Replacing fossil-based building materials with bio-based alternatives is one of the most important ways to reduce emissions in the construction industry and the lifecycle carbon footprint of buildings. It can also improve the building quality and enhance living comfort. VTT helps companies develop building material innovations from concept to commercialisation.
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- Biomaterials offer advantages such as versatility, superior insulation properties, local sourcing and recyclability compared to traditional materials, enhancing the sustainability and healthiness of buildings.
- Emerging manufacturing technologies like foam forming and fold technology allow energy-efficient production of construction materials, creating new opportunities for innovative solutions in the industry.
- VTT provides research infrastructure for developing and scaling up new building materials, illustrated by its collaboration with Aisti, which uses VTT's foam forming expertise to create environmentally friendly acoustic tiles.
This summary is written by AI and checked by a human.
All construction projects have environmental impacts, and the life-cycle emissions of a building are also significantly affected by energy consumption, heating and cooling. The shift away from traditional, long-established materials is slow but inevitable. Sustainability regulation in the construction sector will unavoidably tighten, accelerating the transition towards recyclable and bio-based materials.
“Those who develop new solutions before they become mainstream will be well-positioned when the market enters a rapid growth phase. Collaboration with the right product development partner ensures cost-efficient progress and tangible results,” says Jaakko Kuusisaari, Solution Sales Lead at VTT.
Buildings and the construction sector are a major contributor to greenhouse gas emissions, accounting for 37% of global emissions. The production and utilisation of materials like cement, steel and aluminium as well as insulation materials made from petrochemical feedstocks have a significant carbon footprint. By shifting to bio-based materials, there is enormous potential for emission savings, as these materials can offer carbon-neutral or even carbon-negative solutions.
The winning properties of biomaterials
The potential of biomaterials in the construction industry is impressive. The advantages of using biomaterials include:
Versatility: Biomaterials can be used in paints, pigments, fire retardants, acoustic panels, insulation, adhesives, films, biocomposite structures, flooring and furniture. They can replace harmful chemicals and create antimicrobial surfaces that prevent disease transmission, making buildings healthier for their users. It is also possible to develop self-healing and smart properties in biomaterials.
Insulation properties: Products made from biomaterials often surpass traditional insulation materials in sound and thermal insulation and moisture regulation. This can improve a building’s energy efficiency and indoor air quality.
Local sourcing: Biomaterials often utilise industrial side streams, such as lignin. These by-products are typically generated closer to construction sites, reducing costs and emissions associated with transport logistics.
Recyclability and circularity: Biomaterials are more recyclable and reusable compared to their fossil-based alternatives. For instance, glass wool and mineral wool are practically impossible to recycle, whereas equivalent biomaterial-based solutions are fully recyclable. Using recycled or renewable materials lowers the total lifecycle carbon footprint and can also reduce costs.
Wood is one example of a renewable, recyclable and healthy material with versatile potential.
“Wood can be used for much more than just wooden panels and logs. Wood fibre-based insulation materials can replace glass and mineral wool, while various wood composites are versatile and durable building materials,” says VTT’s Senior Scientist Antti Oksanen.
Manufacturing processes matter – the rise of new technologies
The manufacturing processes of building materials are also worth attention as their impact on construction emissions is significant. Foam forming and fold technology are some of the most talked-about technologies today.
Foam forming is particularly suitable for producing filters and insulation products from biomaterials with significantly lower energy and water consumption than traditional wet-laying or water-laying methods.
Fold technology is a novel folding technology inspired by origami which can be used in packaging, product design and lightweight protective solutions. In the construction context, fold technology provides solutions for light shading, interior design elements and lightweight panels.
“Foam forming, for example, enables us to also develop entirely new material properties. It creates a porous, lightweight, yet durable structure with excellent thermal and sound insulation properties. VTT offers research environments for applying foam forming at scales ranging from laboratory experiments to pilot production,” Oksanen says.
VTT’s research facilities turn ideas into commercial products
VTT’s research infrastructure and expertise offer extensive benefits to building material developers. VTT’s comprehensive facilities enable development, piloting and analytics, allowing companies to develop innovations and refine manufacturing processes without making significant investments in their own pilot environments.
VTT supports companies from laboratory research to pilot production, both in process optimisation and material development. Techno-economic analysis helps determine production costs for different scenarios.
“Once we have reached a process that works, companies can confidently make the investments required to scale up production. Our clients include both traditional building material manufacturers and companies developing entirely new raw materials,” Kuusisaari says.
Aisti develops bio-based acoustic tiles in long-term cooperation with VTT
The Finnish company Aisti manufactures plastic-free, fully recyclable acoustic tiles from wood fibre using foam forming technology. Their product is low-carbon – it captures carbon and is produced using renewable energy.
Aisti’s products are healthy for people, as they release very low levels of VOC emissions (volatile organic compound) and the fibres used do not cause irritation. The company is currently constructing a commercial-scale factory in Kitee, Finland.
According to CEO Mikko Paananen, Aisti has relied on VTT's research infrastructure throughout its product development journey. Aisti has effectively leveraged the subsidies and funding mechanisms available in Finland. While Aisti has operated its own pilot plant since 2022, it has also continued to utilise VTT’s services to test continuous production processes.
“For example, we’ve explored different fibre types, fire protection methods and stages of the manufacturing process in VTT's research environment in Jyväskylä. VTT offers the expertise and equipment for foam forming of thick products that is not available anywhere else,” says Paananen.
VTT's basic research on foam forming was the original spark for the creation of Aisti. With two of the company's founders having a VTT background, a deep understanding of R&D has been key to Aisti’s success.
“Success in the construction sector with sustainable materials requires a highly competitive product, both in price and technical performance,” says Paananen.
