Ultra-light foam concrete designed to crumble like a marshmallow during emergencies is being tested as a runway safety solution. This material, developed by researchers at the China Building Materials Academy and their partners, can absorb aircraft energy to help planes stop safely during overrun events. Its lightweight and controlled crushability make it an effective and affordable alternative to traditional runway safety measures like sand or water.
The most dangerous parts of any flight are takeoff and landing. To mitigate these risks, airports have traditionally relied on Runway End Safety Areas (RESAs), where materials like sand, soil, grass, or water pools are used. However, these materials often have significant limitations—soil becomes unstable in wet or freezing conditions, water can freeze and attract wildlife, and sand and grass may not effectively stop heavier aircraft. These shortcomings have highlighted the need for a more reliable and consistent safety solution, which marshmallow concrete now provides.
Unlike some expensive international systems that rely on calcium sulfoaluminate cement, marshmallow concrete uses ordinary cement, making it far more affordable for airports, especially those with limited budgets. The research team has also engineered a two-stage strength-control system that allows the material to adapt to harsh climates and maintain performance consistency throughout the year. Real-world data from 14 airports in China, including one in the challenging climate of Tibet, has demonstrated the material’s consistent performance, with properties fluctuating by only three percent over a year—well within the design tolerance of ten percent.
With its unique combination of low cost, environmental resilience, and life-saving performance, marshmallow concrete is poised to become the new global standard for runway safety. Already installed at 14 Chinese airports, this material offers a promising solution that can save lives and reduce costs worldwide. Its potential impact is especially significant for smaller regional airports in the U.S., where budget constraints and weather extremes often pose additional challenges. As global airports seek affordable and effective ways to enhance safety, marshmallow concrete presents a strong candidate for adoption, potentially transforming the aviation industry’s approach to runway safety.
The material’s ability to absorb energy and cushion the impact of a plane’s emergency landing makes it a critical advancement in aviation safety. While this innovation is currently being implemented in China, its performance is drawing attention from aviation experts worldwide, including those in the United States. As U.S. airport authorities explore ways to modernize infrastructure and improve safety, marshmallow concrete could play a vital role in ensuring safer flights for all travelers. By combining strength, flexibility, and affordability, this new material offers airports a smarter way to protect passengers and crews, setting a new standard in aviation safety.