Following the Grenfell Tower fire the industry sector concerning cladding of high-rise buildings has been endeavouring to find alternative cladding materials that are both safe and financially viable. The technological challenge is to find a solution that is fire resistant, lightweight, durable, thermally insulating and will support its own weight (sufficiently robust /engineeringly substantial). This combination of properties is not easily achieved using conventional materials. Currently the industry standard is a composite panel with aluminium skins and a polyethylene core, whilst this fulfills the requirements of cost, durability and weight, it lacks sufficient insulating capabilities (therefore requiring it to be used in combination with an insulating layer) and fire resistance. The latter property is most important given recent events where the polyethylene core has been observed to melt and ignite the flammable insulating layer below the panel.

The proposed project will use a material to make cladding which does not burn, melt or produce noxious or poisonous fumes when exposed to flame and high temperatures. This material is non-oxidising hybrid carbon-carbon, a variant of a material that is used in high performance braking systems. The proposed system will use two flat sheets of this material separated by a ceramic foam filled gap that will provide the insulating performance and through which water may be conducted to provide additional cooling. The simple and slimline construction will provide a cost-effective solution through the reduction of installation costs and the non-requirement for an insulating layer. This will offset the higher cost of manufacture of the new panel.

The project is planned to last six months and take the product from small scale testing through to a full scale demonstration in an industry recognized test. A successful project will produce significant export and licensing opportunities for UK companies in what is projected to become a $15bn market in 5 years time.