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In the event of an emergency landing, a new material called marshmallow concrete behaves like regular concrete but crumbles like a marshmallow. This unique ultra-light foam is designed to absorb the energy of an aircraft and assist in bringing it to a safe stop during runway overruns.
Researchers at the China Building Materials Academy (CBMA) and their collaborators have engineered the material to have a weight of just 12.5 pounds per cubic foot. This is approximately one-tenth the weight of standard concrete. The strength of marshmallow concrete comes from a network of microscopic bubbles, each coated with a special maleated rosin. This structure enables the foam to crush in a controlled manner and provide cushioning for even the heaviest aircraft.
“Although it appears solid, it crumbles upon impact,” explained Fang Jun, a research and development engineer at CBMA. “This characteristic allows it to decelerate planes smoothly and effectively.”
Why traditional runway safety systems are inadequate
The most critical phases of any flight are takeoff and landing. To mitigate risks, airports utilize Runway End Safety Areas (RESAs) to halt planes that overshoot the runway. Historically, airports have used materials such as sand, soil, grass, or water pools for this purpose. However, each of these materials has its own limitations.
Soil becomes unstable in wet or freezing conditions. Water can freeze in winter and attract wildlife, posing new hazards. Sand and grass may not always perform adequately, especially with heavier aircraft. These shortcomings have underscored the need for a more reliable and consistent safety solution at airports.
How marshmallow concrete operates: The science behind the softness
Engineered with a specific strength between 0.30 and 0.35 megapascals, marshmallow concrete is designed to crush and absorb energy upon impact. The research team likened the process to introducing bubbles into a concrete mix. These bubbles create the soft, crushable texture that aids in stopping a plane during an emergency.
To ensure the bubbles remain strong until impact, a special air-entraining agent was used by the team to form a durable coating around each bubble. As a result, the material remains intact until an aircraft overshoots the runway, at which point it collapses at the right moment to maximize safety.
Benefits of marshmallow concrete for airports: Durability and cost-effectiveness
In contrast to international systems that rely on costly calcium sulfoaluminate cement, marshmallow concrete utilizes ordinary cement, making it much more affordable for airports, especially those with limited budgets. The team also developed a two-stage strength-control system that enables the material to adapt to harsh climates and maintain consistent performance throughout the year.
Data from 14 airports in China, including one in Tibet’s challenging climate, demonstrated that the material’s properties fluctuated by just three percent over a year. This is well below the design tolerance of ten percent, indicating that airports can rely on the material to consistently perform, irrespective of the weather conditions.
Marshmallow concrete airport safety: The future standard?
With its blend of low cost, environmental resilience, and life-saving performance, marshmallow concrete is positioned to become the new global standard for runway safety. The material has already been implemented at 14 Chinese airports, showcasing consistent and reliable performance even in extreme conditions. As more airports seek cost-effective ways to enhance safety, marshmallow concrete offers a promising solution that can save lives and reduce expenses worldwide.
Implications for travelers
If you frequently travel by air in the U.S., marshmallow concrete could soon enhance the safety of your journeys. While this innovation is currently in use at Chinese airports, its effectiveness is garnering attention worldwide, including from U.S. aviation experts seeking improved runway safety solutions.
Though runway overruns are infrequent in the United States, the consequences can be severe when they do occur. Major airports like LAX, JFK, or Atlanta can experience significant disruptions from a single overrun, putting numerous flights and lives at risk. Marshmallow concrete offers a cost-effective, highly efficient safety enhancement that could prevent such incidents or minimize their impact.
Moreover, this upgrade does not entail a billion-dollar overhaul. By utilizing standard cement and being designed to function in varied weather conditions, including harsh winters and extreme heat, marshmallow concrete presents a practical option for airports across the U.S., from Maine to Arizona. Even smaller regional airports in the country stand to benefit from this innovative material.
While passengers may not visibly see marshmallow concrete, it could be quietly safeguarding their flights behind the scenes, ready to absorb impact and bring a plane to a safe stop in case of an emergency. As U.S. airport authorities and the FAA explore more innovative and cost-effective infrastructure modernization approaches, marshmallow concrete emerges as a secure bet for the future of American aviation.
Kurt’s key insights
Marshmallow concrete is revolutionizing airport safety by offering a combination of strength, flexibility, and affordability. This new material presents airports with a smarter way to ensure the safety of passengers and crew members. As airports worldwide seek dependable solutions, marshmallow concrete stands out as a proven choice that delivers results. Given its impressive performance in real-world conditions, it is evident why experts believe this innovation will establish a new benchmark for runway safety.
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