Department of Energy Bandwidth Study on Non-Manufacturing Construction

The U.S. Department of Energy’s (DOE) Bandwidth Studies are a series of analytical reports designed to evaluate energy consumption and greenhouse gas (GHG) emissions across various industrial sectors in the United States. Historically produced by the Advanced Manufacturing Office (AMO), which was restructured into two separate program offices in 2022—Advanced Materials and Manufacturing Technologies Office (AMMTO) and Industrial Efficiency and Decarbonization Office (IEDO)—the Bandwidth Studies initially focused exclusively on the energy consumption of manufacturing sectors. However, following the restructuring, IEDO took the lead in expanding the studies to include energy- and emissions-intensive non-manufacturing industrial sectors, such as construction.

The Bandwidth Studies provide a clear, accessible way to understand the “bandwidth”—the range of energy consumption and GHG emissions—within a given industry. These analyses examine the potential for energy savings and emissions reductions by comparing conventional, state-of-the-art, and future process technologies currently under research and development (R&D) against typical energy usage practices and processes within each industrial sector. Specifically, the studies identify current energy consumption patterns and estimate the technical potential for energy efficiency improvements and process changes.

The main goal of the Bandwidth Studies is to support decision-making by providing benchmarks and data that can help manufacturers, policymakers, and researchers target energy efficiency improvements and technology development. Additionally, the studies assist in developing roadmaps for industries to reduce energy consumption, improve processes, and lower operational costs, all while aligning with national energy goals and sustainability objectives. Now in its third iteration, the Bandwidth Studies also consider both embodied and operational emissions of manufactured and non-manufactured products—such as materials used in buildings and infrastructure—to more comprehensively examine energy flows and associated emissions through life cycle assessments (LCA) and environmental extended input-output (EEIO) modeling.

The data used in these models comes from a combination of sources:

1. Industry Reports and Surveys: These include data from manufacturers, trade organizations, and academic partnerships that reflect real-world energy use and operational practices.

2. Government Data: Sources include DOE surveys (e.g., RFIs), the U.S. Census Bureau’s Annual Survey of Manufactures (ASM), and the U.S. Energy Information Administration’s (EIA) Manufacturing Energy Consumption Survey (MECS).

3. Technology Assessments: Data on available technologies are gathered through literature reviews and expert interviews, supplemented by the subject matter knowledge of researchers and peer reviewers in the respective sectors. These data are used to construct quantitative models that estimate energy consumption and emissions profiles for various technologies in different contexts.

Two key sectors directly related to building decarbonization in the Bandwidth Studies are Cement and Concrete and Non-Manufacturing Industries (including construction).

The cement and concrete sector is particularly energy- and emissions-intensive due to processes like limestone calcination, which requires high temperatures (around 1400°C) in kilns to produce clinker—the primary ingredient used as a binder in cement. Decarbonizing this sector is challenging because conventional kilns rely heavily on natural gas to achieve the necessary temperatures, releasing GHGs through both combustion and the calcination of limestone (CaCO3 → CaO + CO2), which inherently emits CO2. In contrast, the construction sector’s energy consumption and associated GHG emissions primarily stem from materials production (e.g., steel, concrete) and on-site machinery (e.g., heavy equipment). These emissions can vary depending on factors such as project size, location, and material choices.

Previous Bandwidth Studies have identified areas where energy efficiency improvements could significantly reduce energy use and GHG emissions in the cement and concrete sector. These include the use of alternative fuels to reduce reliance on fossil fuels (e.g., waste-derived fuels); carbon capture technologies to capture CO2 emissions from combustion and the calcination process, and; process optimization to improve kiln efficiency, enhance heat recovery, and improve overall process control.

However, addressing energy efficiency in the construction sector is more complex. While strategies like modular and prefabricated construction can minimize waste and improve material efficiency, and higher-performance insulation materials can reduce operational energy use, buildings and infrastructure must balance embodied and operational emissions. Higher-performance materials or systems often require more energy to manufacture, which could offset the operational energy savings over the material's lifecycle. Additionally, the embodied emissions of different materials or systems vary due to factors such as installation methods (e.g., crane vs. manual labor), maintenance needs (e.g., patching vs. demolition & reconstruction), and disposal processes (e.g., biodegradation vs. incineration) for which data is currently lacking. Local climate conditions, building energy codes, and regulations further complicate the generalization of energy and emissions data for construction projects.

The latest iteration of the Bandwidth Studies is currently ongoing and aims to address some of these challenges. Previous iterations are available on the DOE’s website: https://www.energy.gov/eere/iedo/manufacturing-energy-bandwidth-studies.