10043300Design & production optimisation of a novel low embodied carbon concrete structural beam solutionClosedGrant for R&DInnovate UKThe enclosed project is presented by a construction sector startup company (Net Zero Projects - "NZP") that has a vision for more sustainable structural engineered products e.g. concrete beams, slabs and frames. At present the construction sector produces concrete beams based on methods that are biassed toward simplified manufacturing processes. In effect, rectangular form work (elongated boxes) are produced in the required size and then concrete is poured into the form to set solid. However, this is very wasteful, a good proportion of the volume of the concrete beam provides limited strength to the beam so a large proportion of the carbon footprint, associated with concrete and production process, is emitted wastefully. NZP has a radical solution for an "optimised" concrete beam that combines 3D concrete printing, intelligent structural design and steel cables to drastically reduce the amount of concrete, reinforcing steel and embedded carbon needed to produce a concrete beam. To date, NZP has developed and produced a 3D printed concrete beam that provides 70% reduction in embodied carbon and up to 50% reduction in material costs, compared to similar traditional concrete beams. NZP has had commercial interest from construction sector clients. However, at present NZP can only produce a beam suitable for being supported at both ends. To be commercially viable, the company needs to produce cantilever beams (i.e. beams only supported on one side). This is possible but only with the development of some specialist automated design software and experimental testing of cantilever beam designs. The enclosed Fast Start Innovation application will enable NZP to resolve these challenges and exploit commercial demand for lower carbon structural engineered products. This project is fully aligned with the "Achieving net zero and reducing environmental impact" competition priority.