The NEOM Water Innovation Center has pioneered sustainable brine concrete, transforming desalination brine into eco-friendly building materials to tackle environmental challenges
Desalination, vital for water security, generates brine—a byproduct with significant potential environmental challenges. To address these challenges, the NEOM Water Innovation Center has developed sustainable brine concrete, turning desalination brine into eco-friendly building materials.
What began as lab-scale research with TUDelft has grown into real-world applications. Using desalination brine from NEOM’s Duba seawater desalination plant and with the support of TAMVINCI for industrial 3D printing, and of Topian for marine restoration projects in islands on the Red Sea, brine use for production of concrete has transitioned from concept to practice. By reducing freshwater usage by 75%, cement consumption by 35%, and CO2 emissions by 35%, brine concrete represents a sustainable leap forward for construction and environmental restoration.
The Science Behind Brine Concrete
The core innovation of brine concrete is in its ability to repurpose desalination brine—a byproduct traditionally regarded as waste—into a key ingredient for sustainable construction. By combining brine with supplementary cementitious materials such as ground granulated blast-furnace slag (GGBS) and calcined clay, the brine enhanced material achieves reduced cement usage and improved environmental performance. This aligns with circular economy principles, turning a waste product into a valuable resource for large-scale applications.
A significant breakthrough in this project is the adaptation of brine concrete for tri-dimensional (3D) printing. Conventional 3D printers are not equipped to handle brine’s unique properties, such as its corrosive nature. The 3-D printing brine-enhanced concrete system adopted corrosion-resistant components and optimized material pumpability and buildability.
This innovative approach uses brine as a concrete accelerator, mixed with water to create a printing system involving two pumpable composites: one with Portland cement (Low Concentration Brine) and the other with Concentrated Brine. The Concentrated Brine is a mix of two streams as presented in Figure 1 below. The resulting product has a compressive strength suitable for use as a construction material for structures and art installations.
Synthetic brine was prepared based on the mass balance calculations from brine streams produced at the NEOM brine management plant. These brine streams were selected for their compositions which were deemed most suitable for 3D printed concrete (3DPC). Synthetic concentrated brine (stream 2+3) was used as a concrete accelerator and synthetic low concentration brine (Stream 1) was used as mixing water for the concrete. Different concentrations of brine were prepared, with the major limiting factor being the saturation point of the salt used. The change in concentrations was achieved by modifying the salt content in each of the prepared brines.
The development of brine concrete is the result of collaboration with industry partners. Initial research with TUDelft focused on validating the concept at lab scale using synthetic brine. TAMVINCI then played a critical role in scaling the material up for industrial 3D printing and in customizing the equipment for compatibility. The partnership with Topian further demonstrated the material’s natural marine habitat enhancement benefits in marine restoration, showcasing its adaptability to various environments and applications.
Sustainability Impact
Brine concrete is a true example of sustainable innovation that addresses critical environmental challenges in both desalination and construction industries. By incorporating desalination brine into concrete production, it reduces freshwater usage by 75%, cement consumption by 35%, and CO2 emissions by 35%. The reduction in freshwater use, cement consumption, and CO2 emissions leads to minimizing the environmental footprint of concrete production and aligns with global sustainability goals and Saudi Arabia’s Vision 2030.
The project exemplifies the circular economy by transforming industrial waste into a high-value resource. Brine, which is traditionally discharged into marine or terrestrial ecosystems, is instead integrated into the construction cycle. This process eliminates waste, conserves natural resources, and promotes a closed-loop system that benefits both the environment and the economy.
Deployment of brine concrete in marine restoration efforts on the islands of the Red Sea shows its value across multiple challenges. This project highlights how the material effectively combines environmental benefits with functional performance. Its adaptability to different applications proves its potential to address both urban development and restoration challenges on a larger scale.
Applications and Future Prospects
Brine concrete has proven its effectiveness in diverse applications, one of which is related to marine environments. On the islands of the Red Sea, brine concrete has been successfully utilized for coral reef restoration and the creation of underwater structures, as shown in Figures 2 and 3. The successful applications of brine concrete show its ability to tackle environmental challenges and contribute to achieving sustainability goals.
This sustainable brine concrete demonstrates exceptional performance with a compressive strength of 38.4 MPa after 28 days and a tensile strength of 3.4 MPa, making it suitable for marine and infrastructure applications. Its low water absorption rate of 4.6% and chloride resistance (measured at 4990 coulombs) ensure durability in harsh environments. The dynamic yield stress of 2082.2 Pa and plastic viscosity of 34.6 Pa·s enhance pumpability, while the 66-minute initial setting time supports efficient 3D printing and rapid deployment.
Demand for sustainable construction materials is growing. This growth emphasizes the need to scale up the production of brine concrete. The material addresses environmental and industrial challenges by reducing reliance on fresh water and cement. Advancements in 3D printing technology and strategic collaboration with industry leaders are expected to play a vital role in meeting urban development needs and other large-scale applications. The increasing global awareness of sustainability and stricter environmental standards make brine concrete a timely innovation. Its ability to replace traditional materials paves the way for green construction practices. Future opportunities include expanding into infrastructure projects, modular building systems, and applications where performance and environmental protection are considered.
Conclusion
The journey of brine concrete from concept to real-world application reflects the power of innovation. What began as a lab-scale experiment with TUDelft has evolved into a scalable, sustainable solution addressing global challenges in desalination brine management and construction. Deployment in projects such as coral reef restoration near the islands of the Red Sea and underwater structures show its versatility and environmental benefits.
By significantly reducing freshwater usage, cement consumption, and CO2 emissions, brine concrete aligns with the principles of a circular economy and global sustainability goals. Its ability to repurpose desalination waste into durable, eco-friendly materials opens new opportunities for marine restoration, and beyond.
As demand for sustainable materials continues to rise, brine concrete stands ready to shape the future of construction and environmental restoration. Through ongoing partnerships, advancements in technology, and market expansion, this innovation is poised to redefine what is possible in green construction.
