Modular homes made from recycled plastic

By Anthony Clark

A Welsh company, Affresol, has developed the technology to build affordable low carbon homes from recycled waste plastic and minerals – including packaging and manufacturing waste. Each house consists of approximately 18 tonnes of material that would otherwise be destined for landfill.

The first of the modular buildings has been ordered by Worcester Bosch, a UK manufacturer of domestic heating and hot water systems, for its plant in Warndon, Worcestershire. Supplying Affresol with plastic recovered from recycled boilers will enable the heating specialist to achieve a zero waste policy.

Affresol has developed a material called Thermo Poly Rock (TPR) from recycled plastics and minerals for use as a structural building product. The patented process uses a low energy cold process which converts the plastics into a strong structural element.

The TPR panels are bolted together to form the load bearing frame of the house, which can be externally clad using a material of choice (brick, block or stone), and the interior insulated and plastered as standard. The roof is tiled from recycled materials.

Outlining the benefits, managing director Ian McPherson said TPR is stronger and lighter than concrete, waterproof, fire retardant, does not rot and has excellent insulation properties.

A sustainable code 4/5 home built using TPR can be up to 12% cheaper than standard build, the TPR superstructure can be erected on site within four days. The houses have an estimated life cycle of more than 60 years and the TPR elements are 100% recyclable at the end of life.

The company has spent the last two years working with Cardiff and Glamorgan universities, the Building Research Establishment (BRE) and the Carbon Trust developing the product.

The Welsh Assembly Government also provided support through the Single Investment Fund in the test and development stage, setting up an automated production facility and in the final stages leading up to accreditation.

Finance Wales, a provider of commercial funding to businesses in Wales and a subsidiary company of the Assembly Government, has also provided debt investment in the business

McPherson said: “Our management team and business partners believe there is tremendous potential for this new product particularly with the growing focus on carbon reduction, low energy affordable homes and sustainability.”

Affresol forecast building 3,000 homes per annum – recycling 40,000 tonnes of waste – with the main market being affordable homes for social housing.

Source: http://www.prw.com/subscriber/newsmail2.html?id=1267180929