Optimising CO2 emission reduction and cost-effective quality control testing in large-scale concrete infrastructure projects

This study evaluates the environmental and economic impact of optimising concrete sampling protocols for quality control in large-scale infrastructure projects. A comparative analysis was conducted between a conventional scenario and an optimised strategy, using daily field data collected over a nine month period on a project involving 25,000 m³ of concrete. The proposed plan reduced 3,010 test cylinders, corresponding to 4.73 m³ of unused concrete. This reduction led to savings of 3,289 kg of CO₂-equivalent emissions, 4,043 kg of fine aggregate, 3,948 kg of coarse aggregate, 2,057 kg of cement, 852 kg of water, and 36 kg of admixtures. These savings translated into a direct cost reduction of $36,875.05 USD, encompassing materials, transport, production, laboratory procedures, and disposal. Unlike most previous studies focused on material substitutions, this research demonstrates that procedural optimisation alone can yield significant environmental benefits while maintaining compliance with ACI and ASTM specifications. The findings confirm that many concrete mixtures achieved design strength within seven days, enabling rationalised sampling based on statistical performance. The proposed methodology offers a replicable framework for integrating sustainability into quality control systems, proving that environmental efficiency and cost-effectiveness can be achieved simultaneously in high volume construction contexts.