SENSE 600® delivers lower embodied carbon at Level Crossing Removal Project

The Level Crossing Removal Project is helping set a new benchmark for how infrastructure can be delivered using lower embodied carbon solutions.

At Hopkins Road in Truganina and Ferris Road in Melton, our SENSE 600® reinforcing steel has been used in the deflection walls of the new road bridges, supporting the removal of two major level crossings.

Manufactured in Australia from recycled scrap, SENSE 600® is designed to deliver the same performance as standard reinforcing, while using less material.

That means up to 16.7% less steel is required, helping reduce the overall embodied carbon of the structure without compromising strength or safety.

This project shows what is possible when design, engineering and materials work together to deliver better outcomes.

By using higher strength reinforcing, the project team has been able to reduce the total volume of steel required across key elements.

Level Crossing Removal Project Environment and Sustainability Advisor Ashleigh Smith highlighted the impact:

“SENSE 600® is innovative because it’s made from scrap metal, so it’s a part of that closed loop, circular economy, and it’s stronger and lighter than its traditional steel counterparts, which means that there’s actually going to be less steel in the overall product.

So, when we’re installing the SENSE 600® in the deflection wall, we can actually use less of it, which means that there’s less embodied carbon in the structure.”

SENSE 600® is produced using Australia’s only Electric Arc Furnace, where scrap is melted and remade into new steel, supporting a circular model that keeps materials in use.

In one example at Hopkins Road, a design change removed around 20 tonnes of CO₂ from the project.

Projects like this demonstrate the role Australian steel can play in delivering infrastructure more efficiently, with lower embodied carbon.

You can also watch the Victorian Government video below to see how the project is being delivered and the role materials innovation is playing on site.

The new road bridges are expected to open in May 2026, improving safety, reducing congestion and supporting growing communities in Melbourne’s west.

Congratulations to the InfraBuild Reinforcing team in Victoria who played a key role in bringing this opportunity together.