DefCrete · Deformable concrete composites for durable infrastructure

Current infrastructure elements requiring controlled deformation, such as tunnel support systems and bridge expansion joints, predominantly rely on steel components that face significant durability challenges due to corrosion. This project advances an innovative solution through auxetic cementitious composites (ACC) - a novel class of materials combining 3D-printed thermoplastic polyurethane (TPU) auxetic frames with cementitious mortar. Initial laboratory testing has demonstrated remarkable properties, including compressive strains up to 40% and highly recoverable deformation under cyclic loading (up to 10% strain). Building on breakthrough findings from an ERC Starting Grant, this Proof of Concept project will advance the technology from TRL 2-3 to TRL 4 through four key activities: numerical modelling for design optimization, cyclic performance characterization, manufacturing scale-up, and market validation. The project will establish manufacturing protocols for larger-scale elements (decimetre size), validate performance under application-relevant conditions, and develop a comprehensive commercialization strategy. The innovation addresses a clear market need by eliminating corrosion concerns while providing superior mechanical performance. The technology's unique combination of controlled deformation capacity and durability opens possibilities for multiple infrastructure applications beyond initial target markets. The project will engage key stakeholders including infrastructure owners, engineering consultants, and manufacturers to validate requirements and identify pilot opportunities. Successful completion will establish the foundation for scale-up through subsequent funding (EIC Transition), leading to pilot demonstrations and market entry. The technology offers significant potential for reducing infrastructure maintenance costs while improving performance and reliability of critical deformableelements.