Decarbonised Brick-facade project

The UK housebuilding sector is grappling with a myriad of critical challenges that threatens to undermine efforts to address the nation's housing deficit of 4.3million homes, needed to house our growing population. Central to this crisis is a severe shortage of skilled labour, particularly in bricklaying which has been exacerbated by an aging workforce and a protracted lack of investment in training and apprenticeships.

The bricklayer shortage within the UK, currently in excess of 33,000 has led to increased construction costs, extended project timelines, and compromised quality standards. Compounding these issues are outdated construction practices and reliance on traditional materials, which are both inefficient and detrimental to the environment.

The sector is further strained by an alarming deficit in material supply, despite escalating demand. In the period May 2022-2024 there was a 34% reduction in UK brick production, leading to insecure supply chains, a widening trade deficit and an alarming increase in carbon emissions, compounded by the annual import of 500 million bricks, shipped from across the globe.

Sustainability presents the most alarming challenge. Bricks require significant energy and resource in their production and transport; contributing in excess of 1.45m tonnes Co2e pa, conflicting with the UK's commitment to achieving net-zero emissions by 2050, and Welsh Governments target of achieving net-zero within the pubic sector by 2030\.

To overcome these challenges, there is an urgent need for a multifaceted approach; embracing innovative construction technologies, implementing sustainable construction materials, and building practices simultaneously. In response to a challenge to catalyse solutions posed by a UK leading construction manufacturer, Carapace has been tasked with investigating whether its proprietary technologies in heavily-filled composites can be adapted to create UK-made low-carbon, recycled panels; aesthetically replicating traditional brickwork to reduce costs, embodied carbon and build speed.

The project will be focused on investigating and demonstrating the technical feasibility to an industry leader, positioned and determined to drive positive change. Key value propositions include:

**Rapid installation, deskilled, low cost**. Using patented fixing methods installation time would reduce from 1 hour to 2 minutes per square meter, or from 35 day to 3 days per 3-bed house

**Low carbon**. Saving an average of 4.7t of carbon emissions per installation, or 6,400t of carbon emissions if 1% of the market was displaced.

**Aesthetics**: Replicating a wide range of traditional brick features, textures and colourings. Acting as a sustainable replicant of carbon-heavy materials, with out the 'eco-premium' financial penalty.