Production of cement accounts for around 5% of human-made carbon emissions. When the selection of a cement-intensive mix with low porosity is driven by durability requirements, the resulting low permeability of the material is only fully exploited in peripheral regions of the element where the material acts as a physical barrier against the penetration of aggressive substances. This paper explores the potential of casting layered prismatic elements composed of an external durability layer and a lightweight core section as a means to achieve cement and weight savings. Layered elements are traditionally obtained by casting new concrete layers onto already hardened older concrete layers. A major problem with this technique is that planes of weakness are obtained at the interfaces between the layers. The bond between the layers can be improved by casting the materials at approximately the same time. However, research to date has not yet demonstrated the viability of producing elements with wet cast external layers and the effects of delays between successive pours on the mechanical tensile performance of the interfaces in layered elements have not been quantified. An original method is presented to form prismatic elements composed of an external durability layer and a lightweight core section by casting two concrete mixes at approximately the same time. The approach is validated by realising a proof-of-concept prototype layered element. A set of additional layered elements are cast with various pour delays and cored across the interface between their layers to characterize the interlayer bond strength by direct tension. To interpret the mechanisms affecting the bond, the variation of tensile bond strength with the location of the sample and the impact of roughness are also investigated. When the pour delay was minimal, failure did not occur at the interlayer but the relationship between pour delay and bond strength is markedly nonlinear, with bond strength reductions of more than 30% for pour delays of only three hours. It was also found that the bond strength of the interface varies significantly with the considered location and that up to 40% of the bond strength reduction due to a delay between the castings can be recovered by roughening the surface of the older concrete prior to casting of the newer mix. The successful realisation of wet cast prismatic elements with an external durability layer is an important step towards the realisation of light-weight layered concrete elements with low embodied energy
