This 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.

The 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.