Reconsidering Sustainability  

Critically evaluating decisions in the built environment

Sponsored by Bison Innovative Products, New Millennium, and Rieder USA | By Amanda C Voss, MPP

Photo courtesy of Rieder USA/Ditz Fejer

New advances in glassfibre reinforced concrete (GRC) elements are defeating old conceptions of concrete.

 

“May your choices reflect your hopes, not your fears.” — Nelson Mandela

Greenwashing. A pejorative label that no design professional, specifier, or construction expert ever wants leveled at a project. Greenwashing creates the impression of sustainability through false or misleading claims. Unfortunately, greenwashing is a rising trend. Growing environmental awareness and demand for sustainable products have incentivized the use of the label “green.” While at its core it is a matter of “doing what you say you are doing, or are going to do,” in practice it is far from that simple.

Managing the risk of greenwashing is challenging and complex. Adding to the complexity, poorly defined and expansive terms such as “green” create peril in decision making because they can mean many different things. Technical terms specific to carbon reduction and impacts, like “net zero,” have created further confusion in the marketplace.  “Every practitioner (and consumer) applies their own lens of experience to these terms, which can vary widely in different geographic markets,” writes Nicole DeNamur, Esq., Owner, Sustainable Strategies. “For example, a ‘green’ building in Seattle may vary from one in Kansas City, which may vary from one in Atlanta, based on factors such as market demand, geographic limitations, availability of products and supply chain issues, government incentives, and many others.”

In the face of these difficulties, the design professional can be assured that there are reliable tools and strategies. These tools enable confident decision-making for the built environment. Across a diverse range of products and materials, using verifications and certifications, and weighing the benefits of the product itself, allows the professional to capture true sustainability and meet project performance goals.

Photo: Kyle J Caldwell; courtesy of Bison Innovative Products

Identifying the essential qualities of truly sustainable products becomes clearer through understanding independent certifications.

 

Strategies for Avoiding Greenwashing

Assessing Materials at their Source

Outdoor decks connect residents to the natural environment using natural materials, such as wood and stone, and incorporate vegetation and greenery into an individual’s regular routine through the use of planter cubes and pots. This connection brings a host of sustainable and wellness benefits. Regular interactions with the outdoors are proven to lower blood pressure, reduce stress, expedite healing, and improve a person’s mood and focus. From utilizing unused space in the city, upgrading a porch or backyard in the suburbs, or creating a luxurious oasis by the sea, elevated deck systems can be a solution for a variety of projects while creating valuable outdoor space.

The modular design of surface materials and accessories in elevated or pedestal decks allows designers to achieve an abundance of different design visions without the need for custom or costly materials. Deck materials can accommodate any project’s specific and particular needs. Pedestal decks can be used in a variety of spaces: balconies, rooftops, and on-grade applications. Versatile, adjustable pedestal deck systems can be utilized over any structural surface—on bare structural decks, rooftop decks, roof membranes, green roofs, terraces, compacted grade, pavement, pool surrounds, or water features. Modular and versatile deck systems provide designers the flexibility to create unique and beautiful rooftop environments and outdoor spaces.

Enhancing outdoor space and the connection to nature is a definitive sustainability win. However, how can the design professional make sure that the materials they use also support the design intent?

This is where third-party verifications become paramount. Many certification programs require independent verification, including documentation reviews, site visits, and performance testing. The third-party verification process enhances credibility, ensures compliance, and helps prevent misleading sustainability claims, often referred to as “greenwashing.” 

Manufacturers of wood tiles and products can associate with governing groups such as the Forest Stewardship Council® (FSC) to ensure quality standards and practices of wood acquisition and plantation farming. FSC®-certified wood, used in certain outdoor decking products, comes from forests certified by the Forest Stewardship Council® to meet high global standards for forest sustainability. FSC® certification assures that labeled wood products have positive environmental attributes and are backed by a global system of verification. Additionally, wood material manufacturers can commit to meeting the Lacey Act’s objectives, which prevent illegally sourced wood from being trafficked in the United States. Manufacturers can demonstrate a chain of custody, with global partners who support these core values and meet or exceed the standards of environmental management. Designated sources utilize a select method where only mature trees are harvested, leaving a vast majority of the forest intact. This also ensures that project material has not knowingly been transported, sold, received, or purchased from illegally taken or sourced trees. Additional standards include meeting FAS One Face (F1F) Standards as allowed for by the NHLA (National Hardwood Lumber Association).

Certain manufacturers are taking the sustainability of outdoor deck materials one step further, engineering planks and tiles from remnants or shorts leftover from other milling operations. This method demonstrates that wood tiles can be crafted from premium-grade remnants to preserve the economic viability of rainforest hardwoods. For elevated deck systems, pedestals and supports can be made with high-density polypropylene plastic, comprised of 20% post-industrial recycled content, that are 100% recyclable. Deck supports create level rooftop decks over sloped surfaces. Pedestals elevate and support Wood Tiles, Concrete Pavers, Site Furnishings, and a variety of other surfaces.

Leading manufacturers are not only offering verifiable chain of custody on materials, but they are also making advances in waste capture. This brings more closed-loop products to market.

Utilizing Recaptured and Recycled Material

An undeniable element of true sustainability is the ability to maintain viable growth while avoiding depletion of resources. Construction and demolition materials are recognized as one of the largest components of the solid waste stream in the U.S., according to a study at the University of Florida by the Department of Environmental Engineering Sciences, Engineering School of Sustainable Infrastructure and Environment. The construction industry is responsible for over 30% of the extraction of natural resources, as well as 25% of all solid waste generated in the world. This consumption of materials and production of waste from the building sector is due to a linear economic model that takes, makes, and then disposes of materials at the end of their life or service. The governing assumption under a traditional, linear view is that products and materials assembled for a one-time use don’t retain any potential for reuse. 

However, a paradigm shift is occurring in the construction industry at large with the adoption of a Circular Economy (CE) model. Under a CE, materials exist within a closed loop and have a retained value. This promotes the maximum reuse or recycling of materials, goods, and components in order to decrease waste generation to the largest possible extent. Applying the principles of a CE avoids material waste, preserves natural resources, and works seamlessly to address a project’s sustainability goals. Often, using products and materials that are recycled or reusable also improves the health, welfare, and safety of occupants. Products that embrace CE are available in multiple categories.

Photo courtesy of Rieder USA/Ditz Fejer

The assurance from verification, certification, and inherent material properties can ease the stress surrounding decision-making for sustainable projects.

 

The construction sector has both the potential and the responsibility to drive change in sustainability and eco-friendly building practices. A zero-waste strategy, by definition, creates true sustainability.

To reduce waste in the production of glass fiber reinforced concrete facade elements and minimize environmental impact, an innovative facade concept of using residual materials from concrete was developed using data analysis and computer-generated design. Digital software tracks leftover materials and creates project-specific design options for facades. The software uses already fabricated scrap pieces as the basis to generate a multiplicity of potential designs. The project transforms irregular, non-uniform stocks of concrete offcuts into new forms, finding beauty and intricacy in neglected waste. By combining the logic of the quilt with customized shape and pattern detection, the software, in effect, uses big data to tackle big waste, creating a search engine to find custom material solutions.

The 13-millimeter-thick glass fiber reinforced concrete (GRC) elements are durable, low-maintenance, and robust. This not only conserves resources but also contributes significantly to energy efficiency. GRC also combines aesthetic, technical, and ecological benefits: non-combustible, weather-resistant, long-lasting, large panel sizes, 3D shapes, and a wide range of colors, textures, and formats.

Material examples, like this sustainable facade solution, offer the creation of sustainable building elements and enable a project’s active contribution to the energy revolution.

Understanding a Product’s Lifecycle

Fabricated products, like steel deck and open-web steel joists, require Environmental Product Declarations (EPDs). These are third-party verifications that compare information across different manufacturers in the same product category. In addition to product-specific EPDs, companies like New Millennium go further by having plant-specific EPDs.

EPD reports are standardized, verified documents that transparently present credible information about a product’s impact on the environment. They allow the design team to communicate, compare, and make informed decisions. EPDs follow the ISO14025 standard. These published standards simplify specification. EPDs may report a variety of life cycle impacts, including global warming potential, acidification, eutrophication, ozone depletion, and smog formation.

An EPD is based upon the information from a Life Cycle Assessment (LCA) study. The EPD report includes a summary of LCA results, environmental impact data, and other relevant information. LCA is a systematic and comprehensive methodology used to evaluate and quantify the environmental impacts of a product over its entire life cycle, from raw material extraction and production to use, end-of-life disposal, and potentially recycling or reuse. An LCA is usually made for a specific characteristic unit, or quantity, of a product and a specific set of life cycle stages.

Comparative LCAs and EPDs for steel, as an example, are revelatory. Steel is the most recycled material in the world, according to the World Steel Association (WSA). New technology in electric arc furnace (EAF) steel mills uses recycled ferrous, or steel scrap, as the single-largest raw material input in the production of new finished steel products. In 2024, 82% of the raw materials used in an EAF furnace to produce steel were recycled ferrous scrap and internally produced iron. This is in contrast to traditional blast furnace steelmaking, where the proportion of recycled ferrous scrap has been between 25% and 35%. EAF steelmaking technology generates a fraction of the carbon emissions produced and energy intensity required by traditional blast furnace steelmaking technology. This means EAF-produced steel has a highly favorable LCA.

Photo courtesy of New Millennium

This acoustical roof deck with high-performance coating was selected by In-Situ Architecture at the Westside Natatorium in El Paso, Texas. An EPD provides insights into potential environmental impacts the product may have, including the global warming potential of embodied carbon. Steel has always been a leading material for safe, sustainable construction.

 

LCAs track products to end of life, asking the important question about what happens to materials at demolition. At a building’s end-of-use, there is only one structural material salvaged. Steel is recovered, reused, and recycled. The US has a consistent supply chain of recycled scrap material. In addition to building-related steel like structural, reinforcing, and appliances, materials come from automobiles and industrial containers. The result is that less than 3% of steel goes to a landfill at the end.

EPDs also reveal the culture of the manufacturer, reporting on commitments to providing safe and healthy working conditions for the prevention of work-related injuries and illness; protections for the environment, by preventing pollution and conserving natural resources; and contributions to the communities in which they operate, by acting with integrity and fulfilling compliance obligations. This indicates that the manufacturer strives to incorporate sound environmental, health, and safety practices into their daily decisions.

Commitment to sustainability does not spell the end of building and design. Rather, by applying sustainable goals to the construction supply chain, the focus turns on the integration of environmental considerations, including material flow reduction and the minimization of inadvertent negative consequences of the production and consumption processes.

 

The Nexus of Energy and Sustainability

Addressing Energy Consumption

The sustainability of a product begins with its materials. However, those materials undertake a journey to the finished product. The steps in that transformation can help or hinder sustainability goals.

The production of sustainable steel starts with recycled content. Reducing energy consumption is another key to sustainability. A major innovation for steel manufacturing is the evolution of Electric Arc Furnaces (EAF) from Blast Furnaces (BOF). The latter uses iron ore and coke as the primary fuel, emitting large amounts of carbon dioxide. This antiquated approach is being replaced by EAFs that use recycled scrap material and electricity as their main source of energy. These facilities are smaller, cleaner, and cut production time versus aging BOFs.

Image courtesy of New Millennium

A comparison of EAF and blast furnace technology.

 

U.S. EAF mills generate a fraction of the carbon emissions produced and energy intensity required by blast furnace steelmaking. EAFs produce substantially fewer emissions – 75% less carbon emissions – and have 78% less energy usage than traditional blast furnace producers worldwide. U.S. SDI EAF mills use recycled metal to produce new steel, facilitating lower emissions, energy, waste, and water usage.

Flat roll, bar, and structural shapes are produced with significantly less energy. By connecting the casting and rolling processes in flat roll mills, EAF mills roll slabs into steel coils while the steel is still hot, requiring significantly less energy compared to traditional blast furnace technology, which typically requires reheating slabs before rolling.

Another key metric for analyzing product sustainability is Global Warming Potential (GWP), otherwise known as “Embodied Carbon.” It is the potential of a greenhouse gas to trap heat in the atmosphere that is increasing the natural greenhouse gas effect. U.S. EAF steel mills recently announced third-party verified science-based greenhouse gas emissions targets in alignment with the Paris Agreement. This sets a 2050 emissions intensity target for steel mills of 0.12 metric tons of CO₂e per metric ton of hot rolled steel produced. Interim 2030 emissions intensity target of 0.80 metric tons of CO₂e per metric ton of hot rolled steel produced, representing a 15% reduction, compared to 2022 as a base year. These new targets were established using GSCC’s Steel Climate Standard, which includes key GHG emissions through hot rolling from Scope 1, Scope 2, and upstream Scope 3 categories. The GSCC Steel Climate Standard science-based emissions target certification is aligned with the Paris Agreement’s goals and with the International Energy Agency’s Net Zero by 2050.

Innovative paths are transforming the sources that power steel mills to meet these goals. The US is among the world leaders in sustainable steel production. Domestic steel companies may use 25% of the energy needed per metric ton compared with world steel averages.

Biocarbon is a renewable material used to melt scrap at EAF facilities in the production process. This is an alternative to fossil-fuel-based carbon sources like coal. Energy created by biocarbon facilities is driven by wind energy, also offsetting Scope 1 Carbon Emissions. Another decarbonization strategy for the steel industry is nuclear energy. Data centers are already employing this approach; Microsoft and Google are planning small modular reactors to power their data centers, as demand escalates to fuel Artificial Intelligence power needs. Nuclear energy produces carbon-free energy in a relatively small footprint compared to typical power plants.

Photo courtesy of Rieder USA/Ditz Fejer

Concrete skins can be in large format, slats, or three-dimensional elements. Innovative programs allow for waste capture that transforms leftover materials into a precisely designed facade, all from off-cuts.

 

Reducing Carbon Footprints

The construction industry is increasingly prioritizing sustainability, with a strong focus on reducing environmental impact and improving energy efficiency. This focus is rising to meet the growing demand for innovative, eco-friendly building materials that not only satisfy sustainability requirements but also offer aesthetic and functional advantages.

Sustainable facade elements made from glass fiber reinforced concrete (GRC) provide a unique combination of technical performance and environmental benefits. “The construction industry doesn’t just have the potential to change — it has a responsibility. I couldn’t live with knowing we stood by while the planet suffered, despite knowing better,” says Wolfgang Rieder. “That’s why we assessed our sustainability performance, calculated our CO₂ footprint, and identified the key levers for a climate strategy. Now we’re putting that plan into action, measuring progress, and continuing to improve—step by step toward climate neutrality.”

New techniques that marry digital technology and manufacturing have pioneered the development of CO₂-reduced concrete matrices, significantly lowering the carbon footprint of facade elements. This innovative approach aligns with the global shift toward greener construction practices and helps meet climate targets.

The development and impact of CO₂-reduced concrete also raises a vital question: Can concrete be made without cement? The gradual replacement of cement in the concrete matrix is just one of several ways of meeting climate neutrality for this common building ingredient. Innovation through new material combinations, digitalization, the radical reduction of waste, and the extension of the useful life of products and buildings are the driving forces in the transition to become a climate-positive material.

A more ecological construction industry that is economical at the same time can be achieved not only by converting and revitalizing existing buildings, but also through more durable building materials. The model for revolutionizing concrete is the opus caementicium, the cast masonry used by the Romans. The Romans added pozzolana as a binder, which gave the material a durability that often exceeds that of modern concrete. This durability remains on display today, illustrated by such famous examples as the Pantheon in Rome, built at the beginning of the 2nd century.

The cement used in new facade panels is gradually being replaced by natural pozzolana, which has significantly lower CO₂- emissions during production. GRC elements with reduced cement content have 50 percent of the cement in the concrete matrix replaced by alternative materials, resulting in a CO₂-reduction of 30 percent.

Demonstrating Conservation Throughout Production

Another tool for the design professional weighing sustainability claims is assessing whether a manufacturer is dedicated to providing products that are manufactured in an environmentally sensitive and efficient manner. Conservation measures can occur at every stage of business practices: office and warehouse operations, product design, manufacturing, packaging, and delivery.

Pedestal and modular deck systems allow designers to recapture wasted space and provide green roof environments that are functional and beautiful, while helping support the environment. Besides recycled and recyclable content, modular pedestal decks provide passive solar heating and cooling. Pedestal deck systems can help reduce the cooling loads of the building structure because they are air permeable.

Photo courtesy of Bison Innovative Products

Incorporating raised decks in a design brings tested, innovative solutions to create rooftop decks, plazas, terraces, pop-up parks, and other architectural features. With the right products, these designs are also maintenance-free with a low-maintenance surface.

 

When combined with pedestals, wood tiles offer one of the most labor- and cost-efficient methods of creating a flat, level deck over a sloped sub-surface. Manufacturers today offer domestically made pedestals constructed out of high-density polypropylene plastic, comprised of 20% post-industrial recycled content, that are also 100% recyclable. Pedestal deck support systems are impervious to water, mold, and freeze-thaw cycles, ensuring durability and longevity. Using a gravity system, the supports protect roofing membranes and waterproofing and do not damage or harm the surface below. Pedestal systems can support decks over occupied space, allowing cavity space for electrical systems, ductwork, and irrigation. Deck supports are designed to elevate a variety of surfaces, including granite or concrete pavers, wood tiles, composite materials, fiberglass grating, or conventional wood decking systems.

Leading manufacturers have created wood deck tiles that are commercial grade and available in standard and FSC® Certified options. Wood tiles are crafted from premium-grade remnants and material harvested in an environmentally responsible method and are designed to preserve the economic viability of rainforest hardwoods. Wood species include fused bamboo, cumaru, garapa, ipe, itauba, massaranduba, and tigerwood. Tropical hardwoods contain a rich variety of graining and coloration, are exceptionally dense, and naturally resistant to insects. These commercial-grade, high-density wood species weather well, allowing for minimal maintenance. If maintaining the wood color is desired, wood tiles can be periodically cleaned and sealed. Left to weather naturally, the wood tiles will develop a silvery-gray patina. Weighing one-third as much as concrete tiles, wood tiles are a good alternative when surface material weight is a factor.

Pedestal and modular decks can help to achieve prerequisites and accumulate points for project certification. Using deck and exterior products that have a modular design for surface materials and accessories allows designers to fulfill an abundance of different design visions without the need for custom or costly materials. Harnessing the power of recycled and certified materials, modular decks bring additional advantages to the table. Offering tremendous design flexibility, coupled with ease of installation, adjustable pedestal deck systems provide a unique and viable alternative to traditional deck building materials and methods.

Photo courtesy of Rieder USA/Ditz Fejer

New advances in glassfibre reinforced concrete (GRC) elements are defeating old conceptions of concrete.

 

“May your choices reflect your hopes, not your fears.” — Nelson Mandela

Greenwashing. A pejorative label that no design professional, specifier, or construction expert ever wants leveled at a project. Greenwashing creates the impression of sustainability through false or misleading claims. Unfortunately, greenwashing is a rising trend. Growing environmental awareness and demand for sustainable products have incentivized the use of the label “green.” While at its core it is a matter of “doing what you say you are doing, or are going to do,” in practice it is far from that simple.

Managing the risk of greenwashing is challenging and complex. Adding to the complexity, poorly defined and expansive terms such as “green” create peril in decision making because they can mean many different things. Technical terms specific to carbon reduction and impacts, like “net zero,” have created further confusion in the marketplace.  “Every practitioner (and consumer) applies their own lens of experience to these terms, which can vary widely in different geographic markets,” writes Nicole DeNamur, Esq., Owner, Sustainable Strategies. “For example, a ‘green’ building in Seattle may vary from one in Kansas City, which may vary from one in Atlanta, based on factors such as market demand, geographic limitations, availability of products and supply chain issues, government incentives, and many others.”

In the face of these difficulties, the design professional can be assured that there are reliable tools and strategies. These tools enable confident decision-making for the built environment. Across a diverse range of products and materials, using verifications and certifications, and weighing the benefits of the product itself, allows the professional to capture true sustainability and meet project performance goals.

Photo: Kyle J Caldwell; courtesy of Bison Innovative Products

Identifying the essential qualities of truly sustainable products becomes clearer through understanding independent certifications.

 

Strategies for Avoiding Greenwashing

Assessing Materials at their Source

Outdoor decks connect residents to the natural environment using natural materials, such as wood and stone, and incorporate vegetation and greenery into an individual’s regular routine through the use of planter cubes and pots. This connection brings a host of sustainable and wellness benefits. Regular interactions with the outdoors are proven to lower blood pressure, reduce stress, expedite healing, and improve a person’s mood and focus. From utilizing unused space in the city, upgrading a porch or backyard in the suburbs, or creating a luxurious oasis by the sea, elevated deck systems can be a solution for a variety of projects while creating valuable outdoor space.

The modular design of surface materials and accessories in elevated or pedestal decks allows designers to achieve an abundance of different design visions without the need for custom or costly materials. Deck materials can accommodate any project’s specific and particular needs. Pedestal decks can be used in a variety of spaces: balconies, rooftops, and on-grade applications. Versatile, adjustable pedestal deck systems can be utilized over any structural surface—on bare structural decks, rooftop decks, roof membranes, green roofs, terraces, compacted grade, pavement, pool surrounds, or water features. Modular and versatile deck systems provide designers the flexibility to create unique and beautiful rooftop environments and outdoor spaces.

Enhancing outdoor space and the connection to nature is a definitive sustainability win. However, how can the design professional make sure that the materials they use also support the design intent?

This is where third-party verifications become paramount. Many certification programs require independent verification, including documentation reviews, site visits, and performance testing. The third-party verification process enhances credibility, ensures compliance, and helps prevent misleading sustainability claims, often referred to as “greenwashing.” 

Manufacturers of wood tiles and products can associate with governing groups such as the Forest Stewardship Council® (FSC) to ensure quality standards and practices of wood acquisition and plantation farming. FSC®-certified wood, used in certain outdoor decking products, comes from forests certified by the Forest Stewardship Council® to meet high global standards for forest sustainability. FSC® certification assures that labeled wood products have positive environmental attributes and are backed by a global system of verification. Additionally, wood material manufacturers can commit to meeting the Lacey Act’s objectives, which prevent illegally sourced wood from being trafficked in the United States. Manufacturers can demonstrate a chain of custody, with global partners who support these core values and meet or exceed the standards of environmental management. Designated sources utilize a select method where only mature trees are harvested, leaving a vast majority of the forest intact. This also ensures that project material has not knowingly been transported, sold, received, or purchased from illegally taken or sourced trees. Additional standards include meeting FAS One Face (F1F) Standards as allowed for by the NHLA (National Hardwood Lumber Association).

Certain manufacturers are taking the sustainability of outdoor deck materials one step further, engineering planks and tiles from remnants or shorts leftover from other milling operations. This method demonstrates that wood tiles can be crafted from premium-grade remnants to preserve the economic viability of rainforest hardwoods. For elevated deck systems, pedestals and supports can be made with high-density polypropylene plastic, comprised of 20% post-industrial recycled content, that are 100% recyclable. Deck supports create level rooftop decks over sloped surfaces. Pedestals elevate and support Wood Tiles, Concrete Pavers, Site Furnishings, and a variety of other surfaces.

Leading manufacturers are not only offering verifiable chain of custody on materials, but they are also making advances in waste capture. This brings more closed-loop products to market.

Utilizing Recaptured and Recycled Material

An undeniable element of true sustainability is the ability to maintain viable growth while avoiding depletion of resources. Construction and demolition materials are recognized as one of the largest components of the solid waste stream in the U.S., according to a study at the University of Florida by the Department of Environmental Engineering Sciences, Engineering School of Sustainable Infrastructure and Environment. The construction industry is responsible for over 30% of the extraction of natural resources, as well as 25% of all solid waste generated in the world. This consumption of materials and production of waste from the building sector is due to a linear economic model that takes, makes, and then disposes of materials at the end of their life or service. The governing assumption under a traditional, linear view is that products and materials assembled for a one-time use don’t retain any potential for reuse. 

However, a paradigm shift is occurring in the construction industry at large with the adoption of a Circular Economy (CE) model. Under a CE, materials exist within a closed loop and have a retained value. This promotes the maximum reuse or recycling of materials, goods, and components in order to decrease waste generation to the largest possible extent. Applying the principles of a CE avoids material waste, preserves natural resources, and works seamlessly to address a project’s sustainability goals. Often, using products and materials that are recycled or reusable also improves the health, welfare, and safety of occupants. Products that embrace CE are available in multiple categories.

Photo courtesy of Rieder USA/Ditz Fejer

The assurance from verification, certification, and inherent material properties can ease the stress surrounding decision-making for sustainable projects.

 

The construction sector has both the potential and the responsibility to drive change in sustainability and eco-friendly building practices. A zero-waste strategy, by definition, creates true sustainability.

To reduce waste in the production of glass fiber reinforced concrete facade elements and minimize environmental impact, an innovative facade concept of using residual materials from concrete was developed using data analysis and computer-generated design. Digital software tracks leftover materials and creates project-specific design options for facades. The software uses already fabricated scrap pieces as the basis to generate a multiplicity of potential designs. The project transforms irregular, non-uniform stocks of concrete offcuts into new forms, finding beauty and intricacy in neglected waste. By combining the logic of the quilt with customized shape and pattern detection, the software, in effect, uses big data to tackle big waste, creating a search engine to find custom material solutions.

The 13-millimeter-thick glass fiber reinforced concrete (GRC) elements are durable, low-maintenance, and robust. This not only conserves resources but also contributes significantly to energy efficiency. GRC also combines aesthetic, technical, and ecological benefits: non-combustible, weather-resistant, long-lasting, large panel sizes, 3D shapes, and a wide range of colors, textures, and formats.

Material examples, like this sustainable facade solution, offer the creation of sustainable building elements and enable a project’s active contribution to the energy revolution.

Understanding a Product’s Lifecycle

Fabricated products, like steel deck and open-web steel joists, require Environmental Product Declarations (EPDs). These are third-party verifications that compare information across different manufacturers in the same product category. In addition to product-specific EPDs, companies like New Millennium go further by having plant-specific EPDs.

EPD reports are standardized, verified documents that transparently present credible information about a product’s impact on the environment. They allow the design team to communicate, compare, and make informed decisions. EPDs follow the ISO14025 standard. These published standards simplify specification. EPDs may report a variety of life cycle impacts, including global warming potential, acidification, eutrophication, ozone depletion, and smog formation.

An EPD is based upon the information from a Life Cycle Assessment (LCA) study. The EPD report includes a summary of LCA results, environmental impact data, and other relevant information. LCA is a systematic and comprehensive methodology used to evaluate and quantify the environmental impacts of a product over its entire life cycle, from raw material extraction and production to use, end-of-life disposal, and potentially recycling or reuse. An LCA is usually made for a specific characteristic unit, or quantity, of a product and a specific set of life cycle stages.

Comparative LCAs and EPDs for steel, as an example, are revelatory. Steel is the most recycled material in the world, according to the World Steel Association (WSA). New technology in electric arc furnace (EAF) steel mills uses recycled ferrous, or steel scrap, as the single-largest raw material input in the production of new finished steel products. In 2024, 82% of the raw materials used in an EAF furnace to produce steel were recycled ferrous scrap and internally produced iron. This is in contrast to traditional blast furnace steelmaking, where the proportion of recycled ferrous scrap has been between 25% and 35%. EAF steelmaking technology generates a fraction of the carbon emissions produced and energy intensity required by traditional blast furnace steelmaking technology. This means EAF-produced steel has a highly favorable LCA.

Photo courtesy of New Millennium

This acoustical roof deck with high-performance coating was selected by In-Situ Architecture at the Westside Natatorium in El Paso, Texas. An EPD provides insights into potential environmental impacts the product may have, including the global warming potential of embodied carbon. Steel has always been a leading material for safe, sustainable construction.

 

LCAs track products to end of life, asking the important question about what happens to materials at demolition. At a building’s end-of-use, there is only one structural material salvaged. Steel is recovered, reused, and recycled. The US has a consistent supply chain of recycled scrap material. In addition to building-related steel like structural, reinforcing, and appliances, materials come from automobiles and industrial containers. The result is that less than 3% of steel goes to a landfill at the end.

EPDs also reveal the culture of the manufacturer, reporting on commitments to providing safe and healthy working conditions for the prevention of work-related injuries and illness; protections for the environment, by preventing pollution and conserving natural resources; and contributions to the communities in which they operate, by acting with integrity and fulfilling compliance obligations. This indicates that the manufacturer strives to incorporate sound environmental, health, and safety practices into their daily decisions.

Commitment to sustainability does not spell the end of building and design. Rather, by applying sustainable goals to the construction supply chain, the focus turns on the integration of environmental considerations, including material flow reduction and the minimization of inadvertent negative consequences of the production and consumption processes.

 

The Nexus of Energy and Sustainability

Addressing Energy Consumption

The sustainability of a product begins with its materials. However, those materials undertake a journey to the finished product. The steps in that transformation can help or hinder sustainability goals.

The production of sustainable steel starts with recycled content. Reducing energy consumption is another key to sustainability. A major innovation for steel manufacturing is the evolution of Electric Arc Furnaces (EAF) from Blast Furnaces (BOF). The latter uses iron ore and coke as the primary fuel, emitting large amounts of carbon dioxide. This antiquated approach is being replaced by EAFs that use recycled scrap material and electricity as their main source of energy. These facilities are smaller, cleaner, and cut production time versus aging BOFs.

Image courtesy of New Millennium

A comparison of EAF and blast furnace technology.

 

U.S. EAF mills generate a fraction of the carbon emissions produced and energy intensity required by blast furnace steelmaking. EAFs produce substantially fewer emissions – 75% less carbon emissions – and have 78% less energy usage than traditional blast furnace producers worldwide. U.S. SDI EAF mills use recycled metal to produce new steel, facilitating lower emissions, energy, waste, and water usage.

Flat roll, bar, and structural shapes are produced with significantly less energy. By connecting the casting and rolling processes in flat roll mills, EAF mills roll slabs into steel coils while the steel is still hot, requiring significantly less energy compared to traditional blast furnace technology, which typically requires reheating slabs before rolling.

Another key metric for analyzing product sustainability is Global Warming Potential (GWP), otherwise known as “Embodied Carbon.” It is the potential of a greenhouse gas to trap heat in the atmosphere that is increasing the natural greenhouse gas effect. U.S. EAF steel mills recently announced third-party verified science-based greenhouse gas emissions targets in alignment with the Paris Agreement. This sets a 2050 emissions intensity target for steel mills of 0.12 metric tons of CO₂e per metric ton of hot rolled steel produced. Interim 2030 emissions intensity target of 0.80 metric tons of CO₂e per metric ton of hot rolled steel produced, representing a 15% reduction, compared to 2022 as a base year. These new targets were established using GSCC’s Steel Climate Standard, which includes key GHG emissions through hot rolling from Scope 1, Scope 2, and upstream Scope 3 categories. The GSCC Steel Climate Standard science-based emissions target certification is aligned with the Paris Agreement’s goals and with the International Energy Agency’s Net Zero by 2050.

Innovative paths are transforming the sources that power steel mills to meet these goals. The US is among the world leaders in sustainable steel production. Domestic steel companies may use 25% of the energy needed per metric ton compared with world steel averages.

Biocarbon is a renewable material used to melt scrap at EAF facilities in the production process. This is an alternative to fossil-fuel-based carbon sources like coal. Energy created by biocarbon facilities is driven by wind energy, also offsetting Scope 1 Carbon Emissions. Another decarbonization strategy for the steel industry is nuclear energy. Data centers are already employing this approach; Microsoft and Google are planning small modular reactors to power their data centers, as demand escalates to fuel Artificial Intelligence power needs. Nuclear energy produces carbon-free energy in a relatively small footprint compared to typical power plants.

Photo courtesy of Rieder USA/Ditz Fejer

Concrete skins can be in large format, slats, or three-dimensional elements. Innovative programs allow for waste capture that transforms leftover materials into a precisely designed facade, all from off-cuts.

 

Reducing Carbon Footprints

The construction industry is increasingly prioritizing sustainability, with a strong focus on reducing environmental impact and improving energy efficiency. This focus is rising to meet the growing demand for innovative, eco-friendly building materials that not only satisfy sustainability requirements but also offer aesthetic and functional advantages.

Sustainable facade elements made from glass fiber reinforced concrete (GRC) provide a unique combination of technical performance and environmental benefits. “The construction industry doesn’t just have the potential to change — it has a responsibility. I couldn’t live with knowing we stood by while the planet suffered, despite knowing better,” says Wolfgang Rieder. “That’s why we assessed our sustainability performance, calculated our CO₂ footprint, and identified the key levers for a climate strategy. Now we’re putting that plan into action, measuring progress, and continuing to improve—step by step toward climate neutrality.”

New techniques that marry digital technology and manufacturing have pioneered the development of CO₂-reduced concrete matrices, significantly lowering the carbon footprint of facade elements. This innovative approach aligns with the global shift toward greener construction practices and helps meet climate targets.

The development and impact of CO₂-reduced concrete also raises a vital question: Can concrete be made without cement? The gradual replacement of cement in the concrete matrix is just one of several ways of meeting climate neutrality for this common building ingredient. Innovation through new material combinations, digitalization, the radical reduction of waste, and the extension of the useful life of products and buildings are the driving forces in the transition to become a climate-positive material.

A more ecological construction industry that is economical at the same time can be achieved not only by converting and revitalizing existing buildings, but also through more durable building materials. The model for revolutionizing concrete is the opus caementicium, the cast masonry used by the Romans. The Romans added pozzolana as a binder, which gave the material a durability that often exceeds that of modern concrete. This durability remains on display today, illustrated by such famous examples as the Pantheon in Rome, built at the beginning of the 2nd century.

The cement used in new facade panels is gradually being replaced by natural pozzolana, which has significantly lower CO₂- emissions during production. GRC elements with reduced cement content have 50 percent of the cement in the concrete matrix replaced by alternative materials, resulting in a CO₂-reduction of 30 percent.

Demonstrating Conservation Throughout Production

Another tool for the design professional weighing sustainability claims is assessing whether a manufacturer is dedicated to providing products that are manufactured in an environmentally sensitive and efficient manner. Conservation measures can occur at every stage of business practices: office and warehouse operations, product design, manufacturing, packaging, and delivery.

Pedestal and modular deck systems allow designers to recapture wasted space and provide green roof environments that are functional and beautiful, while helping support the environment. Besides recycled and recyclable content, modular pedestal decks provide passive solar heating and cooling. Pedestal deck systems can help reduce the cooling loads of the building structure because they are air permeable.

Photo courtesy of Bison Innovative Products

Incorporating raised decks in a design brings tested, innovative solutions to create rooftop decks, plazas, terraces, pop-up parks, and other architectural features. With the right products, these designs are also maintenance-free with a low-maintenance surface.

 

When combined with pedestals, wood tiles offer one of the most labor- and cost-efficient methods of creating a flat, level deck over a sloped sub-surface. Manufacturers today offer domestically made pedestals constructed out of high-density polypropylene plastic, comprised of 20% post-industrial recycled content, that are also 100% recyclable. Pedestal deck support systems are impervious to water, mold, and freeze-thaw cycles, ensuring durability and longevity. Using a gravity system, the supports protect roofing membranes and waterproofing and do not damage or harm the surface below. Pedestal systems can support decks over occupied space, allowing cavity space for electrical systems, ductwork, and irrigation. Deck supports are designed to elevate a variety of surfaces, including granite or concrete pavers, wood tiles, composite materials, fiberglass grating, or conventional wood decking systems.

Leading manufacturers have created wood deck tiles that are commercial grade and available in standard and FSC® Certified options. Wood tiles are crafted from premium-grade remnants and material harvested in an environmentally responsible method and are designed to preserve the economic viability of rainforest hardwoods. Wood species include fused bamboo, cumaru, garapa, ipe, itauba, massaranduba, and tigerwood. Tropical hardwoods contain a rich variety of graining and coloration, are exceptionally dense, and naturally resistant to insects. These commercial-grade, high-density wood species weather well, allowing for minimal maintenance. If maintaining the wood color is desired, wood tiles can be periodically cleaned and sealed. Left to weather naturally, the wood tiles will develop a silvery-gray patina. Weighing one-third as much as concrete tiles, wood tiles are a good alternative when surface material weight is a factor.

Pedestal and modular decks can help to achieve prerequisites and accumulate points for project certification. Using deck and exterior products that have a modular design for surface materials and accessories allows designers to fulfill an abundance of different design visions without the need for custom or costly materials. Harnessing the power of recycled and certified materials, modular decks bring additional advantages to the table. Offering tremendous design flexibility, coupled with ease of installation, adjustable pedestal deck systems provide a unique and viable alternative to traditional deck building materials and methods.

CASE STUDY

Project: Visionaire Apartments, New York City
Architect: Pelli Clarke Pelli
Contractor: Albanese Development Corporation

Photo courtesy of Bison Innovative Products

This LEED Platinum-certified project in New York City prioritized its green roof, targeting it as both a beacon of sustainability and a refuge for occupants.

 

Designed by world-renowned architects Pelli Clarke Pelli, The Visionaire was New York City’s first condominium to achieve LEED Platinum, the highest level of recognition awarded by the U.S. Green Building Council. This 35-story condominium demonstrates the latest green technologies and practices, including energy and water conservation, indoor environmental quality, and material conservation. The Visionaire is a progressive, green building masterpiece that features a green roof covering 70% of the rooftop and offers stunning views of New York City and the Hudson River. The architects specified ribbed ipe tiles and adjustable pedestals for this landmark project.

The project won the 2009 Building Type Honor citation from the American Institute of Architects’ New York Chapter, which recognizes innovation in specialized design fields. The native plants and natural building materials offer occupants a visual and material connection with nature. The tranquil, open space is a welcome and quiet refuge from the busy city streets below. This green space benefits occupants’ health and wellness by enabling programmatic flexibility; the space can be used for recreation, refuge, and/or restoration. The rooftop deck helps to boost community morale and strengthen community relationships within the building while providing neighboring building users a visual connection to the natural environment

 

The Value of Sustainable Building Certification

Since 1993, with the founding of the U.S. Green Building Council (USGBC), third-party certification programs, such as LEED, the Living Building Challenge, the WELL Building Standard, and others, have served as one form of a common definition for sustainable projects. These frameworks make it easier to encapsulate something as complicated as a sustainable building.  As such, parties often refer to these external standards in contracts or other project documents.

According to Nicole DeNamur, Esq., Owner, Sustainable Strategies, sustainable building certifications provide several key benefits, contributing to their widespread adoption:

  • Standardization and Clarity: Certifications create a shared language around sustainability, reducing ambiguity. For instance, a project labeled simply as a “green building” is open to interpretation, whereas a project pursuing “LEED v4.1 Interior Design and Construction (ID&C) Silver Certification” has clear, defined expectations. 
  • Third-Party Verification: Many certification programs require independent verification, including documentation reviews, site visits, and performance testing. This process enhances credibility, ensures compliance, and helps prevent misleading sustainability claims, or greenwashing.
  • Legal and Market Value: Many certifications align with regulatory requirements and provide access to incentives. Additionally, these certifications can help organizations demonstrate their commitment to sustainability goals. 

Sustainable certifications, therefore, allow designers to viably demonstrate that sustainability goals were met. A manufacturer’s ability to partner with the design team to meet project goals through products and materials provides a gold standard for dividing real sustainability from greenwashing.

Using Innovations in Concrete to Certify Projects

The driving force behind solution-oriented, eco-friendly, and commercially viable concrete products is the striving to create not only sustainable concrete elements, but also for the projects to form an active contribution to the energy revolution. The aim of these new products offer architects and builders an intelligent facade with countless possibilities in terms of aesthetics, flexibility of design, sustainability, and cost-effectiveness.

While new products are exciting, it is important that their claims are verified. EPDs give precise indicators from LCAs. ISO 9001 and ISO 14001 certifications demonstrate the satisfaction of high standards for environmental protection.

New GRC facade elements undergo the highest quality control standards and are certified with several certifications: ISO 14001, ISO 9001, EPD Product Declaration, and LEED v4 Product Information. Numerous projects with these facades are already certified under LEED, DGNB, or BREEAM. BREEAM (Building Research Establishment Environmental Assessment Method) is a sustainability assessment method that is used to masterplan projects, infrastructure, and buildings. It offers a science-based suite of validation and certification systems in order to craft a sustainable built environment.

Toward a Greener Exterior: Meeting Certification Requirements with Decking and Modular Systems

Innovative and versatile modular deck systems provide architects the design flexibility to create unique and beautiful rooftop environments and outdoor spaces. Architects can include a mix of pavers and surface materials, including wood, stone, structural porcelain, crushed rock, grating, artificial turf, and concrete, and planter cubes and benches, to create unique, custom looks that allow for a maximum diversity of material use. Versatile, adjustable pedestal deck systems can be created over any structural surface, including bare structural decks, rooftop decks, roof membranes, green roofs, terraces, compacted grade, pavement, pool surrounds, or water features. This flexibility allows capture of unused space in the city, or for upgrades to a porch or backyard in the suburbs, creating a low- or zero-waste renovating solution for a variety of applications while creating valuable outdoor space.

Photo: Leonid Furmansky; courtesy of Bison Innovative Products

Thoughtful use of products and design can create exponential gains in sustainability: pedestal decks can help to decrease a building’s carbon footprint, reduce the roof’s ambient temperature, add potential for green space, meet rainwater collection initiatives, and diminish the need for roof replacement.

 

Modular deck systems can contribute to sustainable design goals and may help projects earn certification through LEED, SITES, WELL, and other green building design initiatives. Pedestal decks can help to reduce a building’s carbon footprint through a reduction in a roof’s ambient temperature, potential for green space, rainwater collection initiatives, and/or reduced need for roof replacement (additional construction materials). Some applicable areas of contribution include, under LEED v4 BD+C: Materials and Resources, Sustainable Sites, Water Efficiency, Location and Transportation, and Innovation. For SITES v2, multiple credit opportunities are available within Site Design – Material Selection and Site Design – Human Health + Well-Being. Under WELL v2, opportunities for points exist under Nourishment, Movement, Materials, and Mind categories.

Supporting Certification Goals with Steel

As of October 30, 2016, the USGBC transitioned from LEED v2009 to LEED v4. According to the USGBC, LEED v4 was developed to reflect a life-cycle assessment-type approach, which provides a more comprehensive view regarding the sourcing of materials.

Steel building systems adhere to LEED. Those produced via EAF offer particular advantages, given their favorable LCAs. Steel can also generate points under categories for recycled content, regional materials, and environmental product declaration information. Additionally, a LEED Letter provides the current “recycled content” information from manufacturing facilities. The average breakdown may vary at the time of production depending on coil availability and coil source. In 2024, EAF furnaces recorded 85% recycled content.

Photo courtesy of New Millennium

Steel deck, featuring realistic wood-grain finishes, offers a new world of design possibilities through revolutionary coil-coated digital printing processes.

 

Depending on the jobsite location, domestically produced steel joists and deck products may be considered regional materials and count toward points under the Materials and Resources Credit. Qualifying for this credit earns points toward LEED certification if the project is using building materials or products that have been extracted, harvested, or recovered, as well as manufactured, within 500 miles of the project. Steel can also earn points under LEED for indoor air quality.

Case Study: Glemm21 Headquarters, Maishofen, Austria

Photo courtesy of Rieder USA/Ditz Fejer

The latest advance in concrete panels involves eliminating cement and replacing it with natural pozzolana, which has significantly lower CO2- emissions during production.

 

An existing building with historical significance was utilized, and many other components were also reused or recycled during this renovation. The focus of the renovation work was on preserving the existing building stock as much as possible. The project also allowed for the testing and showcase of cement-free concrete facade technology.

The GRC elements combined aesthetics, technical, and ecological benefits: non-combustible, weather-resistant, long-lasting, large panel sizes, 3D shapes, and a wide range of colors, textures, and formats. This new product challenged the misconception of concrete facades by showing itself as a high-performance, durable, and aesthetically versatile solution that unites form, function, and sustainability.

Additional recycled elements included concrete columns from old factories, a previously produced massive concrete beam, 150 tons of recycled steel girders, and much more. An old wall made of arolla pine wood was dismantled at a separate project and employed to create the pleasant ambience of a modern working environment. The principle of building in the existing materials allowed the company to save around 1,000 tons of CO2, compared with a new building, while at the same time turning the renovated building into a prime example of resource-efficient circular construction. The transformation process was supported by an engineering firm specializing in energy-efficient construction.

Walls were removed and large windows were added to create modern loft-like office spaces. Old windows were replaced with triple insulating glazing. The shell of the headquarters and the roof were insulated using mineral wool. Switching from oil to pellet heating proved advantageous in terms of efficient combustion and selecting wood as a renewable fuel source.

 

Considering Inherent Sustainable Gains

Certifications and third-party verifications provide essential assurance to the professional team engaged in creating a sustainable project. However, there is a final category that allows for confident assessment: the ability of the product itself to capture desired benefits.

Photo: Kyle J Caldwell; courtesy of Bison Innovative Products

Integrating the exterior with the interior offers sustainable benefits of its own, connecting occupants to nature.

 

Biophilic Design and Modular Decks

The definition and applications of sustainability have expanded beyond material content and safety into material resource resiliency and design adaptability. The most recent versions of LEED include considerations relating to human health and well-being as well as social and cultural connections. Both LEED for Neighborhood Development (LEED ND) and Sustainable SITES provide performance measures for designing functional and regenerative landscapes that increase outdoor opportunities.

There are many ways to incorporate biophilic elements into a building’s design: through a visual connection to the outdoors, incorporation of natural elements, or expanding the indoors to the outdoors. Many rooftop or outdoor deck projects that incorporate biophilic design elements also align with sustainability goals. Outdoor decks connect residents to the natural environment using natural materials, such as wood and stone, and incorporate vegetation and greenery into an individual’s regular routine through the use of planter cubes and pots.

Regular interactions with the outdoors are proven to lower blood pressure, reduce stress, expedite healing, and improve a person’s mood and focus. Modular deck systems can contribute to sustainable design goals and may help projects earn certification through LEED, SITES, WELL, and other green building design initiatives. Modular decking with a pedestal system can help to reduce a building’s carbon footprint. Designing a green roof deck with modular decking provides shade, improves stormwater management, reduces temperatures of the roof surface and surrounding air, and reduces energy demands. Green roof systems can incorporate rooftop deck components such as wood tiles and planter or cube tops with high solar reflectance index (SRI) values. A high SRI indicates the material’s relative ability to stay cool and reject solar heat, reducing heat flow into the building. Such designs and products can help mitigate the built environment’s contribution to urban areas’ heat island effect.

Modular and pedestal decking also aids in passive solar heating and cooling. A raised, air-permeable, open-grid pavement system helps reduce the cooling loads of the building, thereby lowering energy costs, facilitating water drainage, and providing an insulating barrier between the roofing system and the new deck. The raised system design protects the roof and its membrane from damage from the elements, like hail, wind, and UV rays, significantly extending its lifespan. The modular decking system does not penetrate the waterproofing system, maintaining the integrity of the building’s envelope. This extra layer of insulation also acts as a noise dampener, reducing noise transmission to the interior of the building.

Incorporating a pedestal system provides pedestrian access to green roofs. Native plants and natural building materials offer occupants a visual and material connection with nature. Green spaces benefit occupants’ health and wellness by enabling programmatic flexibility. Rooftop decks help boost community morale and strengthen community relationships. For the occupant, outdoor decks provide living spaces with a direct visual and material connection with nature that form a peaceful refuge to rejuvenate the body, mind, and soul. A deck’s sweeping views of the encircling landscape can provide users the opportunity to visually survey and contemplate the surrounding environment. These broad landscape views inspire an emotional attachment to the building’s natural surroundings and promote positive interactions between the building users and the neighboring ecosystem. Modular planters provide a space for seasonal growing, giving building users a direct interaction with nature and a connection to food supply and seasonal patterns.

There is even demonstrable evidence linking biophilia to economics. Terrapin Bright Green’s report states, “By assigning value to a variety of indicators influenced by biophilic design, the business case for biophilia proves that disregarding humans’ inclination towards nature is simultaneously denying potential for positive financial growth.” Indicators of increased productivity from the inclusion of biophilic elements include: reduced illness and absenteeism, higher staff retention, better job performance (reduction of mental stress and fatigue), increased healing rates and classroom learning rates, bigger retail sales, and fewer violence statistics. These metrics demonstrate gains when linked to the impacts of a connection with nature, which companies and institutions can use to their advantage.

Sustainability by Design with Steel

Photo courtesy of New Millennium

Flush-frame connections allow for 35% weight savings with performance equal to wide-flange beams.

 

Steel is a domestic, recyclable, and sustainable product. With the advances of EAF, it is also a highly environmentally friendly product.

Besides its inherent favorable characteristics as a material, design strategies are where some of the greatest advantages to designing in steel reside. Steel joists are fabricated per project, allowing for 25 to 35 percent lighter bearing components. Chord members can be specifically sized to address large point loads like mechanical units or fire suppression lines. Flush-frame connections offer the design team an alternative from wide-flange beams to steel joists for floors and roofs.

Steel joists with flush-frame end connections offer significant weight savings compared to wide-flange beams while providing equivalent stiffness and vibration performance. An innovative design approach, these connections feature a joist reaction point designed to occur at the center line of the wide-flange girder. This better-performing design eliminates girder torsion concerns during erection and/or due to final design loading of a perimeter wide-flange girder. Simplifying the flush-frame specification process, published standards improve coordination between the specifier, joist manufacturer, steel fabricator, and erector. This reduces design time, accelerates joist and girder fabrication, and streamlines erection.

Composite joists offer the same benefits of roof joists: weight savings versus wide-flange, reduced live-load deflection, routing of MPE through the webs, and equivalent vibration to wide-flange beams. 

Another strategy is utilizing steel deck for spanning capacity. In addition to the standard profile deck, acoustical and architectural profiles eliminate the need for secondary ceiling systems. The most sustainable approach to design is choosing ‘not to build’, which eliminates unnecessary materials. By eliminating acoustic ceiling tile or some other suspended ceiling, the project saves time and resources. An entire trade can be cut out, noting the construction waste and freight associated with a given product. Architectural profiles may be long-span deep-deck cellular, cellular acoustical, and dovetail. It creates a deck that can span upwards of 30 feet. Variations on acoustics and pre-finishing also give architects immense design freedom. From water-based primers to high-performance coatings to the exotic wood-print finishes, there is an incredible palette at the design team’s control.

 

Case Study: Cedar Grove Elementary School, San Jose, California

Steel deck was used at this school and incorporated dovetail acoustical and architectural profiles, eliminating the need for a secondary ceiling. The ceiling was finished with an epoxy-polyester coating.

Photo courtesy of ICS

The exposed acoustical deck at Cedar Grove provides a high noise reduction coefficient for sound control, eliminating the need for a secondary ceiling system.

 

 

Adding Natural Durability with Concrete

Extruded concrete is an ideal material. The manufacturing process creates a material that is thinner, stronger, and more manageable for both design and installation. GRC elements are layered alternately, creating high tensile strength and durability. The thin, lightweight panels disprove misconceptions about using concrete in building, and they are durable, flexible in design, and significantly lower in CO₂ emissions thanks to an optimized concrete matrix.

Another misconception is related to installation complexity. Many assume that GRC panels require complicated mounting systems, when in fact, panels are designed for efficient and straightforward installation. This often allows for prefabrication and reduces on-site construction time.

Photo courtesy of Rieder USA/Ditz Fejer

A diverse range of colors allows extruded concrete panels to blend well into landscapes and correspond with nature and the environment. 3D elements expand the design possibilities and architectural expression.

 

Extruded concrete panels are naturally cured, typically for 28 days at room temperature. This requires very low energy use. The product is also all natural and not prone to off-gassing vapors. Natural pigments blend in well with the environment, and panel surfaces can be sandblasted and honed to create vivid textures. Formed parts, with their monolithic appearance, offer exceptional flexibility in design. Customized to specific requirements, they enable the realization of complex 3D geometries and bring sculptural depth to architectural concepts.

 

END NOTES

  1. “What is greenwashing? Exposing deceptive tactics”. Forest Stewardship Council©. October 7, 2024. https://fsc.org/en/blog/what-is-greenwashing. Accessed April 11, 2025.
  2. “Why the Construction Industry Needs to Be Worried About ‘Greenwashing’.” Squire Patton Boggs. August 2023. https://www.squirepattonboggs.com/-/media/files/insights/publications/2023/08/why-the-construction-industry-needs-to-be-worried-about-greenwashing/why-the-construction-industry-needs-to-be-worried-about-greenwashing.pdf?rev=35c7150cafb54a07b1c52e6d1c61ef1f. Accessed April 11, 2025.
  3. DeNamur, Nicole Esq. “Defining ‘Green’: the importance of clarifying key terms on sustainable projects.” AIA Contract Documents. The American Institute of Architects. January 18, 2024. https://learn.aiacontracts.com/articles/defining-green-the-importance-of-clarifying-key-terms-on-sustainable-projects/. Accessed April 11, 2025.
  4. Ibid.
  5. DeNamur, Nicole, Esq. “Defining ‘Green:’ the importance of clarifying key terms on sustainable projects.” AIA Contract Documents. The American Institute of Architects. January 18, 2024. https://learn.aiacontracts.com/articles/defining-green-the-importance-of-clarifyin-key-terms-on-sustainable-projects/. Accessed April 11, 2025.
  6. “The Benefits of Construction and Demolition Materials Recycling in the United States.” Prepared for The Construction & Demolition Recycling Association. Prepared by The Department of Environmental Engineering Sciences Engineering School of Sustainable Infrastructure and Environment University of Florida. Timothy Townsend, Principal Investigator Christina Wilson, Student Assistant Blaine Beck, Student Assistant.Version 1.1. December 2014 (updated January 14, 2015)  June 7, 2022. https://cdrecycling.org/site/assets/files/1050/cd_recycling_impact_executive_summary-1.pdf
  7. Gabriel Luiz Fritz Benachio, Maria do Carmo Duarte Freitas, Sergio Fernando Tavares. “Circular economy in the construction industry: A systematic literature review.” Journal of Cleaner Production. Volume 260, 2020. 121046. ISSN 0959-6526. https://doi.org/10.1016/j.jclepro.2020.121046. (https://www.sciencedirect.com/science/article/pii/S0959652620310933)
  8. Ibid.
  9. Patrizia Ghisellini, Maddalena Ripa, Sergio Ulgiati. “Exploring environmental and economic costs and benefits of a circular economy approach to the construction and demolition sector. A literature review.” Journal of Cleaner Production. Volume 178, 2018. Pages 618-643. ISSN 0959-6526. https://doi.org/10.1016/j.jclepro.2017.11.207. (https://www.sciencedirect.com/science/article/pii/S0959652617328809).
  10. Lalonde, Emily. “Environmental Product Declaration (EPD) – The complete guide.” Ecochain. February 13, 2024. https://ecochain.com/blog/environmental-product-declaration-epd-basics/. Accessed April 15, 2025.
  11. Ibid.
  12. DeNamur, Nicole Esq. “Defining ‘Green’: the importance of clarifying key terms on sustainable projects.” AIA Contract Documents. The American Institute of Architects. January 18, 2024. https://learn.aiacontracts.com/articles/defining-green-the-importance-of-clarifying-key-terms-on-sustainable-projects/. Accessed April 11, 2025.
  13. DeNamur, Nicole Esq. “Sustainable Building Certifications- Where did they come from, why they are important, and where can you learn more.” AIA Contract Documents. The American Institute of Architects. November 29, 2023. https://learn.aiacontracts.com/articles/sustainable-building-certifications-where-did-they-come-from-why-they-are-important-and-where-can-you-learn-more/. Accessed April 11, 2025.
  14. “The Economics of Biophilia: Introduction.” Terrapin Bright Green. February 27, 2018. https://prismpub.com/introduction-economics-biophilia/. April 18, 2025.

 

 

Amanda Voss, MPP, is an author, editor, and policy analyst. Writing for multiple publications, she has also served as the managing editor for Energy Design Update.

 

Originally published in Architectural Record

Originally published in June 2025

LEARNING OBJECTIVES
  1. Confidently apply third-party accreditations and verifications, like EPDs, to ensure that material and product selection is sustainable, using evaluations for steel, concrete, and exterior decking as examples.
  2. Specify a variety of products that satisfy sustainability and design goals while meeting strenuous certifications, including LEED v4.1, SITES v2, and the WELL v2 Building Standard.
  3. Using concrete, steel, and exterior decking products as a lens, address energy consumption and carbon implications of products.
  4. Gain technical knowledge about the innate sustainability characteristics of products and systems and how these enhance performance goals.
Buyer's Guide
Bison Rooftop Deck Systems
Bison Rooftop Deck Systems
Bison Pedestals are manufactured in Denver, Colorado, with 20% post-industrial recycled materials and have patented features that improve performance and stability. These versatile, adjustable pedestal deck systems create level rooftop decks over sloped surfaces, support a variety of different surface materials, and can be installed over any structural surface.
Bison Innovative Products
www.bisonip.com
Riveted Cellular Deck
Riveted Cellular Deck
New Millennium’s factory-riveted Cellular Deck offers an alternative to standard profile deck. Riveting the liner panels provides a smooth appearance to meet your aesthetic, acoustic, and structural needs. Cellular and Cellular Acoustical profiles for 1-1/2” B-deck, 3” N-deck, and Composite Floor Deck (1-1/2”, 2”, and 3” depths). Available in galvanized (G60 and G90), factory-applied primers, and high-performance factory finishes (including New Millennium’s IMPRESSIONS® coil-coated wood-grain finishes). ICC-ES Reports, FM Approvals, UL Certifications, EPDs, and supporting LEED information can be found at www.newmill.com.
New Millennium, A Steel Dynamics Company
www.newmill.com
CO2-Reduced Facade Panels
CO2-Reduced Facade Panels
On its way to climate neutrality, Rieder developed Matrix 3.0, a CO2-neutral material for sustainable facade elements made of glass fiber-reinforced concrete. Fifty percent of the conventional cement was replaced by local natural pozzolana. The rock flour, which has been used in the construction of buildings since ancient times, has excellent properties in terms of structural density and hardening. The cement substitution allows a CO2 reduction of 30%.
Rieder USA
www.rieder.cc/us