Chloe Zhang
Nzambi Matee from Nairobi, Kenya is the inventor of the plastic brick, which is made from a mix of sand and plastics. Matee is a materials engineer who set out to address the plastic waste polluting her country. Her company, Gjenge Makers, produces around 1500 bricks a day out of a mix of different plastics, including plastic milk and shampoo bottles, sandwich bags, buckets, and ropes. The process involves shredding the plastic, packing it into a mould, heating it, and then pressing it into the final brick shape. These bricks are twice as sturdy as concrete, and provide an innovative solution to the global plastic waste problem.
| Characteristics | Values |
|---|---|
| Inventor | Nzambi Matee from Nairobi, Kenya |
| Raw Materials | Sand, high-density plastics, low-density plastics, concrete |
| Plastic Sources | Post-industrial waste, post-consumer plastic waste |
| Plastic Types | Polypropylene, Polyethylene |
| Plastic Sources | Plastic bags, trays, containers, milk and shampoo bottles, sandwich bags, buckets, ropes, bottle tops and seals |
| Process | Mixing sand and plastics at high temperatures, compressing the mixture into bricks, cooling the bricks, placing them in a water bath |
| Benefits | Eco-friendly, affordable, lightweight, damp-proof, sturdy, reduces brickwork costs, conserves natural resources, reduces landfill waste and greenhouse gas emissions |
| Use Cases | Pavements, small construction units, roads, sidewalks, footpaths, driveways |
| Production Time | 40 minutes per batch |
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What You'll Learn
Plastic waste is a global issue
The annual global production of plastic is over 359 million tons, and every year, 19-23 million tons of plastic waste leak into aquatic ecosystems, polluting lakes, rivers, and seas. Plastic pollution can alter habitats and natural processes, impacting millions of people's livelihoods, food production, and social well-being. It also affects all life forms and natural ecosystems. Plastic waste does not readily degrade and thus persists in the environment for long periods. As plastics degrade, they can break down into micro and nano-sized particles that spread in air, water, and soil, leading to various negative impacts on both terrestrial and aquatic animals, such as ingestion, entanglement, ulcers, low reproduction rates, and oxidative stress.
The plastic brick invention offers a solution to plastic waste management. In Nepal, for example, plastic waste has been a significant problem in growing cities. The UNDP Accelerator Lab has introduced a technology to create bricks using non-recyclable plastic waste, which was used to build a demonstration toilet in Pokhara Metropolitan City in 2021. These plastic bricks have passed compressibility strength tests and are suitable for non-load-bearing walls like pavements and small construction units.
The plastic bricks developed by Matee's company, Gjenge Makers, are twice as sturdy as concrete and are sold at a cheaper price, making them affordable for Kenyan citizens. The production of these bricks also provides jobs, particularly for youth groups and women. By converting plastic waste into bricks, Matee's innovation addresses the global issue of plastic waste while also providing a sustainable and cost-effective construction solution.
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Shredding, moulding, and heating
The shredded plastic is then placed into a pan or oven and heated to temperatures above 180°C, with some sources recommending 270°C. During heating, the plastic waste is transformed into a semi-solid or half-melted state, ideal for moulding. At this stage, additives such as sand, M-sand, or mineral additives, can be mixed with the heated plastic to enhance its properties. Sand, for instance, improves the compressive strength of the bricks, making them suitable for construction.
The mixture of heated plastic and additives is then poured or placed into moulds to give them the desired brick shape. These moulds can be made of steel or other suitable materials. The moulds are then transferred to a press rig or furnace to compress and further melt the plastic mixture, respectively. This step solidifies the mixture into a brick shape.
Finally, the moulded bricks are left to cool and harden. The resulting plastic bricks are sturdy, affordable, and environmentally friendly, providing a creative solution to plastic waste disposal and a unique approach to construction.
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Plastic bricks are sturdy and affordable
Plastic bricks are an innovative solution to the growing problem of plastic waste. These bricks are made from a mixture of sand and plastics, including factory waste and other unrecyclable plastic scraps. The process of creating these bricks involves mixing the sand and plastic at very high temperatures before compressing the mixture into brick form.
One of the key advantages of plastic bricks is their superior strength and durability compared to traditional bricks. Lab tests have shown that plastic bricks can be up to 40% stronger and 20% lighter than conventional bricks. This increased strength can lead to a reduction in brickwork costs for building projects. Additionally, the lightweight nature of plastic bricks makes them easier to work with during construction.
Plastic bricks are also a more affordable option. Because they are made from waste materials, the production costs are relatively low, resulting in a lower product price. For example, in Kenya, plastic bricks are sold at a more affordable rate than regular bricks, making them accessible to local communities. The affordability of these bricks can have a significant impact, especially in areas where there is a need for affordable housing, schools, and other essential infrastructure.
The use of plastic bricks promotes sustainability and environmental conservation. By utilising waste plastic, these bricks help reduce plastic pollution and provide a permanent solution by making the plastic static within the bricks. This process also reduces the consumption of natural resources, such as clay, coal, wood, and water, which are typically used in traditional brick production, thereby further reducing environmental harm and contributing to a more sustainable future.
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Eco-friendly alternative to clay bricks
Plastic waste is a pressing global issue, causing significant environmental challenges. The construction industry is a major contributor to this issue, with unsustainable development considered a key threat to the environment. For instance, a brick kiln emits about 70-282g of carbon dioxide, 0.001-0.29g of black carbon, 0.29-5.78g of carbon monoxide, and 0.15-1.56g of particulate matter per kilogram of brick fired.
The traditional clay brick industry in India, for example, consumes vast amounts of coal, wood, and water and is responsible for almost 9% of the country's carbon emissions. Clay bricks are also responsible for releasing approximately 400 grams of CO2 per brick.
To address these issues, engineers and entrepreneurs have explored the concept of converting plastic waste into bricks, providing an eco-friendly alternative to traditional clay bricks. This innovation aims to reduce the environmental impact of the construction industry by minimizing resource depletion, energy consumption, and waste generation.
One such initiative is "Wricks" (waste + bricks), developed by Kunjpreet Arora, co-founder of Angirus, an India-based circular economy startup. Wricks are lightweight, damp-proof bricks made entirely from waste, including single-use plastic and construction waste such as concrete. By eliminating clay, coal, wood, and water from the production process, Wricks conserve natural resources, reduce greenhouse gas emissions, and provide a permanent solution to waste disposal. Lab tests have shown that Wricks are 40% stronger and 20% lighter than traditional bricks in India, resulting in potential cost savings for building projects.
Another approach is "Ecobricking," also known as "bottlebricking." Ecobricks are created by packing PET (polyethylene terephthalate) bottles with clean and dry used plastic. This method extends the usefulness and life cycle of plastic waste. However, it is important to note that plastic remains an unsafe and unsustainable building material due to health concerns and the need for regulation. To address this, Ecobricks can be encased in clay soil and covered with concrete to prevent plastic deterioration, although this adds complexity to the process.
By embracing low-carbon alternatives like Wricks and exploring the use of plastic bricks in construction, we can simultaneously address two critical environmental issues: reducing plastic waste and mitigating climate change through sustainable practices.
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Plastic waste collection and income
Plastic waste is a significant environmental concern, with most plastic ending up as waste and harming the environment. However, several innovators have found ways to convert this waste into bricks, creating an eco-friendly alternative to traditional clay bricks and providing a stable income source for waste collectors.
Plastic Waste Collection
Nzambi Matee from Nairobi, Kenya, is a materials engineer and the founder of Gjenge Makers, a company that produces plastic bricks. Matee sources plastic waste from two main sources: post-industrial unrecyclable broken bits and post-consumer plastic waste, such as discarded products and packaging. Gjenge Makers accepts waste that other facilities cannot recycle, including plastic milk and shampoo bottles, sandwich bags, buckets, and ropes. They also partner with manufacturers of plastic bottle tops and seals in the beverage and pharmaceutical industries.
In Nepal, the United Nations Development Programme (UNDP) Accelerator Lab has introduced a new technology to make bricks using non-recyclable plastic waste. This technology aims to help sustainably manage plastic waste while providing a business opportunity for the private sector.
Kunjpreet Arora, co-founder of Angirus, an India-based circular economy startup, also makes bricks from plastic waste. Angirus aims to replace traditional clay bricks, which contribute to carbon emissions and environmental destruction, with a sustainable alternative.
Income Generation
The plastic brick industry provides a stable income for waste collectors and promotes local job creation. For example, Gjenge Makers in Nairobi works with informal waste collectors, providing them with stable income opportunities. Additionally, the company produces affordable bricks for the local community, helping to reduce the cost of construction for houses, schools, and roads.
Angirus, the Indian startup, also generates income by selling its eco-friendly bricks to "green" builders, architects, and contractors who are open to using sustainable alternatives in their construction projects. They have completed deliveries for residential and factory projects, contributing to a positive environmental impact and a successful business venture.
By converting plastic waste into bricks, these innovators are not just creating a sustainable product but also fostering economic opportunities for waste collectors and local communities.
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Frequently asked questions
Plastic bricks are made from a mix of sand and plastics. The sand and plastic are mixed at high temperatures and then compressed into bricks.
The process of making plastic waste bricks involves shredding the plastic, packing it into a mould, heating it in an oven, and then pressing it into the final brick shape.
Plastic waste bricks provide a use for factory waste and ensure it is recycled. They are also more affordable than regular bricks and can reduce brickwork costs by up to 20%.
Plastic waste bricks are suitable for non-load-bearing walls like pavements, driveways, and small construction units. They can also be used for footpaths and sidewalks.
Nzambi Matee from Nairobi, Kenya, is the inventor of plastic waste bricks. She is a materials engineer and the founder of Gjenge Makers, which produces around 1500 bricks per day.
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