What recycled plastic bricks currently exist worldwide

This research is part of the FEASIBILITY STUDY OF A RECYCLED PLASTIC BRICKS WORKSPACE IN NIGERIA, where we investigate the possibility to install a brick making workspace in Nigeria to provide a local alternative to conventional construction material. We divided this research into 4 research topics : Nigeria brick market study What recycled plastic bricks currently exist worldwide Brick regulations in Nigeria Precious Plastic brick model 2.0 We are also using Discord to chat about these topics : https://discord.com/channels/586676777334865928/967864368295448577

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Introduction

created almost 3 years agoedited almost 3 years ago

For this research topic we will need you ! We will try to gather as much information as possible on the different existing alternatives creating bricks or blocks out of plastic waste. We are trying to look as wide as possible, so it can be companies compressing plastic, making pavement, mixing with concrete. Anything is worth being documented at this stage as long as some plastic waste is incorporated in the process. We will try to answer the following questions : 1- General description of the brick and the manufacturing process 2- Pure plastic or mix ? 3- Self locking or piling ? 4- Need additional material to link the bricks ? 5- Need additional structure to hold the walls ? 6- Need additional material to cover the bricks ? 7- Size(s) of the brick(s) ? 8- Weight(s) of the brick(s) ? 9- Price per brick ? 10- Price per kg ? 11- Price per wall ? We will create one step per found alternatives, and try to answer all these questions. Don’t hesitate to comment below or on Discord for companies and examples of recycling plastic bricks we can start documenting them !

2

Ramtsilo

created almost 3 years ago

1- General description of the brick and the manufacturing process https://www.ramtsilo.com/ South African company Conventional aggregated bricks with plastic mixed in Conventional manufacturing method for sandcrete block : "blend of plastics and aggregates, and with simultaneous vibration, the brick are moulded and left to cure until they have reached the required compressive strength." 2- Pure plastic or mix ? 30% of plastic mixed with aggregate 3- Self locking or piling ? Pilling, like standard brick 4- Need additional material to link the bricks ? Linked with cement like usual sandcrete blocks 5- Need additional structure to hold the walls ? No : can create self standing wall : brick can hold 7-15Mpa pressure 6- Need additional material to cover the bricks ? Not 100% necessary as brick are fire resistant, but seems to be covered plaster usually, at least for aesthetic 7- Size(s) of the brick(s) ? L210 X W70 X H105 & L290 X W90 X H140 8- Weight(s) of the brick(s) ? Around 2kg and around 4,5kg 9- Price per brick ? ??? 10- Price per kg ? ??? 11- Price per wall ? ???

3

Byblocks / Byfusion

created almost 3 years ago

1- General description of the brick and the manufacturing process https://www.byfusion.com/ & https://www.youtube.com/channel/UCLuAMSTMe8DC6XNJfoN9_0Q Based in Los Angeles, USA Pattent manufacturing process : steam super heated and compressed 2- Pure plastic or mix ? Seems to be pure plastic : mix of HDPE, LDPE and PET 3- Self locking or piling ? Self locking system 4- Need additional material to link the bricks ? The bricks are compressed together with threaded bars 5- Need additional structure to hold the walls ? It seems they are self standing for single floor building Anchored to the floor and compressed together with threaded bars and wooden plank 6- Need additional material to cover the bricks ? The bricks are not intended to be exposed to weather and sun : UV protection need to be applied on them Unless suggested in the video, bricks are considered ASTM E-84 class C as per their documentation (very flammable) 7- Size(s) of the brick(s) ? 16″W x 8″D x 8″H or 406W x 203D x 203H 8- Weight(s) of the brick(s) ? 22lbs or 10kg 9- Price per brick ? ??? 10- Price per kg ? ??? 11- Price per wall ? 10500$ for a 10’ l x 12’ w x 9’ h. Approx 120 sqft shed (all included, bricks, structure, roof, UV covers...) = 9700€ for a 3m l x 3,6m w x 2,7 h. Approx 11m2 shed

4

Unibrick

created almost 3 years ago

1- General description of the brick and the manufacturing process https://www.unibrick.global/ Plastic extruded into a mould 2- Pure plastic or mix ? Pure plastic (no indication about the plastic or plastic mix used) 3- Self locking or piling ? Self locking 4- Need additional material to link the bricks ? Metal rod going through 5- Need additional structure to hold the walls ? ??? Attached together with metal rod and wood structure. There is no information about the need for the wood to be structural. 6- Need additional material to cover the bricks ? As they are 100% plastic, UV resistant and fire resistant cover is probably mandatory for outside and housing application. 7- Size(s) of the brick(s) ? 200L x 100B x133H mm 8- Weight(s) of the brick(s) ? 1,6kg 9- Price per brick ? ??? 10- Price per kg ? ??? 11- Price per wall ? ???

5

Conceptos Plasticos

created almost 3 years ago

1- General description of the brick and the manufacturing process https://conceptosplasticos.com/ Also found as "bloqueplas" or "blockarp" Plastic is extruded into a mould. Manufacturing is more industrial, with heavier mould, big extruder, cranes, big water bath etc... 2- Pure plastic or mix ? Seems pure plastic but not sure, old information are mentioning 100% PET, to be confirmed 3- Self locking or piling ? Self locking 4- Need additional material to link the bricks ? No 5- Need additional structure to hold the walls ? They have a whole set of bricks and structural beams, all can be done from their product 6- Need additional material to cover the bricks ? According to their website no, but this is 100% plastic therefore it would be negatively impacted by fire and UV 7- Size(s) of the brick(s) ? Base brick is 530x70x130 8- Weight(s) of the brick(s) ? Base brick is 3,3kg 9- Price per brick ? ??? 10- Price per kg ? ??? 11- Price per wall ? ??? Other : on the old website they mention that one 40m2 house is 6000kg of plastic, and that one line can produce 50 house per month. This means processing 300T of plastic per month. But that means processing 1200 to 1900kg of plastic per hours, so less then 10s per brick. Something doesn't seems right in this calculation, unless one line has multiple extruder.

6

Planetary Ecologist + OTHER

created almost 3 years agoedited almost 3 years ago

1- General description of the brick and the manufacturing process https://www.planetaryecologist.com/ Plastic is mixed with sand an introduced in an extruder. Plastic and sand is properly dried before. The mix is extruded on a table and manually transferred to a 100T press with a mould. Plastic takes around 40s to cool down in the mould (mould seems water cooled) Then is placed on a jig and cool down in water 2- Pure plastic or mix ? 70% sand and 30% plastic (in mass) 3- Self locking or piling ? Not used for bricks 4- Need additional material to link the bricks ? Not used for bricks 5- Need additional structure to hold the walls ? Not used for bricks 6- Need additional material to cover the bricks ? Not used for bricks 7- Size(s) of the brick(s) ? Not used for bricks 8- Weight(s) of the brick(s) ? Not used for bricks 9- Price per brick ? Not used for bricks 10- Price per kg ? Not used for bricks 11- Price per wall ? Not used for bricks Other : Flexural strength........1.60 kN 100% Water resistant Temperature range....... From -65°C to +150°C Frost resistance....... to minus 100 Combastibility class....... B2 Flame penetration group....... PП1 Acid resistant High impact Wearability....... 0.2 gr/cm2 Density....... 1500 kg/m3 Tile weight...... 2.6 kg per item (23.4 kg/m2) Ridge tile weight...... 2.2 kg per item (6.6 kg/running meter) Similar method : Plastcam (Cameron) Gjenge Makers (Kenya) Zecoplast (India)

7

Wasteaid and OTHER

created almost 3 years ago

1- General description of the brick and the manufacturing process https://wasteaid.org/ Plastic is mixed with sand in a barrel. Here it is presented in a very manual / low-tech process : fire heated and manually mixed Some mixer exist with electric heating and controlled temperature as well as an automatic mixing system Plastic is poured into a mould once the consistence of the mix is similar to concrete. There is no pressing or accelerated cooling. 2- Pure plastic or mix ? Mixed with sand. Plastic used seems to be mostly LDPE 3- Self locking or piling ? Not used for bricks 4- Need additional material to link the bricks ? Not used for bricks 5- Need additional structure to hold the walls ? Not used for bricks 6- Need additional material to cover the bricks ? Not used for bricks 7- Size(s) of the brick(s) ? Not used for bricks 8- Weight(s) of the brick(s) ? Not used for bricks 9- Price per brick ? Not used for bricks 10- Price per kg ? Not used for bricks 11- Price per wall ? Not used for bricks Other similar process : FSK (Philippines) : https://www.fskbuilders.com/ Though they are adding used engine oil to the mix

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