Researchers at Newcastle University in the United Kingdom have developed a mortar made from recycled plastics and silica aerogel with greater insulating capacity than traditional mortars.
To manufacture this new eco-friendly building material, scientists replaced conventional sand with a mixture of recycled polyethylene terephthalate (rPET) and silica aerogel. As a result, the new mortar reduces heat loss by up to 55% compared to traditional mortar, without compromising the structural strength necessary for masonry construction.
Furthermore, it complies with international standards such as BS-EN 413-1:2011, ASTM C270-10, and AS 1012/AS 3700, making it a viable option for sustainable construction and energy efficiency. Its application could significantly improve the thermal insulation of buildings, reducing heat loss in critical areas such as thermal bridges at the junctions between bricks and walls.
The Development Process
During the research, experts tested seven different formulations alongside traditional mortar. The most effective version consisted of:
- 7% untreated silica aerogels as a substitute for natural sand.
- 3% recycled PET plastic, sourced from crushed bottles.
The recycled PET particles, between 2.5 and 3.5 mm, were washed and dried before being incorporated into the mix. The team evaluated key properties such as setting time, fluidity, density, strength, and thermal conductivity, confirming that the new material significantly improves thermal insulation without affecting the mortar’s workability.
Toward More Sustainable Construction
The study’s lead researcher, Kaniaw Marof, highlighted the importance of this breakthrough in the construction sector:
“Improving the thermal performance of buildings by reducing energy consumption for heating and cooling is a key challenge in modern construction. In our study, the incorporation of silica aerogel and recycled PET into the mortar was a crucial step toward achieving an efficient and sustainable material,” he commented.
This development represents a significant advance in sustainable construction, offering an innovative alternative to reduce the environmental impact and improve the energy efficiency of buildings.