10126148Structural liability and risk mitigation study for a novel low embodied carbon concrete structural beam solutionClosedCollaborative R&DInnovate UKThis project is presented by an innovative company (called NZP) who are trying to reduce the amount of concrete and steel used in construction of large buildings and bridges by optimising the design of structural elements including beams, slabs and frames. At present the construction sector produces concrete beams based on methods that emphasise simplified manufacturing processes. In effect, rectangular formwork (elongated boxes) are produced of the required size, and steel reinforcement is positioned inside, then concrete is poured into the formwork to set solid. However, this is very wasteful, as the majority of the material in the beam is not required for strength, so a large proportion of the carbon footprint, associated with the concrete and steel production processes, is emitted wastefully. NZP has a radical solution for an "optimised" concrete beam which combines 3D concrete printing, intelligent structural design, and steel cables to drastically reduce the amount of concrete, reinforcing steel and embodied carbon needed to produce a concrete beam. To date, NZP has developed and produced a 3D printed concrete beam that provides up to 70% reduction in embodied carbon and up to 50% reduction in material costs, compared to equivalent traditional concrete beams. Using Innovate UK Net Zero competition funding, NZP has been able to develop and demonstrate the design and production of these novel printed beams. However, adopting these 3D printed beams in a real world construction project is the next major challenge. A completely new design which reduces the amount of material in the beam is clearly a perceived risk for the construction sector and insurance providers. To make commercial progress, NZP has to be able to show construction and insurance companies that the 3D printed beam is just as safe as conventional concrete beams. NZP has approached a construction sector training facility in Norfolk with the opportunity to build a 3D printed concrete footbridge that can then be tested, monitored and showcased to the construction and insurance industries. NZP is applying for Net Zero Pre-Commercialisation funding to exploit this opportunity and address these risk and insurance related concerns with their novel low carbon beams. If proven, it will enable NZP to secure sales of their innovative solution, supporting a reduction in embodied carbon in construction.