Revolutionizing sustainable construction through an experimentation and modelling approach for optimization of bio-based plasterboard manufacturing

This advert will close once a suitable candidate has been found.

This PhD is one of a number of projects hosted by the Centre for Doctoral Training in Green Industrial Futures (CDT-GIF). We are offering pioneering research projects that will enable PhD researchers to explore key technologies and solutions that will support UK industry to reach net zero. https://greenindustrialfutures.site.hw.ac.uk/the-programme/training-programme/

Project: Are you passionate about sustainable innovation and eager to tackle one of the construction industry’s biggest environmental challenges? This fully funded PhD offers a unique opportunity to develop energy-efficient, cost-effective, and carbon-reducing manufacturing processes — placing you at the forefront of sustainable materials research.

Plasterboard is the third most-used construction material globally, contributing significantly to the 40% of carbon emissions attributed to the construction industry. To combat this, Adaptavate has developed Breathaboard—a sustainable plasterboard alternative made from mineral binders and bio-aggregates/biochar. Breathaboard offers comparable structural performance while dramatically lowering embodied carbon emissions.

A resource intensive stage of Breathaboard production is curation. This PhD will focus on transforming the manufacturing process by delivering novel form of industrial symbiosis, through of co-location of several Breathaboard processes, enhancing both efficiency and sustainability.

The PhD will focus on three key objectives:
• Investigate Microstructural and Chemical Changes: Analyse how curation and drying impact mechanical properties and hygrothermal performance.
• Develop a Predictive Model: Create a computational model linking operational variables and material properties.
• Integrate Pyrolysis and Curation: Build a combined model to optimize energy consumption and assess the effects of pyrolysis parameters on biochar quality, curation rate, drying behaviour, and material performance.

Throughout this PhD, the successful applicant will gain expertise in cutting-edge modelling approaches and experimental techniques including:
• Thermogravimetric Analysis (TGA) with Mass Spectrometry (MS) to study reaction and drying kinetics.
• X-ray Diffraction (XRD) for crystalline phase identification.
• Scanning Electron Microscopy (SEM-EDX) for microstructural and elemental analysis.
• Numerical and Mathematical Modelling of kinetic and thermodynamic performance of material to optimize the production process.

The research is expected to deliver a step change in manufacturing efficiency, allowing a reduction in capital and production costs, improve product consistency, and enhance environmental benefits, contributing to circular economy principles and sustainable construction material manufacturing.

Lead supervisor/s: Dr Richard Ball, Prof. John Chew, Dr Usman Shoukat (Adaptavate Ltd), Jeff Ive (Adaptavate Ltd)

Project partner: Adaptavate. Adaptavate is a forward-thinking business, driven by a dynamic team of engineers, thinkers, parents, walkers, traders, dreamers, climbers, scientists, gardeners, friends, family, and visionaries — people who think differently to create a meaningful impact. Committed to answering the urgent call to decarbonize construction globally, Adaptavate is developing low-carbon and carbon-negative technologies, as well as building the industrial ecosystem needed to deploy them rapidly and effectively worldwide. Situated near Bath, Adaptavate will provide industrial support for this project. The student will collaborate closely with Adaptavate and complete their industrial placement at the company’s site, gaining access to its technical expertise, prior knowledge, and R&D facility.

CDT in Green Industrial Futures: The CDT is funded by the UK Engineering and Physical Sciences Research Council and is a partnership between Heriot Watt University, Imperial College London, and the Universities of Sheffield and Bath. The CDT is further supported by contributions from industrial partners. Bringing these leading universities together allows CDT-GIF students access to a wide range of academic expertise, resources and facilities.

The CDT-GIF has an exciting and challenging programme specifically designed for top performing junior researchers. Alongside the four-year research project, students will receive expert training and opportunities to contextualise their research within the wider net zero landscape, including:
• Residential taught courses at each of the partner universities in Years 1 and 2 that provide training in the systematic considerations for industry including: Life Cycle Analysis (LCA), technoeconomics, business models, policy & regulation, public engagement, plant operation.
• An international opportunity in Year 2 or 3 of the programme, including opportunities to visit a world-leading facility, conference or forum and explore the global context of industrial decarbonisation.
• A work placement with one of our industrial partners.
• A bespoke ‘net-zero leadership programme’, including regular exchanges with cohort members from the other universities, student-led activities, industry challenge sandpit, industrial site visits, and professional development opportunities.

Candidate requirements: A strong undergraduate degree in engineering, sciences and mathematics such as chemical engineering, chemistry, material engineering and sciences or a related field. .

Candidates should be aware of and meet any additional entry requirements for the university hosting the PhD studentship.

Non-native English speakers must ensure they meet the English language requirements.

Enquiries and applications. Informal enquiries regarding the research project can be directed to the supervisor. Alternatively, if you have a question regarding the wider CDT-GIF programme, please contact cdtgreenindustrialfutures@hw.ac.uk .

Formal applications can be made here: https://greenindustrialfutures.site.hw.ac.uk/the-programme/how-to-apply/ . Applications are open until filled so we would encourage early application.

The initial application involves an application form (including a short personal statement and CV). You may select up to two CDT-GIF projects. Applicants will then be selected to interview. If successful at interview, candidates will be asked to complete the application process for the home university.

Funding notes. The programme is four years and starts in Oct 2025. Funding includes full UK fees, tax-free stipend (2025/2026 stipend is £20,780), plus budget for travel and consumables. The positions are in the first instance for UK students.

Equality, Diversity and Inclusion. We warmly encourage applications from individuals of all backgrounds, experiences, and perspectives. Our programme values diversity as a cornerstone of innovation and collaboration, and we are committed to creating an inclusive environment where everyone feels respected, supported, and empowered to thrive. The CDT-GIF are committed to ensuring flexibility throughout our programme to support student’s needs and personal circumstances, for example those with medical conditions, caring responsibilities and other considerations. For example, we are open to exploring part-time options if appropriate for the nature of the research.