Lifecycle Emissions: Comparing ShapeShell™ vs Traditional Materials
The architecture and construction industries are under increasing pressure to reduce environmental impacts—not only during building operations, but across the full lifecycle of the materials used. As regulatory frameworks tighten and sustainability certifications become standard, attention is shifting toward the embodied emissions of construction materials: the total greenhouse gas emissions generated from raw material extraction through to manufacture, transport, installation, and eventual end-of-life treatment. For architects and building consultants, the choice of materials is now a critical decision point in reducing project-wide carbon intensity. This shift places reinforced material systems like ShapeShell™—developed by ShapeShift Technologies—at the forefront of low-carbon design strategy. Offering lightweight, high-strength alternatives to traditional materials such as precast concrete, aluminium, and GFRC, ShapeShell™ enables ambitious design outcomes with significantly lower environmental burdens. Defining Lifecycle Emissions Lifecycle emissions, often referred to as embodied carbon or whole-of-life emissions, represent the total greenhouse gas emissions generated throughout the lifespan of a material or product—from raw material extraction to final disposal or reuse. In the context of construction materials, lifecycle emissions are typically divided into several stages: Upstream (Cradle-to-Gate): Emissions from raw material extraction, processing, manufacturing, and transportation to site. Construction Phase: Emissions from installation processes, site waste, and temporary works. Use Phase (Operational Interface): Though materials like façades and internal linings may not emit carbon directly during use, they can influence energy performance, insulation, and durability, indirectly affecting a building’s operational footprint. End-of-Life: Emissions from demolition, transport to landfill or recycling, and associated waste processing. Traditional materials such as aluminium, precast concrete, and steel typically have high embodied carbon due to energy-intensive production processes. For example, aluminium cladding systems carry heavy carbon loads from smelting and extrusion, while precast concrete contributes significantly through cement production—a known high-emissions activity. Conversely, new-generation reinforced materials like ShapeShell™ have been engineered to minimise embodied carbon by: Using low-weight, high-strength fibre systems to reduce the quantity of material required, Incorporating recycled or repurposed inputs, such as glass aggregates or gypsum by-products, Offering high durability and minimal maintenance, extending service life and delaying replacement cycles. By evaluating materials based on their lifecycle emissions profile—not just up-front cost or strength—design professionals can make more informed decisions that align with both performance and sustainability objectives. ShapeShell™ Material Overview ShapeShell™ is a suite of advanced fibre-reinforced materials engineered for architectural, infrastructure, and interior applications where performance, weight reduction, and environmental efficiency are critical. Each variant within the ShapeShell™ family has been developed to replace traditional heavy, high-emission materials without sacrificing durability, aesthetics, or design flexibility. ShapeShell™ RT – Reinforced Thermoset ShapeShell™ RT is a lightweight, fibre-reinforced thermoset panel system that combines glass, carbon, or aramid fibres within a polymer resin matrix. With flexural strengths exceeding 220 MPa and a weight as low as 5 kg/m², RT panels are suitable for façades, soffits, cladding, and free-form geometries. Manufactured using vacuum infusion and aerospace-grade techniques, RT panels provide: Corrosion, weather, and UV resistance Up to five times the strength of aluminium Low water absorption (<0.1%) and Class A fire performance 50-year structural and 25-year surface warranty This enables long-lasting external performance with significantly lower mass and embodied energy compared to metal or concrete systems. ShapeShell™ RC – Reinforced Concrete ShapeShell™ RC is a glass fibre-reinforced cementitious material, including a Green GRC option that replaces sand with recycled glass to eliminate crystalline silica. Ideal for rainscreens and architectural façades, ShapeShell™ RC offers: Superior compressive strength (45 MPa) and modulus of rupture Thicknesses as low as 15 mm, reducing material mass and associated emissions Class A2-s1 fire rating and non-combustibility Compatibility with architectural coatings and anti-graffiti treatments ShapeShell™ RC is suited to projects where thermal stability, durability, and non-combustibility are mandatory, especially in transport, public space, or mixed-use developments. ShapeShell™ RG – Reinforced Gypsum Designed for internal use, ShapeShell™ RG blends modern fibre reinforcement with a gypsum matrix. At 23 kg/m², it is around 30% lighter than traditional GFRC, allowing for easy handling and reduced substructure demands. Key characteristics include: Excellent acoustic and impact resistance ASTM E84 zero flame and smoke index 100% non-combustible mineral base Rapid installation using conventional drywall fixings Applications include column covers, ceiling vaults, domes, and interior wall systems where sculptural design and fire performance are essential. Traditional Materials in Comparison Traditional construction materials—such as precast concrete, aluminium cladding, steel panels, and conventional GFRC—have long served as the backbone of architectural and infrastructure applications. However, when assessed through the lens of lifecycle emissions, these materials often reveal significant environmental shortcomings. Precast Concrete Widely used for façades and structural elements, precast concrete is durable but extremely carbon-intensive. Cement production alone accounts for approximately 8% of global CO₂ emissions. Even with thin-section panels, the weight (typically 80–120 kg/m²) and need for heavy-duty substructures drive up both material and transport emissions. The thermal mass may offer energy-saving potential, but only under specific climatic conditions and with well-integrated systems. Aluminium Cladding Aluminium is valued for its corrosion resistance, formability, and sleek appearance. However, its environmental cost is steep. The smelting process is energy-intensive and typically powered by fossil fuels. While aluminium is recyclable, the embodied carbon of virgin aluminium is among the highest of any façade material—often exceeding 11 kg CO₂-eq per kg. Aluminium panels also require complex mounting systems, contributing further to upstream emissions. Steel and Metal Panels Steel cladding systems offer strength and fire resistance but come with high embodied energy due to mining, processing, and surface treatments. Finishing processes such as galvanising or coating add to the total carbon footprint. Moreover, their weight (typically 30–50 kg/m²) increases emissions related to transport and installation. Conventional GFRC (Glass Fibre Reinforced Concrete) GFRC remains a popular material for complex geometries and prefabricated façade units. While thinner than precast concrete, traditional GFRC still relies on sand, Portland cement, and silica—materials with high embodied carbon and occupational health concerns. In contrast, newer variants like ShapeShell™ RC use recycled glass to remove crystalline silica entirely Comparative Emissions Analysis Evaluating lifecycle emissions requires considering not just how materials perform in use, but how they are extracted,
