Our largest clients are pushing for carbon neutrality and innovation in sustainable construction has become a top priority. In the industrial sector, we’ve seen great strides in reducing the embodied carbon of a project through using low carbon materials.

In 2021, we had the opportunity to work on a project that began as an endeavor to simply benchmark the embodied carbon; however, through our collaboration we saw a chance to both reduce the overall carbon footprint and pilot the use of CarbonCure Technologies, which introduces recycled CO2 into concrete. The technology injects a precise dosage of captured carbon dioxide into concrete during mixing, where it is mineralized. This improves the concrete’s compressive strength, enabling mix optimization, significant carbon footprint reductions, and cost savings.

With our VDC team we examined the Revit model to get an understanding of the life cycle assessment of the project and see where we could make the greatest possible impacts. We learned, what the industry fully understands now, that concrete has the greatest contribution to the carbon emissions of a traditionally designed project.

Through examining the concrete mix design and working with our national network of concrete suppliers, we determined the automated robotic fulfillment center in Fort Wayne, Indiana posed the best opportunity to apply CarbonCure Technologies and submitted an alternate mix design for portions of the structure and foundations. Our goal was to provide the desired performance and aesthetics while also reducing embodied carbon.

Implementing CarbonCure’s concrete technology to lower the carbon footprint

To lower the carbon footprint of a 2.9M square foot automated robotic fulfillment center, the Layton project team deployed CarbonCure’s sustainable concrete solution to set the precedent for future projects.

The project team performed two test concrete pours on the project, a 21,600 SF (528 cubic yards) slab-on-grade (SOG) pour and a 30,200 SF (604 cubic yards) slab-ondeck (SOD) pour. The team also used CarbonCure in all the footings and foundations of the project, which is approximately 15,500 cubic yards.

Working with the client’s concrete consultants, Layton performed testing and field observations (and reported accordingly) to ensure the overall performance criteria were met.

By using CarbonCure, the project team not only reduced the embodied carbon of the project, but set the standard for more green building practices on large scale projects.

Protecting local biodiversity

The project scope included safeguarding 50 acres of wooded area and adjacent wetlands to protect the Indiana bat (Myotis sodalis), a state and federally endangered species, along with other local flora and fauna.