A Collaborative Leap Towards Greener Steel Manufacturing 

GoSmarter.ai is an integrated suite of tools—including a Rebar Solver, Scrap & Offcut Trackers, and advanced sustainability modules—designed specifically to address the unique challenges of the steel sector. This initiative forms a core part of the Re-imagining Design & Planning for Greener Reinforcement Steel Manufacturing project, spearheaded by Midland Steel, a leading provider of offsite steel reinforcement solutions across Ireland, the UK, Scandinavia, and North America. Key collaborators in this ambitious effort include KUKA, Bastal Steel, OCSC, and the VTT Technical Research Centre of Finland. The project receives vital co-funding from EIT Manufacturing and Innovate UK, underscoring industry-wide commitment to sustainable transformation 

Tackling Rebar Waste: A Global Challenge 

Steel’s vital role in construction is coupled with high embodied energy, making waste reduction and recycling central to a sustainable, circular economy. In 2025, global demand for rebar is forecasted to reach 405 million tonnes, with the market valued at $321 billion USD. However, cutting waste still makes up 3–5% of total production—equating to a staggering 12–20 million tonnes of wasted steel and an associated 17–28.3 million tonnes of CO₂ emissions. GoSmarter directly addresses these losses by harnessing AI and data analytics to optimise production planning, reduce scrap, and maximise resource efficiency. The toolkit’s Rebar Optimisation Tool integrates real-time inventory, order requirements, and Carbon Equivalent (CEQ) data to deliver precise, waste-minimising cutting plans. 

Proven Results from Industry Trials 

During an intensive two-week production trial, GoSmarter optimised 734 tonnes of steel across 193 jobs, achieving a 6% reduction in scrap. This translated to savings of 20.22 tonnes of steel and significant cost savings by the rebar manufacturer. Complementary waste management tools were also trialled: the Offcut Tracker App—enhancing material reusability by monitoring offcuts—and the Scrap Weight Tracker App—enabling real-time insight into waste and recycling processes. 

Voices from Industry Leaders 

Tony Woods, Founder & CEO of Midland Steel, remarked,

“This collaboration has delivered concrete results, proving that smart technology can have a direct, measurable impact on reducing carbon emissions in steel manufacturing. The integration of AI and digital tracking has significantly improved our operational efficiency and sustainability performance.” 

Ruth Kearney, CEO of Nightingale HQ, added,

“Returning unused steel to inventory has cut costs for Midland Steel, boosting profit margins and competitiveness in a tough market. While these trials are ongoing, the positive outcomes highlight both the environmental and bottom-line benefits of digital innovation.” 

The Road Ahead: Accelerating Sustainable Innovation 

Nightingale HQ is committed to advancing the GoSmarter platform, with plans to incorporate optimisation by material type and detailed carbon footprint analysis. As regulatory frameworks like the Corporate Sustainability Reporting Directive (CSRD) and the Carbon Border Adjustment Mechanism (CBAM) accelerate the transition to greener industry, Nightingale HQ and its partners remain at the forefront of supporting the steel sector’s low-carbon future. 

About Nightingale HQ 

Nightingale HQ is a leader in AI-driven industrial sustainability solutions. Through advanced digital tools, the company empowers steel manufacturers to reduce waste, optimise processes, and slash carbon emissions—driving progress towards a more sustainable future for heavy industry. 

For further information, media enquiries, or partnership opportunities, please email hello@nightingalehq.ai

EDITOR NOTES

About Nightingale HQ 

Nightingale HQ is a leader in AI-driven industrial sustainability solutions. GoSmarter.ai offers digital tools to steel manufacturers to reduce waste, optimise processes, and slash carbon emissions.