Combining cardboard and timber to deliver sustainable, cost-effective emergency housing

Author: Dr Joe Gattas

Date published

19 March 2025

The Institution of Structural Engineers The Institution of Structural Engineers
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Combining cardboard and timber to deliver sustainable, cost-effective emergency housing

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Dr Joe Gattas from the University of Queensland (UQ) shares his research findings on innovative materials.

When a natural disaster tears through a town and wipes out homes, large numbers of people can be left without a roof over their head and needing accommodation fast.

But as any builder knows, securing affordable materials at short notice can be a big ask.

And in a disaster scenario, it’s even harder than usual to find skilled labour to build temporary structures for victims in dire need of emergency housing.

What if there was a material to build panels light enough to be handled by only one or two people, and made from recycled waste products so they weren’t subject to the shortages and soaring costs plaguing traditional building materials?

UQ PHD student Mahmoud Abu-Saleem have developed innovative new timber-cardboard construction panels, with research findings recently published in Structures.

The new sandwich panels bond spaced-out cardboard studs, to thin timber skin. Lab testing found that while being 50 per cent lighter than previous monolithic designs, they were just as strong, or stronger, for their weight.

The panels were also 33 per cent stronger than foam or bio-based panels of similar density.
 



Extensive use of cardboard reduces the cost and environmental impact of the panels, meaning builders of temporary housing are less exposed to the shortages and soaring costs of traditional construction materials.
Cardboard is one of the most highly recycled materials for packaging in Australia so there’s no impact on waste generated and no increase in resource consumption. You're essentially extending the service life of that material before it gets recycled again.

The panels have also been used in a prototype ‘cardboard house’ constructed at UQ’s Pinjarra Hills Research Facility and have held up well to the wet Queensland summer.

The panels are intended for short-term use, possibly for temporary housing or granny flats for people displaced by natural disasters

The fact they are lighter means they will be easier to lift and fit together quickly in a post-disaster scenario, where temporary structures are in high demand.

We need systems that suit short-term use cases as there's a lot of need for this class of accommodation in Australia, and internationally.

The cardboard house also recently weathered the wild winds and torrential rains experienced by Brisbane as tropical cyclone Alfred made landfall.

Both Mahmoud and I have kept the elements at bay by incorporating the same principles used for timber-clad homes – including substantial eaves, often seen on iconic Queenslander-style homes.

Mahmoud states that while replacing some of the monolithic cardboard in the TCS with the air gaps reduced the weight, this could also reduce the insulation effectiveness of the panels.

This could be addressed in future by adding another waste material like paper into the air gaps to improve their insulation properties.

Associate Professor Joe Gattas

Dr Joe Gattas is as an Associate Professor at the University of Queensland's School of Civil Engineering, where he heads the Folded Structures research group. His research expertise spans various fields, including origami-inspired engineering, computational building design, advanced manufacturing, lightweight and modular structures, and timber engineering. In 2009, Joe obtained his Bachelor of Engineering from the University of Queensland, and in 2013, he completed his Doctor of Philosophy at the University of Oxford, funded by a prestigious John Monash Scholarship. He remains an active participant in the John Monash Scholar community.