The development and modernisation of UK infrastructure requires the ubiquitous use of concrete, but conventional casting methods are inefficient, inflexible and dangerous. The UK Industrial Strategy White Paper identifies that the UK has insufficient skilled labour to undertake the next 10 to 20 years of essential infrastructure development, to deliver the £600Bn National Infrastructure and Construction Pipeline. Hence, the development of world-leadership in automation of key parts of the construction supply chain is critical. 3DCP removes the need for conventional moulds or formwork, by precisely placing and solidifying specific volumes of cementitious material in sequential layers under a computer controlled positioning process. This represents a radical 'mould-breaking' change, that challenges the implicit mind-sets of architects and engineers, where for millennia casting has required moulds, which in turn constrain the form, geometry and variety of building components and systems. 3DCP technology implicitly binds design and manufacture in contrast to current practice where designers and constructors are separated organisationally, institutionally and professionally. 3DCP is creating worldwide interest from the construction sector and lends itself to using readily available robotic arms as positioning tools for clever material deposition devices, which enable the manufacture of components to be digitally driven. However the required pull into commercialisation requires architects and engineers to engage their clients with designs suitable for the manufacturing process. However the underlying science as it relates to concrete composite materials simply does not exist. This project will be the first in the world to systematically investigate the interrelationships between rheology, process control, design geometry and reinforcement design in relation to there impact on the hardened properties of the final material. The project goes further and makes the first steps towards encoding the rules learnt into a software environment that will seed the development of new design software in the future.

Reducing the demand for new materials and reducing embodied carbon will be one of the most significant challenges that the construction sector faces in the coming decades. The 20th century oversaw a 23-fold increase in accumulated resources extracted, including materials currently locked in buildings and infrastructure. This rate of consumption far exceeds the planet's capacity to regenerate, and has serious implications for global greenhouse gas (GHG) emissions. Addressing this interlinked material demand and emissions problem requires a step-change in practice, and implementation of circular economic (CE) reduce-reuse-recycle strategies, where materials are highly valued and remain in use for as long as possible. However, detailed knowledge of material types and quantities that are locked in the building stock is lacking, making estimation of CE potential unfeasible. This project will develop a spatially multi-scale framework to assess CE potential in individual buildings, cities and countries. Application of this new framework to non-residential construction in the UK will enable estimation of CE potential in the existing stock - at building, city and national level. The framework will utilise bottom-up material flow analysis to assess building level material intensity, embodied carbon and CE potential. This will be combined with remote sensing and satellite data to assess city level building stocks, with demand modelling applied to explore future material demand scenarios - considering different construction mixes and optimised CE potential. The embodied carbon implications of this material demand will also be forecast so it can be considered as part of UK decarbonisation pathways. This will be essential as the proportion of embodied carbon in the whole life carbon of the built environment is only increasing, and will continue to do so as the electricity grid is decarbonised and thus operational GHG emissions are minimised. This research will build the evidence base to demonstrate the role the circular economy can have in tackling these challenges in construction, and provide the knowledge required to facilitate shifts in policy and practice.