How Sugarcrete turned sugarcane bagasse into four-hour fire resistance

Sugarcrete sets new EI 240 benchmark

The University of East London (UEL) has reported that its Sugarcrete® low-carbon building material has achieved an EI 240 fire resistance rating in full-scale testing in Spain, supporting its use in high-risk and safety-critical building applications.

According to UEL, Sugarcrete is formed from sugarcane by-product bagasse combined with sand-mineral binders and is intended as an alternative to conventional bricks and concrete blocks.

The university stated that the material has an estimated carbon footprint around six times smaller than traditional clay brick while maintaining performance in use.

Sugarcrete was developed at UEL’s Sustainability Research Institute, where researchers have focused on combining lower embodied carbon with stringent safety outcomes.

UEL indicated that fire performance has been a central element of the development programme in order to move the material into more demanding settings.

Full-scale AFITI test conditions and results

UEL reported that recent trials at AFITI Laboratories in Spain exposed Sugarcrete walls to one of the construction sector’s more demanding standardised fire resistance tests.

During the test, the internal face of the Sugarcrete wall was subjected to temperatures of 1,100°C inside the kiln chamber.

The external face of the wall reportedly remained at 26°C throughout the trial.

The test was run for 240 minutes, with UEL confirming that the wall maintained its integrity for the full four-hour duration.

Independent assessors concluded that the system achieved an EI 240 classification under EN 13501-2:2023.

The EI 240 rating indicates that the construction prevented fire penetration and limited heat transfer for at least 240 minutes.

UEL stated that this outcome places Sugarcrete among the highest-performing materials in current use for sustained fire resistance.

Performance compared with existing wall systems

According to the university, Sugarcrete’s performance in the AFITI test outstripped that of standard clay brick and concrete block walls assessed under comparable conditions.

The results were also reported to be in line with specialist fire-partition systems designed for higher-risk environments.

UEL said this brings Sugarcrete into the same category as systems currently specified for installations where extended fire resistance is required.

The university added that the testing focused on both structural integrity and thermal insulation across the four-hour exposure.

The material maintained stability while holding the temperature differential between the exposed and unexposed faces of the wall.

Potential use in safety-critical applications

On the basis of the AFITI trial and independent assessment, UEL stated that Sugarcrete is now a viable candidate for a range of safety-critical applications.

The university highlighted potential use in industrial fire walls designed to separate high-hazard areas within facilities.

It also identified protected escape routes as a key area where long-duration fire resistance and controlled heat transfer are required.

Further potential applications include data centres, where thermal protection and compartmentation form part of wider resilience strategies.

UEL added that petrochemical environments are another target sector, given their reliance on robust fire-rated separation systems.

Low-carbon profile alongside fire performance

UEL noted that Sugarcrete had already drawn attention for its lower embodied carbon profile before the latest fire tests.

The university presented the new data as evidence that reducing embodied carbon does not have to come at the expense of fire resistance or durability in use.

It said that the combination of lower carbon footprint and high fire performance could give construction clients another option when assessing materials for high-risk settings.

Alan Chandler, co-creator of Sugarcrete and Associate at the Sustainability Research Institute, said: “This is a defining moment.

“To hold back fire at over 1,000 degrees for four hours proves Sugarcrete® is not only sustainable, but also safe and resilient enough for the most demanding environments.”