumption to produce and install the product. InfraBuild’s cost neutral pricing from its manufacturing mills mean it is cost neutral to site allowing contractors to take the economic advantage of its lighter mass for handling and installation.

While the strength and sustainability credentials of SENSE 600® are the most obvious qualities that set it apart from conventional bars, it is a number of less obvious design innovations, that makes it easy to use. The unique physical construct including bar shape, configuration and deformation pattern has led to Australian Design Registration No. 202418158 being granted and a Patent application (No. 2024205024). The innovation in this product begins with its lower mass, equivalent capacity bars. The concept of each SENSE 600® bar having the same capacity as conventional bar makes a one-to-one substitution easier because the bar configuration or spacing in a concrete element does not need to change. Material optimisation, by moving material from the transverse ribs to four longitudinal ribs and a unique ‘square’ cross-section, gives the product improved buckling properties. The bold bar deformation pattern was conceived to reduce the bond lengths required by the Australian Standard. The 16.7% lighter bar results in less deliveries to site, particularly in remote locations for structures such as wind towers and bridges, adding to the sustainability benefits of 39% less embodied carbon. Manual handling by steel fixers is also easier because of the reduced weight and steel congestion.