An exclusive opportunity to become a vital part of the supply chain for the UK division of a prestigious global blue-chip company. The challenge holder is looking for pioneering material suppliers ,processors and manufacturers, capable of providing cutting-edge sustainable solutions to replace components currently produced with timber, plywood and other traditional construction materials. Successful solution providers will be rewarded with a feasibility and pilot programme. 

Our challenge holder is a UK based global PLC with a portfolio of outdoor product lines with clear strategic sustainability and circular economy targets. &nbsp;
Within one product line they currently use a combination of modular structural elements (uprights/gantries/cross beams/frames) and panels with different finishes to realise a visually attractive sustainable structure with an area of around 15 sqr.m. &nbsp;The product is being redeveloped to meet their corporate sustainability goals, requiring the adoption of more sustainable structural materials with efficient processing, cost and scalability for mass production.
This challenge will require solution providers to demonstrate how their alternative materials can be utilised within the product line whilst providing insight into how their material will align with circular economic values. The challenge holder expects a clear strategy delineating the material's lifecycle management over its 60-year tenure, minimizing ecological footprints and maximizing environmental stewardship.&nbsp;

Challenge Summary

The challenge holder is the UK division of a large global PLC with multiple diverse product lines.
Manufacturing is outsourced to supply chain partners who are well integrated to the PLC, not only commercially but in terms of values and collaborative development for mutual advantage.
Within a product line there are modular components that are currently produced in structural steel, aluminium, composites, timber and plywood. &nbsp;As part of this challenge holder's sustainability strategy the product is being redeveloped to the most sustainable solution, measured against both carbon footprint and the UN Sustainable Development Goalsbut also cost, scalability, ease of use, circularity and robustness.
This challenge relates to these, current steel, aluminium, composites and timber, beam and panel components.
The challenge seeks both sustainable material suppliers and processors that could realise ramped up manufacturing within 6-9 months as well as less well-developed technologies that offer significant sustainability impacts to help the challenge holder meet its stretch sustainability targets. &nbsp;
The ambition is for highly sustainable solutions that offer a significant improvement in whole life cost and sustainability over a 60 year period with minor and easy refit and maximise circularity at the end of the product life-cycle.&nbsp;

Background 

The challenge holder has an established pipeline to deliver a range of modular products that include framed and panellised components. &nbsp;Currently variants of S-235, S-275, S-355, mild steel hollow sections/plates/sheets, EN-AW 6061 extruded aluminium hollow sections/plates/sheets, aluminium honeycomb panels, PMMA and PC (thermoplastic) panels and SC3/SC4 timber and plywood sections/panels are used. &nbsp;There is a strong desire to significantly improve the overall sustainability of this component through novel material technologies; which in turn may require different mass production approaches. &nbsp;
Partners are sought who can provide and process (in quantity) measurably more sustainable materials- it is expected that this will rely upon greatly improved durability extending the time in use and also greater circularity. &nbsp;
It is far from an exhaustive list; but, sustainable solutions could be based upon: &nbsp;
<ul>
<li>Biogenic materials and composites</li>
<li>Natural fibres</li>
<li>Biopolymers</li>
<li>Recovered fibres &nbsp;</li>
<li>Recycled polymers &nbsp;</li>
<li>Repurposed (2nd life) composites &nbsp;</li>
<li>Novel cellulose forms &nbsp;</li>
<li>Repurposed materials</li>
<li>Sustainable reinforced concrete &nbsp;</li>
<li>Orphan stone &nbsp;</li>
<li>Glulam and LVL (timber) &nbsp;</li>
<li>Aluminium &nbsp;</li>
<li>Steel</li>
</ul>
&nbsp;
The need is for both panel items and beam like elements, typically under 2.5m in size supplied in a palletised form for mechanical assembly and ultimate disassembly. &nbsp;An aesthetically pleasing structure is desired through efficient geometry and the intrinsic aesthetic of sustainable materials. &nbsp;It is recognised that the materials, geometry and processing have mutual dependencies.
The challenge holder primarily seeks:&nbsp; Partnerships of material suppliers, designers and processors; offering appropriate sustainable materials and the expertise to process and design them. &nbsp;It is recognised and accepted that organisations may offer only beams of panels, this is acceptable.
As a secondary ask the challenge also seeks lower TRL Material Suppliers and academia.&nbsp; &nbsp;

The Challenge 

Seeking between 1000 and 10000 units per annum from Q1 2025 representing roughly 5000-5000sqm of panel and associated structural elements. &nbsp;The proposition should address the ability to meet this production rate both in terms of production process and materials availability.
Component size is ideally a modular system delivered as a flat-pack set. &nbsp;Depending upon the solutions available this may include flexural framing elements (beams) and one or two way spanning panels. &nbsp;Each set describing some 15sqr.m generally with components roughly the 2.5m long/wide.
Modular solutions based upon standardised thicknesses and sections will be adopted rather than a range of bespoke more complete articles for flexibility of manufacture, storage and efficiency. &nbsp;Aesthetically appealing and optimised structural forms are desirable rather than plain trapezoids, as are elements than can be produced in a 2D curvature.
Materials to have a consistent and acceptable surface finish free of sharp edges, risk of splinters. &nbsp;They are required to age gracefully (EG a high gloss that fades to matt unevenly is not desirable) and be resistant to moss, algae and other biological growth.
Materials that show their sustainable nature are desirable as an aesthetic - so coatings might be transparent to reveal their composition. &nbsp;At this stage there are no specific colour requirements for the finished elements.
Finished product to be non-toxic with clean smooth fillets to all corners and no risk of harm to humans through contact or leachates.&nbsp;

Functional Requirements 

Net Zero or better carbon footprint cradle to cradle and optimal sustainability against the UN sustainable development goals. &nbsp;Materials to be fully circular at end of asset life.
Resistant to graffiti adhesion to enable simple cleaning.
Materials to be mechanically efficient to enable a reasonably slender construction. &nbsp;Broadly to define this, materials should have similar or better structural performance to an SC4 timber.
Suitable for UK climate and environment. &nbsp;Specifically including UV attack, salt exposure, wet-dry cycling, freeze-thaw cycling, fatigue loads, with predictable and understood degradation that can be easily designed for. &nbsp;It is noted that there may be significant permanent stress due to dead loads that could induce creep in some materials.
Impermeable to urine.
Coatings are acceptable to achieve the performance requirements; but, consideration must be given to their sustainability and how they are treated at end of life.
Multi-materials systems including composites and coated systems are acceptable provided they can be reused, repurposed or at worst recycled at end of life. &nbsp;
To process the material, processing businesses should have techniques that meet the projected throughput and are minimal waste, minimal carbon and zero to landfill/incineration, offering no harm to the environment. &nbsp; &nbsp;
Against the timeline, materials that are proven and clearly TRL 7 or at worst TRL 6, with a reliable supply chain and ideally compliant with Eurocodes or other recognised standards are required. &nbsp;
The challenge holder is also interested to understand lower TRL solutions that could offer a substantial sustainability benefit in a 3-4 year horizon. &nbsp;&nbsp;

Technical Requirements 

Units to have a service life of 60 years which will include two major factory refits. &nbsp;Materials may be considered that have a 20 year limited life provided the overall sustainability aspects outweigh longer lived materials that may be less sustainable.
UK wide outdoor exposure including exposure to a marine environment, road de-icing salts / UREA and thermal cycling specifically including freeze-thaw.
In contact with soil (not high sulphate) and exposed to urine and bird droppings. &nbsp;Attached to already cured concrete components.
Cleaning with mild detergent water jet wash and general light brushing / polish on at least a 6 monthly basis; this may adapted slightly to suit specific material characteristics.&nbsp;

Operating Conditions 

The current benchmark is SC4 PSE timber or plywood with a varnish coating. &nbsp;Materials that are inferior to these in terms of cradle to grave carbon footprint, overall sustainability and UK sourcing are out of scope.
Full circularity of all materials involved, including any secondary materials in manufacture such as packaging or release films, is required. &nbsp;Materials that require landfill, combustion or sever loss of value are not desired.
Recycled plastics are in scope; however, processes or supply chains that require the shipping of pellets (nurdles) are considered out of scope due to the potential pollution impact. &nbsp;

Out of Scope 

All solutions are open to consideration at this stage; however, materials that are significantly more costly with limited performance and sustainability improvement, over a baseline of PSE timber are not desired. &nbsp;It is believed that the long-term use of more durable or efficient sustainable materials at scale, should offer a net saving over the product life.&nbsp;

Cost Requirement 

Successful applicants will have the opportunity to present to the challenge holder. &nbsp;Selected solutions, will be assessed, collaboratively developed and trialled with the potential for full adoption. &nbsp;
Lower TRL longer-term solutions, if selected, may attract collaborative development with the challenge holder.
The benefits package for a successful applicant may also include: &nbsp;
<ul>
<li>Support from Innovate UK Business Connect &nbsp;</li>
<li>Support in the development of a prototype or pilot &nbsp; &nbsp;</li>
<li>Technical support &nbsp;</li>
<li>Invitation to attend or present at UK Business Connect events &nbsp;</li>
<li>A potential business collaboration &nbsp;</li>
<li>Investor introductions (if investment is required) &nbsp;</li>
<li>Potential support to qualifying SMES from Innovate UK Business Growth</li>
<li>Support if any Innovate or similar competitions are relevant.&nbsp;</li>
</ul>

Rewards & Market Opportunity

Selection and notification of finalists: typically 3-4 weeks post deadline date&nbsp; Pitch Day: This is intended to be face-to-face in London, typically 2-4 weeks following notification

Timescales 

Entrants to this competition must be: &nbsp;&nbsp; Established businesses, academic institutions, start-ups, SMEs, or individual entrepreneurs
UK based or have the intention to set up a UK base
With the exception of lower TRL solutions requiring development; submissions that offer a supply chain are desired&nbsp;
<ul>
<li>Applications will be assessed on: &nbsp;&nbsp;</li>
<li>Relevance to the defined challenge &nbsp;</li>
<li>Applicability to the UN sustainability Development Goals</li>
<li>Benefit of implementation &nbsp;</li>
<li>Feasibility/economic viability &nbsp;</li>
<li>Innovative nature &nbsp;</li>
<li>Ability to launch in line with expected timescales &nbsp;</li>
<li>Credibility of applicant company and the partners involved</li>
<li>Coherence of the proposed business model &nbsp;</li>
<li>Development potential of the technology and the organisations</li>
<li>Maturity of the solution &nbsp;</li>
<li>Suitability for the intended geographic market&nbsp;</li>
</ul>

Eligibility & Assessment Criteria

Existing background IP associated with a potential solution will remain with Solution Provider(s). Where any new IP generation is envisaged, it will be subject to the mutual IP agreement of the Solution Provider(s) and Innovation Challenger. &nbsp;
Any commercial deployment of a transferred solution or newly developed solution, through licensing, joint venture, partnership, or direct investment, will be subject to the commercial agreement between the Solution Provider(s) and Innovation Challenger. &nbsp;&nbsp; &nbsp;&nbsp; It is highlighted that an non-disclosure agreement (NDA) must be signed to uphold confidentiality in the engagement between the Solution Provider(s) and Innovation Challenger; this would be expected to be after company selection.&nbsp; &nbsp;&nbsp; It is also highlighted that suppliers will need to conform to the commercial terms of the challenge holders procurement protocols.&nbsp; &nbsp;&nbsp; All entries are treated as confidential and only shared with Innovate UK and the challenge holder, however if the innovator is concerned about sharing IP, it is suggested that details of IP are not disclosed. Instead, focus on the outcomes of the technology proposed at this application stage. &nbsp;
Innovate UK do not take any share of IP ownership or enter commercial ventures through the iX programme.&nbsp;

IP & Potential Commercial Route 

&nbsp;A selected panel of assessors will review and score your application. The panel of assessors will meet and agree a consensus score. Successful solutions will be selected by the Challenge holder. Success will be based on total consensus scores, a portfolio approach and the capacity of the challenge holders to carry out the projects.&nbsp;

Terms & Conditions

The application form for this challenge will require applicants to provide company information and answer 3 questions - Idea Summary, Technology Readiness and Intellectual Property &ndash; each with a limit of 300 words.
Optionally, supporting documents can be attached to the application. We recommend that supporting documents are limited to those which are directly relevant to the application. Please note that applications with no supporting document will not receive any penalty in assessment. Supporting documents which the Assessment Panel deems to be superfluous may be disregarded. Examples of useful additional documents include product images or short specification sheets, slide decks detailing the solution and/or company background, or solution case studies.
It is highlighted that the as the challenge is a little non-specific that a supporting document is used to communicate your organisations and partners depth and experience in relevant areas.
We recommend that you complete the application form in Google Chrome as other browsers may have compatibility issues. The application form does not need to be completed in one session and can be saved for future edits. Please ensure that you toggle &ldquo;Stage Complete&rdquo; for each section before submission. Note that you will no longer be able to edit your application once you have clicked &ldquo;Submit Idea&rdquo; at the bottom of the Summary page.&nbsp; &nbsp;

Sustainable, aesthetically pleasing, readily configurable structural elements

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Sustainable, aesthetically pleasing, readily configurable structural elements