Concrete manufacturing is an energy-intensive process that accounts for eight percent of GHG emissions. Many academic and industry-based researchers are focused on the production process with the aim of identifying innovative approaches to drive down emissions.
Taking a different approach an Egyptian start-up is exploring the potential of using plastic to replace concrete across a wide range of building products. Tile Green uses plastic waste to eventually create a range of up to 40 building products. All types of plastic waste can be used as feedstock, including variants not suitable to traditional mechanical recycling. Using a thermomechanical process, powered by electricity, feedstock can be recycled into a concrete equivalent product without the need for cement. It is claimed that this process produces products that require 62% less energy and 35% less water compared to traditional cement-based products.
The first product to be commercially available is an interlocking paving tile, available in a range of colours and sizes and suitable for outdoor use. Tiles are claimed to be stronger, lighter, more resistant to water and abrasion, and therefore more durable than competing products. Tile are available at a competitive price and can be installed using traditional processes.
However, it should be noted that the pavers contain colouring agents, details of which are not provided. What happens to the tiles at the end of their useful life is also not specified, so presumably, they are leading for the landfill, hopefully after a long and useful life.
The energy required to make concrete represents a significant roadblock to meeting emission reduction targets. With many research projects focused on improving the manufacturing process, Tile Green highlights the possibility of finding alternative materials manufactured from waste products and moving toward a more circular economy.