RePlast blocks are made from recycled plastics that are heated and compressed using ByFusion systems.
Replast blocks are entirely made of recycled plastic without additives and fillers. They are designed to be a complementary integration to traditional building materials such as lumber, steel, and cement.
Goal 11: Sustainable cities and communities
Those looking to build homes or landscape constructions. This system is useful for projects located next to oceans or other areas with large quantities of plastic refuse.
ByFusion has developed a machine that produces the RePlast blocks from plastic waste. The machine and the blocks are still in a proof of concept phase. The blocks can be used in infrastructure work or as wall fill.
The ByFusion machine is self contained and can fit into one shipping container so it can be brought where the plastic is located.
Size of the component
List of primary materials in the component
List of secondary materials in the component
Measurement, calculated in hours, of the component’s resistance to fire
R value associated with material/product
The compressive strength of the component, measured in megapascals
List of suitable climates for use of this components
RePlast blocks are created through the following process:
- Plastic trash enters the machine
- Plastic is shredded into small pieces
- The pieces move through a water boiler and compacter that fuses the plastics into RePlast building bricks (the process is non-toxic and no adhesives are used)
- The machine also includes a 600 gallon tank that recycles the waste water for 10-16 weeks
The construction of a RePlast wall includes:
- RePlast blocks
- rebar steel rods (two through each block module)
- steel plate for top of wall
- tape for top of wall
- chicken wire to cover surface of wall
- scratch layer
- stucco layer as final finish
7 types of plastic can be used to make the blocks. They are:
- Poluethylene Terephthalate
- High Density Polyethylene
- Low Density Polyethylene
- Polystyrene (can’t be used individually)
Fusion Machine specifications (for 500 blocks per day):
- Number of Containers: 1 x 40ft High Cube
- Processing Capacity (per day): 3,200 – 4,500kg or 3.5 – 5.0 tons
- Output per shift: ~500 blocks per day
- Number of operators required: 2
- Amount of fuel required per hour (diesel): 11 -19 liters (3 – 5 gallons)
- Space required: 33m2 (40yards2
- Types of plastic processed: 1-7
- Water supply: 1.3cm – 1.9cm (½” – ¾”)
- Electrically supply (optional configuration): Self-powered generator or local power grid (3-phase plug/US 240-watt outlet)
The machine requires minimal staff and training to operate.
The machine itself is made with standard industry parts that can be replaced in most parts of the world.
No glues or adhesives, no crack or crumble, zero-waste process, no specialized labor required.
ByFusion claims that the product has undergone initial independent testing for compression, R-value, and shear strength, but no results are provided. RePlast has been used over the past few years in retaining wall projects and has withstood severe climatic conditions including earthquakes and has not shown signs of failure.
ByFusion claims that the product has undergone initial independent testing, but the names of testing organizations are not provided.
Workers may be exposed to regular dangers of a construction site that include working at heights and with sharp tools and materials. Standard safety procedures must also be followed in the operation of the ByFusion machine.
Although ByFusion intends to conduct testing for fire resistance, they recommend applying a mortar finish to protect from UV damage and to create a thermal heat barrier.
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