Decarbonising Precast Concrete Manufacturing
Lead Participant:
LAING O'ROURKE SERVICES LIMITED
Abstract
The **Decarbonising Precast Concrete Manufacturing** project is to deliver a comprehensive feasibility study for implementing deep decarbonisation interventions at Laing O'Rourke's Explore Manufacturing existing precast concrete production process, based at Steetley, Worksop.
**Strategic priority -- decarbonising construction**
Explore Manufacturing represents the state of the art in offsite manufacturing for the construction industry. Government strategy through Construction 2025 and the Construction Sector Deal targets both higher pre-manufactured value and 50% carbon reduction in the built environment as well as a Net Zero 2030 target. There is significant need to further enable long-term decarbonisation opportunities to meet this strategic direction. Construction represents 6% of UK GDP and the built environment contributes 39% of all greenhouse emissions, specifically 11% of the total being upfront embodied carbon from construction of assets {Global Status Report 2017\], so carbon intensity will make a significant impact on overall carbon usage in the UK. Moving concrete building production from in situ to offsite (precast) immediately has a significant impact on lowering embodied carbon in buildings; moreover we are seeking to increase this further by deep decarbonisation of the precast manufacturing process offering anticipated total savings of some 56% .
**Comprehensive and systematic feasibility review**
Our project will investigate every facet of the production process from low carbon, concrete, steel and aggregate materials and technologies to the overall formwork and curing systems. This initial scoping will quantify, prioritise and define interventions for decarbonisation of the precast production process and will then conduct feasibility trials for these interventions, including incorporation of low carbon materials and production technologies to decarbonise the manufacturing process. Examples of identified technologies include low carbon concrete, recycled reinforcement, recycled and alternative aggregates, and formwork systems. These trials will consider implications into materials supply, handling, materials and technology introduction to production line, throughput considerations including curing time, and other storage and logistics issues.
The feasibility study will conclude with an impact prioritised roadmap and business case for decarbonising precast concrete construction at Explore Manufacturing. This will provide a flagship example to others in the industry to replicate thus widening the impact.
**High quality team**
The study will be led by Laing O'Rourke, based on our Explore Manufacturing facility, in collaboration with the following partners:
\*University of Cambridge -- leading the carbon quantification and decarbonisation impact prioritisation
\*University of Sheffield, Advanced Manufacturing Research Centre (AMRC) -- process impact simulation to understand throughput and productivity implications of interventions
**Strategic priority -- decarbonising construction**
Explore Manufacturing represents the state of the art in offsite manufacturing for the construction industry. Government strategy through Construction 2025 and the Construction Sector Deal targets both higher pre-manufactured value and 50% carbon reduction in the built environment as well as a Net Zero 2030 target. There is significant need to further enable long-term decarbonisation opportunities to meet this strategic direction. Construction represents 6% of UK GDP and the built environment contributes 39% of all greenhouse emissions, specifically 11% of the total being upfront embodied carbon from construction of assets {Global Status Report 2017\], so carbon intensity will make a significant impact on overall carbon usage in the UK. Moving concrete building production from in situ to offsite (precast) immediately has a significant impact on lowering embodied carbon in buildings; moreover we are seeking to increase this further by deep decarbonisation of the precast manufacturing process offering anticipated total savings of some 56% .
**Comprehensive and systematic feasibility review**
Our project will investigate every facet of the production process from low carbon, concrete, steel and aggregate materials and technologies to the overall formwork and curing systems. This initial scoping will quantify, prioritise and define interventions for decarbonisation of the precast production process and will then conduct feasibility trials for these interventions, including incorporation of low carbon materials and production technologies to decarbonise the manufacturing process. Examples of identified technologies include low carbon concrete, recycled reinforcement, recycled and alternative aggregates, and formwork systems. These trials will consider implications into materials supply, handling, materials and technology introduction to production line, throughput considerations including curing time, and other storage and logistics issues.
The feasibility study will conclude with an impact prioritised roadmap and business case for decarbonising precast concrete construction at Explore Manufacturing. This will provide a flagship example to others in the industry to replicate thus widening the impact.
**High quality team**
The study will be led by Laing O'Rourke, based on our Explore Manufacturing facility, in collaboration with the following partners:
\*University of Cambridge -- leading the carbon quantification and decarbonisation impact prioritisation
\*University of Sheffield, Advanced Manufacturing Research Centre (AMRC) -- process impact simulation to understand throughput and productivity implications of interventions
Lead Participant | Project Cost | Grant Offer |
|---|---|---|
| LAING O'ROURKE SERVICES LIMITED | £404,345 | £ 202,172 |
Participant |
||
| SELECT PLANT HIRE COMPANY LIMITED | ||
| UNIVERSITY OF SHEFFIELD | £32,498 | £ 32,498 |
| INNOVATE UK | ||
| UNIVERSITY OF CAMBRIDGE | £119,899 | £ 119,899 |
People |
ORCID iD |
| Adam Locke (Project Manager) |