October 2018

Author:Kinga KorniejenkoUIA Expert

The Urban infra revolution project Journal N° 1

Project led by the Municipality of Lappeenranta

CIRCULARECONOMY

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The Urban infra revolution project

To mitigate the various risks posed by climate change, Urban infra revolution seeks to significantly reduce CO2 emissions - 80% reduction of CO2 emissions from 2007 level is the target for 2030 and completely eliminate waste is the target for 2050.

Urban infra revolution will test new solutions to reduce CO2 emissions in urban construction development. Side streams from industry (ashes, green liquor dregs, tailings, construction waste) will be utilized in urban construction by combining them into a high-value material to replace concrete. Novel material formulas will be created containing suitable side streams to be used as geopolymer binder (replacing cement) and as inorganic aggregates in geocomposites. An innovative bio-fibre reinforced geo-composites will be developed to achieve the high standards of construction industry. Automated, on-site, fast and versatile additive manufacturing construction system, without molds, will be tested in comprehensive urban scale. The material and the piloted technology will be multifunctional and enable aesthetic design with revolutionary shapes with very low CO2 emissions. Selected pilot structures will be manufactured within the urban infra and their properties are tested in real climate conditions. To implement and finally benefit locally the project results, a viable sustainable business ecosystem will be designed and environmental and socioeconomic impacts assessed.

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Partnership:

• Municipality of Lappeenranta;

4 SMEs:

• Apila Group Ltd.;

• FIMATEC Finnish Intelligent Module Apartments Oy;

• Design Reform Ltd.;

• Totaldesign Ltd.;

5 private enterprises:

• UPM-Kymmene Oyj;

• Outotec Ltd.;

• Nordkalk Corporation;

• Metsäliitto Cooperative;

• Stora Enso International Oy;

2 higher education and research institutes:

• Lappeenranta University of Technology;

• Saimaa University of Applied Sciences;

1 Region Development Company:

• Imatra

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Table of Contents

1. Executive summary 5

2. The context for the Urban infra revolution project 6

2.1 Global & European context 6

2.2 Lappeenranta & green reality 7

3. The Urban infra revolution concept 8

3.1 The aims of the project 8

3.2 Key components 10

3.3 Theconsortiumcomposition&keystakeholders 13

4. Implementation status 15

4.1 Themainactivities 15

4.2 Mainchallenges&risks 15

5. Conclusions and next steps 20

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1. Executive summary

The journal presents the progress in implementation the Urban infra revolutionproject is an answer for important global challenges connected with circular economy.The second section of this journal presentsthe background for the project and the global,Europeanandregionalcontextfortheundertakenplanned activities. It stresses the importanceof thisproject forEuropeanpolicy. This sectionalso introduces into themain project idea andshows complementary activities for sustainabledevelopmentthatLappeenrantawasundertaken.

Thenextsectionisashortprojectpresentation,including the main objectives and constructionof theproject. Theproject is very complexandthereisalargenumberoforganizationsinvolvedintheprojectactivities.Intheframeworkoftheconsortiumthedifferentorganizationcollaboratetogether. On the one side it creates hugepossibilities of innovative actions, but on theother side is great challenge for management.Additionally,themainstakeholdersareincludedinthissection.

The fourth section of the journal presents theimplementationstatusoftheproject.TheprojectstartedinNovember2017.Thefirsthalfyearwasaperiodof intenseworknotonly foramaterialsolutions and basement assumptions foradditivetechnology,butalsothecreationofthemanagement structure and the establishmentof the proper procedures of communicationbetween consortium members. In this part, itis also described the difficulties, barriers andchallenges linked to theexperimentalnatureofthe project. This section presents the activitiesthatareundertakentocreatetherightconditionsandloweringthebarriers.Themostofrisksinthisperiodwereconnectedwithinnovativecharacterof the project. There were applied three maininnovative area: material, production processand products. The project has an innovativenature.It isnotonlyimplementationofexistingsolutions, but also defining new standards andprovidingintensescientificresearch.

The last section summarises the state of theprojectandpresentsthestepsthatwillbemadein the near future.

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2. The context for the Urban infra revolution project

2.1 Global & European context

1 http://ec.europa.eu/environment/action-programme/

This project is in line with the EU action planfor circular economy by finding new uses forrecycledmaterials,increasingresourceefficiencyand lowering the carbon demand and achieverecycling level of C&D waste required by theEuropean Union in 2020 (70%). The projectalsopromotes theEU’s7thEnvironmentActionProgramme1withthepriorityobjectives.

Present urban infrastructure consists mainly of steel reinforced concrete based solutions. Boththesematerials contain high energy, virgin rawmaterialsandare intensive inCO2emissions. IntheLappeenrantaareaalone,CO2 emissions from cementandlimeproductionisca.393000ton/CO2. Current productionmethods are alsotimeand labor intensive, and don’t allow innovativeshapesnoradditionalfunctionstotheproducts.Recyclabilityofconcreteisrestricted:recyclingofsteel reinforcedconcreteelements isacomplexandcostlyprocess.Thesedifficultiesusuallyleadtothesituation,thatconstructionwasteremainslandfilled and generates unwanted costs. Littleattentionisalsopaidintorecyclabilityofmoderncomposite materials. Except demolition waste,there are also other materials in industrialcities that are landfilled unnecessarily: tailingsfrommining, green liquor dreg and ashes fromthe forest industry and energy production.This project strives to create sustainable, fullyrecyclablesolutionsforthese localsidestreamsthatare large involumebutalsochallengingto

reuse. In South Karelia, mining generated sidestreams and tailings are 884 000 ton/a. Tailingwaste from partnering Nordkalk equals ca170000ton/a. Total amount of slags and ashesgeneratedinthecountyis21507t/a.

Today, most national research fundingorganisations and EU funding instrumentssupport R&D projects improving the transitiontocirculareconomy.Developmentofalternativesolutionstohighenergyconsumingcementitiousbindersisoneofthemainconcernsoftheproject.There is aneed for new sustainable binderswith lower CO2 emissions and lower embodiedenergy of the binders used in the constructionsectortodesignsustainablebuildingenvelopes.Thereisaworld-widedemandformoreefficientbuildingproducts to significantly reduceenergyand resource consumption. The EU legislationis promoting the idea of eco-design and itsapplication inthe building industry, so the ideaof sustainable product development should beactivelypromoted.

AnotherEUchallengeisawarenessaboutnaturalresourcesandefficiency inwastemanagement.Theprojectfacesthischallengetroughthetakingunder consideration different waste materialsas araw products. Alot of mineral depositsin Europe are mostly depleted and, due toeconomic growth construction and demolitionwaste (CDW), ithasbecomeaseriousproblem.

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In the EU, CDW accounts for approximately25%-30%ofallgeneratedwaste,anditconsistsof numerous materials, many of which can berecycled.TheECWasteDirectivesays,inArt11-2b, that: “…by 2020, the preparing for re-use, recycling and other material recovery, including backfilling operations using waste to substitute other materials, of non-hazardous construction and demolition waste excluding naturally occurring material (...) shall be increased to a minimum of 70 % by weight.” The project will reuse debris generated during construction,renovation,anddemolitionofbuildingsbutalsoother waste materials and by-products, like flyash, bottom ash, biomass ash, mining wastesand other aluminosilicates waste minerals.Reuse of waste in making innovative materials

for urban architecture. The additional valuefor this topic is to change the way of thinkingabout these materials and, by recycling thosecomplexproducts that contain alotof valuablerawmaterials, creatingmore sustainable futureproducts.TheactionsintheareaofRecyclingofproductsandbuildingsarelinkedtotheEuropeanPriority Area “Improving Europe’s wastemanagement regulatory framework conditionsand excellence” in terms of standardisation,including aclassification of construction wasteasconstructionmaterials;aswellasofrecyclingcomplex products and buildings containingalot of valuable raw materials in acost-effective, resource and energy efficient andenvironmentallysoundway inorder to increasedomesticEUproductionofrawmaterials.

2.2 Lappeenranta & green realityLappeenranta is acity funded in 1649 on theshore of the lake Saimaa in south-easternFinland, about 30 kilometres from the Russianborder.ItbelongstotheregionofSouthKarelia.The city has approximately 73,000 inhabitants.Lappeenranta has undertaken alot of activitiesfor sustainable development. The city was theonly Finnish city among the 14 finalists in theinternational Earth Hour City Challenge 2014,organized byWWF.Nowadays, Lappeenranta isthelargestFinnishcitytojoinoftheHINKUcarbonreductioninitiative.Themainaimoftheinitiativeis reduce emissions by 80% by 2030 throughtheincreasingtheuseofrenewableenergyandimprovingenergyefficiency.Thecityisapioneerofenvironmentallyfriendlyenergyproduction.

The Urban infra revolution project is fully inline with this strategy and goes even further.One of the city’s strategic objectives is toestablish Lappeenranta as amodel city forsustainability, where growth is generated from

aclean environment and awaste-free world.In 2050, the city would like to have no landfillwaste, no greenhouse gas emissions and nooverconsumption.

The new solution (material, method, products,business models) enhances business in varietyof industries, and employment is addressed.The project interlinks experiments to normed,regulated industry and supervisory authoritiesby novelmaterial andmethods, aiming to newinnovative approaches in construction industry.Additive manufactured, technically improvedurbanstructuresstriveformoreversatileurbanspace usage exemplary new possibilities foroutdoorrecreation.

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3. The Urban infra revolution concept

3.1 The aims of the projectThe main aims of the project are:

• Enhancingsustainableconstructionincities.

• Developingrevolutionaryurbandesign.

• Enhancing circular economy in local urban constructionbusinesses.

• Developing climate change adaptation andmitigation.

Enhancing sustainable construction in thecitieswill be developed through the integratedapproach and complementary partnerships ofthe project providing aplatform for sustainableurban building development by enabling novel,highqualitysolutionsfortheurbanconstructionvaluechain.Theprojectstrivesfortheintegrationofenvironmental, economic, social and culturaldimensions of urban development. In thisproject the closed loop ofmaterials and faster,safer,more versatile industrial scale productionmethodsthatminimizenegativeexternalitiesofconstructionareexperimented.

Implementation of the other aim- developingrevolutionary urban design- will be based oninteraction of urban authorities, citizens, urbandesign experts, material R&D expertise andadvanced additive manufacturing technology.Applicable manufacturing technology and developed novel bio-fibre reinforcedgeocomposite material allow for designingrevolutionary urban structures about uniqueaestheticvaluethatwillcontributetourbansafetyandwelfarebydemonstratingmultifunctionalityandinnovativeuseofspace.

Enhancing circular economy in local urban construction businesses is also an importantprojectaim.Theobjectistodevelopscalableandtransferable circular economy demonstratingbusiness models based on added valueof local industrial symbiosis. Through theproject, business for local SMEs in technologydevelopment and construction as well as largeindustries will be enhanced. Novel, recyclableand industrial specifications meeting productshave considerable industry relevance withinternationalmarkets.

The project aims are holistic solutions fordeveloping climate change adaptation andmitigationthatenhancethestorageofcarboninprocessofrawmaterialsourcing,manufacturing,transportation, installation and assembly. Theprojectallowstointroducethecirculareconomythrough closing the loop with 3D printable,recyclablegeopolymercompositesmadeofside-streams(Figure1).

Theproject’smainimplementationactivitieswillincludealotoflinkedactivities.Firstly,convertingthe industrial side streams into recyclablematerialsthancanbeutilizedinarcticconditionconstruction including the comprehensivephysical and chemical characterisation ofvarious side streams considered in the projectand tailoring of thesematerials to achieve thedesiredproperties.Nexttaskswillbetodevelopsuitablematerialtechnologyandsimultaneouslymanufacturing methods. These elements areconnected and required perfect feedbackbetween each other. The important element is also scaling the technologies developed to

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industrial scale. This will include designing,buildingandtestinganewadditivemanufacturingdevice that will be used formanufacturing thefinalfunctionalstructuresmadeofindustrialsidestreams.Ithelpswithreformingthemethodsofurban building, creating avision of “urban city2050” with designers, policy-makers, citizensand other participants. Final activities will bedesigning the implementation of the proposedinnovation,additivemanufacturingconstructionelementsfromgeocompositesutilisingindustrialside streams, conjointly from business andenvironmentalperspectives.Asaresult,aviablesustainablebusinessecosystem isdesignedandenvironmentalimpactsareassessed(Figure2).

The outcomes contribute directly to theambitious goal on carbon free and waste freecities by reduced amount of unutilised wastefrom local industries and lower CO2 emissions. New innovative products and new industrialscale technology enhance the local industrybusiness and accelerate the employmentpossibilities in circular economy. Developedmaterialsand technology improve the safetyofconstruction areas and enhance construction

industrysustainabilityandproductivity.Industrialsymbiosiscreatedaddsbilateralvalueforprojectpartnersandlocalconstructionindustrycreatingimproved possibilities to operate in SouthKareliaregion.Aestheticurbansceneryupgradesthe living convenience in the city whereasmultifunctional and technically improved urbanstructures strive for improvedcitizenwelfare inthe city by aholistic approach by enabling forexamplebetternoisecontrol,moreversatileurbanspace usage and new possibilities for outdoorrecreationandlighttrafficinextremeconditions.

As an outcome of the project, the followingresultswillbeachieved:

• Closedloopinconstructiondemonstrated:recyclableproductsofrecycledmaterialsforurbanconstruction.

• Unutilisedsidestreams/recycledmaterialsusedasrawmaterialstoavoidtheuseofvirginmaterials.

• Technicallyimprovednewmaterialsinclosedloopurbanstructuresapplicableforextreme climates.

• Revolutionary,aesthetic,safemultifunctionalurbanstructuressolvingrealurbanissuesforexampleneighbourhoodnoisecontrolandsafetyprotection.

• Productacceptanceproceduresandcriteriacreated.

• Enhancedvalue-generatingcirculareconomybusinessforlocalindustries.

• ExistinginternationalmMarketsforthesolution.

• Lower carbon emissions by replacing use of cement with circular materials and by useof recycled rawmaterials from local sourcesto reduce logistics CO2 production andtransportationenergyconsumption.

Figure 1. Closing the loop with 3D printable, recyclable geopolymer composites made of sidestreams.

Source: Matilainen M., 2018, Urban Infra Revolution UIR Developing a clean, safe and renewable city, https://

geopolymer.org/fichiers/?dir=gpcamp-2018

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3.2 Key componentsNewgenerationurbandevelopment is focusingalot on smart technologies, but modernconstructionengineeringisamoreimportantrolewhencreatingsmartcities.Themainconceptionis that the side-streams from industry will beutilizedinurbanconstructionbycombiningtheminto ahigh-value material to replace concrete.Thanks to it the CO2 emissions will reduce byavoiding the use of cement and preferringlocal material sources. During the project theside-streams will be analysed, characterizedand modified by activation. In the same timethe method to pre-treat and activate tailingswill be developed separately. Novel materialformulas will be created, containing suitable

side-streams thatwill be used as ageopolymerbinder (replacing cement) and as inorganicaggregates in geocomposites. The next step will beafibreadditive.Aninnovativefibrereinforcedgeocompositeswillbedevelopedtoachievethehigh standards of construction industry. Owingtothis,amethodtorecycletheproductsdirectlyaftercrushingcanbedevelopedandunnecessarydumpingofconstructionalwastecanbeavoided.Inthelaboratoryscaleitemswillbepreparedtotestthematerialcombinations(Figure3),beforetheyareusedandtestedinfullscalepiloting,toensurethequality,technicalperformance,safetyand appearance of the materials and productsinarcticclimateconditions.Multifunctionaland

Figure 2. The project conception, including involved organizations.

Source: Matilainen M., 2018, Urban Infra Revolution UIR Developing a clean, safe and renewable city, https://geopolymer.org/fichiers/?dir=gpcamp-2018

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aesthetic products, that cannot to be preparedwithconservativeconstructionmethods,willbedesigned to create anovel urban environment.The innovative future vision, Urban City 2050,will be created and visualized in aVirtualenvironment, in cooperation with designersand stakeholders. Novel construction solutionsfor the urban environment will be designed.Multifunctionalityoftheproductswillbeensuredwithinnovativeshapes.DesignrestrictedproductmethodswillreplacewithanIT-directeddevice,and time and labor intensive methods withautomated,additivemanufacturingmethod.Thisallows alow-carbon and safe on-site building,avoiding disposable moulds and unnecessarytransportation. Selected pilot structureswill bemanufactured within the urban infra and theirpropertiesaretestedinarcticclimateconditions(Lappeenranta). Industrial piloting for moredemandingconditionswillbepilotedinthesameway.Toimplementandfinallybenefitlocallytheproject results, aviable sustainable business

ecosystem will be designed and environmentaland socioeconomic impacts will be assessed.Thefinalimplementationoftheresultsdemandsthe creation of the circular economy businessmodel. Social and technical acceptance of thematerials iscrucial; thisrequiresbothchemical,physical and sociologic testing, and life cycleanalysis.Thefinalrevolutionandenhanceinlocalbusinessispossible,transferrableandreplicableglobally, when the acceptance procedure andincorporation of product specifications areprepared(Figure4).

In the project, it is possible to specify thekeycomponents:

• Material- the materials developed canbe utilized widely in different applicationsin urban infra and industry, also in arctic,extreme weather and chemical conditions,toreplaceconcrete.Assimilarrawmaterials/sidestreamsareproducednationally(millionsof tons annually) and internationally, the

Figure 3. The scheme of the activities in the project.

Source: Matilainen M., 2018, Urban Infra Revolution UIR Developing a clean, safe and renewable city, https://geopolymer.org/fichiers/?dir=gpcamp-2018

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solution is easily transferable and scalable.It is also possible to scale-up the solutioninternationally through the internationallyoperating industrial partners. Because ofthat demand for these new materials isstatedinternationally.

• Products-designedproductsreplacecommon,widelyusedstructuresinurbanenvironment.The global concrete market size 2015 wasUSD492.2billion.Betterperformancemakesthemmoreattractiveandpopular,enhancingbusinesspotential.Thedurability inextremeclimate and recyclability provide sustainablesolutionsforinternationalmarkets.

• Method-additivemanufacturing technologyis amobile application that can also beutilizedbySMEs,andwillbecommercializedinternationally(by2020).

• Business- defined business models areadjustable to enhance local businesses

globally. Solutions provide new possibilitiesfor variety industrial sectors (waste originraw material preparation, urban design,technology developing and manufacturing,construction industry) and sizes. Only inFinland,annualbuildingconstructionmarketsare22billionEUR.

Resources needed- legal acceptance of thesolutions is mandatory for scaling-up. Theoperatorsinthelocalsectorarecontactedintheproject,tofindsuitable/willingactorstostartfull-scale production. If needed, additional nationaloperators will be contacted to scale-up thesolution.Finalresponsibleoperatorsareobligedtoinvestinthetechnologyandlicenses,toutilizethe solution. Local administrative support (alsofinancial) will be needed. Project partners areinternationally operating corporations, creatingabaseforinternationalmarketsforthesolution.

Figure 4. The project team working on materials compositions.

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3.3 The consortium composition & key stakeholdersConstructionhasbeenoneoftheslowlygrowingindustriesinthearea:thereareover1000officesand it employs over 3,800 people. Mining andforestindustryemploysaltogether3,500people.Unemployment (2016) rate in Lappeenrantaarea is ca. 14,6%and in the Imatra area16,4%as average unemployment rate in Finland is13,2%. Partnering Outotec, Norkalk, UPM-Kymmene, Metsä Fibre are among the biggestemploying companies in Lappeenranta. StoraEnso isoneof thebiggestemployers in Imatra.Thisprojectfacilitatespracticalcirculareconomybusinessaffectingwidelytothesocio-economic-environmentalwelfareofthearea.

Theproject is implementedbygrate consortiumthat include different organizations representingdifferent sectors of the economy. The vertical

integrationofwasteproducingindustries(mining,forestry), research, R&D, technology producersand end users enables efficient process fromidea towards commercialised products, as thecooperationofbigorganizationandSME’screatecomplementaryhorizontalintegrations(Figure5).LappeenrantaUniversityofTechnologycontributescomprehensive knowledge about industrial sidestream processing and simultaneous economic-technical-environmental examination of thesolutions developed in the project. R&D SMEsproviderequiredexpertiseinmaterialformulation,urbandesignandproceduresforadhocsolutionbuildingandpromptpiloting.Technologyproducersensuretheconstructabilityoftheaimedsolutionandviceversa.Citiesprovidingaliveurbanpilotingplatform and dialogue with local society ensure

Figure 5. Concortium composition.

Source: Matilainen M., 2018, Urban Infra Revolution UIR Developing a clean, safe and renewable city, https://geopolymer.org/fichiers/?dir=gpcamp-2018

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citizens and urban planning satisfying results.Globally operating industrial partners provideasustainable base for international markets forthedevelopedsolutions.Throughouttheproject,competitive circular economy business models,value chains and cross sectoral cooperation willbe created to develop asustainable solution formarketdemand.

Theprojectplanwillengagethestakeholdersateachstep.Beginningatthecreationoftheidea,throughtheimplementation,endingoftheresultspromotion.TheprojectideawasintroducedfirstinGreenLappeenrantaImatra(GLI)developmentgroup meeting in November 2016. The ideawas approved to initiative measure. GLI groupconsists of members from city of Lappeenranta and Imatra, Regional Council of South Karelia,Tekes–theFinnishFundingAgencyforInnovationandregionalcompanyrepresentatives.ThewiderstakeholdergroupincludeGLIgroupandvariousrelevantstakeholderslikeGreenEnergyShowroom(GES),which isanactivenetworkofenergyandenvironmental sector companies operating inSouth-Karelia, the members of which want togeneratebusinessthroughsustainablesolutions.The wider stakeholders have contributedto project design with supportive actions incommunication and seeking for appropriateactors to start project design. Consultation andco-design by wider stakeholders has started inmid-November 2016. Project design startedwith identifying the needs:widely used cementin concrete manufacturing is very valuable andthereisamassiveamountoftailings,flyash,sodaash (green liquor dregs), industrial side streamsof forestand limestone industryavailable in thearea.Theyearlyamountsofsidestreamsexceedthree times the amount of household waste.Balancing, recycling and innovation is highlyneeded. Promotion of circulation economy isspearhead of City of Lappeenranta’s strategy.

The resource wise road map has approved in2015 for achieving carbon neutral air, ensuringpurewaterandgettingridofwasteby2050.Theconstructionindustryisinprocessofbigchangesconcerning materials, construction techniques,managementanddesign.Thewiderstakeholdergroupparticipatedinco-creationofthesolutionstobetestedandexperimented.

The wider group of stakeholders includeslocal, regional, national and EU institutions,agencies, organisations and associations:GreenLappeenranta Imatra development group,Tekes, Regional Council of South Karelia, Hinku(network of carbon neutral municipalities),FinnishSustainableCommunitiesnetwork,GreenEnergyShowroom(activenetworkofenergyandenvironmental sector companies operating inSouthKarelia(SK),over40members,companies,SMEs, universities, cities, municipalities whowant to generate business through sustainable solutions).Environmental,employmentandotherrelatedauthoritiesandassociations:ChamberofcommerceofSK,EntrepreneursofSKbelongtostakeholders.Intheprojectimplementation,theCity of Lappeenranta maintains aparticipativeapproach, share tasks and responsibilities withthe stakeholders in all WPs. Stakeholders willcontributeinimplementationbysupportiveandassisting tasks for activities. They will enableexperimenting and testing of novel circulatedmaterial and printed products of the newmaterial for urban environment. Infrastructuremodification, city design, environmental testingare taskswhere various actors and experts areneeded.Citizens,students,schoolsareimportantstakeholders in spreading and adapting newinnovationsandfuturemind-set.Stakeholdersareimportantindisseminationactivitiesanddeepenexpertisewith their networks and experiences.Contribution of environmental authorities isessentialthroughouttheproject.

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4. Implementation status

4.1 The main activities

2 ŁachM.,KorniejenkoK.,Hebdowska-KrupaM.,MikułaJ.,2018,The Effect of Additives on the Properties of Metakaolin and Fly Ash Based Geo-polymers,MATECWebofConferences,vol.06005,pp.8.

The project started in November 2017. Thefirst half year was the period of intense worknot only for amaterial solutions and basementassumptions for additive technology, but alsothe creation of themanagement structure andthe establishment the proper procedures ofcommunicationsbetweenconsortiummembers.In this time more than 20 raw materials hasbeencarefullyinvestigatedandtheyareappliedas a part of geopolymer composites. The some promising recipes have been developed. Now,theyaretestedforprocessingproperties.

Animportantelementfortheconsortiumisalsocommunication. The communication base onboth traditional collaboration (team meetings,Figure 6.) andmodern ways of communication(via the Internet). The good communicationis ensured through the consortium leader. Allproject partners participate in the decision

makingprocess.Themanagementoftheprojectis performed in away toensure theactive roleof each of the partners: management plan with milestonesandcleartasksforeachpartner.

4.2 Main challenges & risksThe main challenges connected with projectimplementationonthefirststageareconnectedwiththeinnovativecharacteroftheproject.

Thefirstinnovativeelementismaterial.Growingenvironmental awareness and importanceof development of sustainable constructionmaterials for decreasing environmental impactofconstruction industryaremainmotivators toresearch works on new, innovative materials’solutions.Theproductionofthemostimportantbuildingmaterialof the20thcentury-Portland

cement that there is amain material used forurbanarchitecture,isassociatedwithsignificantenvironmental pollution. The process requiresveryhightemperatureanditisenergyconsuming.During themanufacturing there is theemissionof significant amounts of carbon dioxide andhighlytoxicnitrogenoxidesintotheatmosphere.Moreoverithasalotofotherdisadvantagessuchas:energy-andnon-renewablenaturalresource-intensityandquestionabledurability2.Itisclearlyincompatiblewithrationally“sustainable”.These

Figure 6. The project team working together.

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factors show that new solution in this area isrequired. The most promising alternative isinorganicpolymer(geopolymer)technology3.

Geopolymers are agroup of materials definingas inorganic aluminosilicate polymers with specific composition and properties. The name‘geopolymer’wasfirstusedbytheFrenchscientistProfessor Joseph Davidovits in 1970. Thesematerials have very highmechanical propertiesandexcellentresistancetochemicallyaggressiveenvironments, especially resistance to avarietyofacidsandsalts4.Theywereinitiallydevelopedasafireresistantalternativetoorganicpolymers.They have good fire resistance (up to 1000°C)and no emission of toxic fumes when heated5. Nowadays, the geopolymers aremainly appliedinconstructionindustry.

One of the expected result of the project is todesignnewmaterialsforadditivemanufacturing,materials with tailored properties that areenvironmentally friendly and cost effective.Theprojectwill demonstrate theabilityofnewmaterials– geopolymers and processes toachieve finished components for constructionindustry with reduced life cycle costs. Thiscompositesshould:

• closingtheloopofconstructionmaterial;

• be applicable for extreme (arctic) weatherconditions;

• bereinforcedwithbiofibres

3 PalomoA.,KrivenkoP.,Garcia-LodeiroI.,KavalerovaE.,MaltsevaO.,Fernández-JiménezA.,2014, A review on alkaline activation: new analytical perspectives,Mater.Construcc.,vol.64,Iss.315,pp.22.

4 AlomayriT.,ShaikhF.U.A.,LowI.M.,2013,Thermal and mechanical properties of cotton fabric-reinforced geopolymer composites, „JournalofMaterialScience”,vol.48,p.6746-6752.

5 VickersL.,vanRiessenA.,RickardW.D.A.,2015, Fire-Resistant Geopolymers. Role of Fibres and Fillers to Enhance Thermal Properties,Springer,Singapore-Heidelberg-NewYork-Dordrecht-London,pp.129.

6 KorniejenkoK.,ŁachM.,Hebdowska-KrupaM.,MikułaJ.,2018,The mechanical properties of flax and hemp fibres reinforced geopolymer com-posites,IOPConferenceSeries:MaterialsScienceandEngineering,vol379,pp.9.

7 NataliA.,ManziS.,BignozziM.C.,2011,Novel fiber-reinforced composite materials based on sustainable geopolymer matrix,ProcediaEngineer-ing,vol.21,p.1124-1131.

• bebasedonlocalindustrywastesisdeveloped(Figure7).

The project has undertaken the topic ofbiofibers for reinforcement the composites.The improvement the mechanical propertiesby reinforcing the matrix trough bio fibresaddition is beneficial form the environmentalpointofview6.Thereplacementofthesyntheticfibres with their natural counterparts reducessignificantly the environmental impact (closingimportantlifecycles,includingCO2).Thenaturalfibreshavealsootherfeaturessuchas7: low cost of production, low density, they are renewablein short time, non-toxic, and easy to process.It is also one of themost important innovativeaspects in the project.

Figure 7. The raw materials invastigated in the project.

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Howeverthefirstpublicbuildingwithstructuralgeopolymer concrete was built in 2013 in Australia and also the Russian companyRenca has developed eco-friendly cement foradditive manufacturing technology, still, thereisn’t formula for geocomposite or examplesof construction products created being bothadditive manufactured in construction scaleand achieve the properties to fill the highlyregulated demands of materials in extremeconditions: strength, resistance to frost, dirt,moist,mould.Inaddition,therearenoexamplesof geocomposites successfully reinforced withbiofibres in industrial scale. Finland is one oftheleadingcountriesintheworldinmicro-andnano-scalecellulosecomposites.Thistechnologyis transferred to serve inorganic materialtechnologyandbuildingindustry.Theinnovationitself is potentially the first manufacturingmethod demonstrating fully closed loopconstruction:builton-site,localwastebasedandfullyrecyclableconstructionmaterials.

The second important innovative aspect in theproject is additive manufacturing technology.Themain challenge isnotonlydevelopmentofzero-waste technology of 3D printing, but alsouseasarawmaterialwasteproducts.

Additive Manufacturing is arapidly developingindustrial sector and, potentially, adisruptivetechnology. The project is an answer for new challenges such as resources saving andenergy efficiency and sustainable comparedto subtractive technologies. Unfortunately,the full exploitation of 3D AM processes iscurrently limited due to the in-process and in-service performance of the availablematerials’

8 NematollahiB.etall.,2017,Current Progress of 3D Concrete Printing Technologies,34thInternationalSymposiumonAutomationandRoboticsinConstruction(ISARC2017),pp.8.

9 XiaM.andSanjayanJ.,2016,Method of formulating geopolymer for 3D printing for construction applications.MaterialsandDesign,vol.110,p.382–390.

sets, especially in application in constructionindustry: ‘While 3D printing techniques have been successfully applied in a wide range of industries such as aerospace and automotive, its application in concrete construction industry is still in its infancy8’. Contemporary only someprototype solution in the area of geopolymersmaterial were designed in Australia, Chinaand Russia9.They are based mainly for powderbased technology and have alot of limitations.The limitationsaremainlyconnectedwithusedmaterials. The further development of thistechnology required improvements to designnewmaterials, toassessmaterialsperformanceandtoimproveprocessingstrategies.

The innovative material and manufacturingmethod create the innovative products forurban architecture. This project incorporates urban design, as the gained exquisite processof structures allows novel functionality withmore flexible, unique design in infrastructure.Additionally, in the project there will be thedevelopment of adigital 3D model coveringthecity.Thismodel isused invariousways, forexample for urbanmediation with citizens andurban development purposes such sunshinesimulation and noise modelling. This projectutilizes 3Dmodelling to introduce new, not yetexistingstructurestodifferenturbanactors.

Available additive manufacturing technologiescannotyetmeetthe industrialscaleneededforthe construction industry. Also, the materialsstruggle in meeting the quality standards ofarctic conditions. This project strives for highquality, multifunctional, industrial scale urbanconstructioninextremeweatherareas.Wewant

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tobringtheproductionclosetothebuildingsite,use local raw materials and close the materialloop in order to diminish the CO2 emissions of urban building and enhance zero waste arcticcities. Traditional construction industry is veryregulatedandexperimentally restrictedbut stillakey player when moving from high energysocietytocirculareconomy, low-carbonsociety.Thereforewewanttotakeinitiativestodevelopand provide anew platform to experimentsustainableurbaninnovationsforvivid,modern,cleantechnologypioneeringcities.

The project also emphasizes on new productswith afunctionalized approach that will havestrongsocietalandenvironmentalimpact.Moreimportant social and environmental benefitsfrom the implementation of the project resultswillincludeinparticular:

• Energyefficiency–lowerenergyconsumptioncomparison with cementitious materials,especially because lower temperature of manufacturing.

• Reductionofcarbonfootprint-geopolymersduring production emit much lower

greenhouse gases comparing to traditionalconstruction materials such as Portlandcement. It is estimated that the productionof geopolymers produce 4–8 times lesscarbondioxidethancementproduction,andin the same process the using of energy is limited(2–3times).

• Waste reduction– manufacturingwithout waste.

• Circular economy– possibilities of usingfor manufacturing waste products as arawmaterialssuchasflyashesorclaybricks.

Themostproblematicfortheprojectaredelaysconnectedwithworksonmaterials.Accordingtothepreviouslyplannedscheduletherearesomeslight delays in the project, but there is crucialelementthatwillbecontinuedduringtheprojectand because of that it needsmore time to besuccessfullyfinished.Theotherrisksisconnectedwiththe implementationofanewmaterial intoadditivetechnology.Howevertheconsortium isprepared for this challenge, it is still some riskthatperformanceofthetechnologydon’tmeettheexpectations/demands.

Table 1: Mapping urban infra revolution against the established uia challenges

Challenge Level Observations1.Leadershipfor

implementationLow Theproject leader is involved in theprojectsandmanagevery

professionally.Allprojectpartnersparticipateindecisionmakingprocess.Themanagementoftheprojectisperformedinawaytoensureactiveroleofeachofthepartners

2. Public procurement

Low The public procurement procedures connected with tenderprocedures, predicted for the project, have been successfullyfinished.

3.Integratedcross-departmentalworking

Low The actions delivered by other departments are in time. The cross-departmentalissmooth.

4.Adoptingaparticipativeapproach

Low The consortium is characterized by effective coordinationmechanisms.

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Challenge Level Observations5.Monitoringand

evaluationMedium Accordingthepreviouslyplannedscheduletherearesomeslight

delayedintheproject,butthere iscrucialelementthatwillbecontinueduringtheprojectandbecauseof that itneedsmoretimetobesuccessfullyfinished.

6.Communicatingwith target beneficiaries

Medium Thecommunicationwithtargetbeneficiariesisagreatchallenge,becauseeachurbaninvestmentmustbeacceptedbyallinhabitants(locallegislation).Thecommunicationwithtargetbeneficiariesisveryimportantelementforsuccessfulintroduction.Thecommunicatingwiththetargetuserswillbethemostimportantchallenge in the next period of the project implementation.Theideaofusingsidestreamsincentralcityconstructionsmayawake concerns about health and safety and environmentalsafety inpublic.Thispresumableresistanceisovercomebythedialoguewithauthoritiesandbycreatingatransparentproductacceptance procedure for the product including the physicalandchemicalpropertiesof thematerial.Anotherapproach forovercoming the obstacles mentioned is active dialogue withpublic and construction industry as part of project in piloting,sustainabilityassessmentandcirculareconomybusinessmodelsassessment. Virtual showrooms are utilized in simulating thefuture applications and innovative structures that do not existyet,butareenabledbytheinnovativesolutioncreated

7.Upscaling Medium The most important challenges are connected with upscalingaccording to technology as well as legislation. The solutionrepresents new construction materials which existing productstandardization and regulations cannot be directly applied.Thispossible regulatoryobstacle is taken intoconsiderationbyclarifyingtherelevantstandardsandregulationsinearlyphaseoftheprojectandopendialoguewithrespectiveauthorities.The most important challenge in this stage is legislation.The solution represents new construction materials whichexisting product standardization and regulations cannot bedirectly applied to. This possible regulatory obstacle is takeninto consideration by clarifying the relevant standards andregulationsinthisearlyphaseoftheprojectandopendialoguewith respectiveauthorities. The requiredmaterial andproductproperty testing is carried out in order to have an identifiedproduct acceptance procedure for the material developed inthe project. Revolutionary materials and construction designsmay also face lack of trust from the regulated, conservativeconstructionindustry.Familiartechnologiesareeasilyprioritizedovermoderninitiatives.

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5. Conclusions and next steps

Theprojectisaresponseformarketandsocietyneeds, especially in the area of developmenttechnologies for circular economy. The main challenge is not only the development of zero-wastetechnologyfor3Dprinting,butalsouseasarawmaterialwasteproductsandproduce theprototypesolutionsforurbanarchitecture.CitiesinEuropeareinreformationduetourbanizationand climate change. Novel space usage,multifunctionality of structures and materialresistanceinrapidlychangingclimateconditionsare in demand. As the amount of constructionincreases in the cities, an increased amount ofcement giving way to CO2 emission (being 5.2billion ton in 2015). According to calculationsit’s nearly 10% of all human CO2 emissions. The project aims to develop procedures,technologies and business models that enableunutilized side streams to be converted intosustainable high-quality, low in CO2 materials withimprovedproperties.

However the project is very innovative andchallenging, it is introduced by the strongconsortium.Tillthebeginningoftheprojectalotofworks has been done, especially in the areaof material development: characterizing wastematerialsandfortailoringthepropertiesofthewaste streams to enable their suitability for the process and preparing suitable recaptures forfurtherworks. The next challenge is connectedwith preparing the techniques applied formanufacturing the novel composites, especiallyadjusted to meet the requirements of thematerials as well as the target use.

The further steps are connected with thedesign urban structure using the newmaterialand intensify the activities connected withproject promoting between the citizens. Thesteps of consultation with the potential usersis very important for the project, becausethe acceptance of society is key factor for theprojectimplementation.

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Urban Innovative Actions (UIA) is an Initiative of the European Union that provides urban areas throughout Europe with resources to test new and unproven solutions to address urban challenges. Based on article 8 of ERDF, the Initiative has a total ERDF budget of EUR 372 million for 2014-2020.UIA projects will produce a wealth of knowledge stemming from the implementation of the innovative solutions for sustainable urban development that are of interest for city practitioners and stakeholders across the EU. This journal is a paper written by a UIA Expert that captures and disseminates the lessons learnt from the project implementation and the good practices identified. The journals will be structured around the main challenges of implementation identified and faced at local level by UIA projects. They will be published on a regular basis on the UIA website.