Automated Hybrid AM–Lightweight Steel Framing (LSF) Systems for Zero-Waste Construction

These projects are open to students worldwide, but have no funding attached. Therefore, the successful applicant will be expected to fund tuition fees at the relevant level (home or international) and any applicable additional research costs. Please consider this before applying.

The building and construction sector accounts for nearly 40% of global CO₂ emissions annually, with construction steel alone contributing over 10% of that share, produces over 60% of the UK's waste and consumes approximately 50% of all extracted materials globally. A key contributor is the inefficient use of materials in structural systems: typical multi-storey steel buildings utilise only around 50% of their structural capacity. Improving utilisation could reduce embodied carbon by more than 200 million tonnes of CO₂ annually.

Despite more than one-quarter of global steel production being used in construction, the direct reuse of structural steel remains extremely limited (5–7%), even though steel sections are inherently reusable when undamaged. Direct reuse can deliver 35%–97% carbon savings compared with new production yet remains underexploited due to technical and procedural barriers.

In parallel, lightweight steel framing (LSF)—made of cold-formed steel (CFS) sections—is emerging as a low-carbon, cost-efficient solution in modern construction for both new-build and vertical extensions. LSF systems align closely with offsite manufacturing and Design for Manufacture, Assembly and Deconstruction (DfMA+D) principles, offering reduced material use and waste, improved quality, and 30–50% reductions in time and cost. While offsite manufacturing currently represents only 7% of UK construction output, national policy frameworks emphasise its expansion to address productivity, cost, and sustainability challenges.

As the construction industry seeks more efficient, automated, and reusable solutions, metal additive manufacturing (AM) offers transformative potential. Metal 3D-printing provides geometric freedom, high precision, advanced automation, improved worker safety, and opportunities for repair and strengthening. By integrating cutting-edge metal 3D-printing technologies into construction, the project aims to help the steel construction industry build more efficiently, reduce waste, and move toward a circular and sustainable future. By designing connectors that enable lightweight steel buildings to be rapidly assembled and fully disassembled without damaging components, the work supports faster, more predictable construction, increases adaptability and building lifespan, and significantly lowers environmental impact.

Project Aim and Objectives

This PhD project aims to develop a reusable, resilient, and cost-effective hybrid AM-LSF system enabled by metal additive manufacturing. The research will deliver a next-generation solution suitable for multi-storey automated construction and aligned with zero-waste, circular-economy principles.

The project will involve:

• Advanced computational modelling using FE packages (ABAQUS) to optimise structural behaviour and utilisation.
• Large-scale experimental testing at the Aberdeen Structures Laboratory to evaluate performance under gravity, lateral, and cyclic loading.
• Development of a design framework and guidelines for AM-enabled hybrid LSF systems, supporting scalability, and industrial adoption.

Decisions will be based on academic merit. The successful applicant should have, or expect to obtain, a UK Honours Degree at 2.1 (or equivalent) in civil engineering and ideally MSc in Civil/Structural engineering. They must have a relevant engineering background, a very strong understanding of structural behaviour, and in particular steel structures. Individual applying for this post should possess an excellent written and oral communication skills in English, and willing to publish high quality journal papers. The appointed researcher will join a vibrant research team under the supervision of Dr Alireza Bagheri at the School of Engineering.

Application Procedure:

Formal applications can be completed online: https://www.abdn.ac.uk/pgap/login.php.

You should apply for PhD in Engineering to ensure your application is passed to the correct team for processing.

Please clearly note the name of the lead supervisor and project titleon the application form. If you do not include these details, it may not be considered for the studentship.

Your application must include: A personal statement, an up-to-date copy of your academic CV, and clear copies of your educational certificates and transcripts.

Please note: you do not need to provide a research proposal with this application.

Informal enquiries can be made by contacting Dr A Bagheri on alireza.bsabbagh@abdn.ac.uk

Funding Notes

This is a self-funding project open to students worldwide. Our typical start dates for this programme are February or October.

Fees for this programme can be found here Finance and Funding | Study Here | The University of Aberdeen

Additional research costs / bench fees may also apply and will be discussed prior to any offer being made.