Turning Plastic Waste into Building Blocks: How KFUPM is Paving the Way for Sustainable Construction

Affiliated Research Group:

Applied Research Center for Metrology, Standards and Testing

Key Researcher

Dr. Luai M. Alhelms

College of Engineering and Physics

Department of Mechanical Engineering

Imagine a world where plastic waste doesn’t pile up in landfills or pollute the oceans, but instead finds a new life as part of our cities' infrastructure. KFUPM’s Applied Research Center for Metrology, Standards, and Testing is making that vision a reality. Led by Dr. Luai Alhelms, the team is tackling plastic pollution by turning it into building materials that are strong and sustainable.

Using a mix of plastic waste, like old bottles, food containers, and other common plastics, and industrial leftovers like red mud and fly ash, the team has developed a method to mold these materials into lightweight blocks, tiles, and slabs. The process is clever and efficient, combining a specially designed grinder, an extruder, and custom molds to produce durable building blocks.

Not only does this process save on energy, it operates at a modest 200°C, meaning lower energy usage, but it’s also cost-effective. With production costs coming in at less than 25 SAR per square meter, these materials offer an affordable alternative that aligns with Saudi Arabia’s sustainability goals.

As part of a pilot program, these blocks will soon be laid on the KFUPM campus, where their durability will be put to the test against sun, heat, and daily wear and tear. By giving plastic waste a second life as construction material, this project directly supports the United Nations Sustainable Development Goals (SDGs), especially those focused on waste reduction and clean energy.

 

United Nations SDGs

Through our commitment to sustainable development, this project aligns with the following United Nations Sustainable Development Goals (SDGs):