1. Your Name: Mayuresh Malusari Kamble
2. School/College: Government Polytechnic Pune
3. Project Title: The Eco-Block Project: Advanced Waste-to-Construction Technology (High- Performance Composite Masonry)
4. Brief Description of the Project: The Eco-Block project addresses two critical environmental challenges: the overflow of non-recyclable plastic waste (MLP/HDPE/PP) and the depletion of natural construction resources like river sand and topsoil.
We have engineered a Composite Masonry Unit that replaces traditional cement/clay with shredded waste plastic as a binder. The result is a brick that is 2.5x stronger (>15 MPa), 20% lighter, and 100% waterproof. This project transitions waste management from simple recycling to “High-Value Engineering Upcycling,” offering a solution for smart city pavements, low-cost housing, and disaster relief structures.
5. Working Principle / Explanation: The Eco-Block operates on the principle of Thermal Polymer Encapsulation.
Matrix & Binder: Unlike traditional bricks that use a chemical bond (hydration in cement) or ceramic bond (kiln firing), Eco-Blocks use Thermoplastic Adhesion. When heated to approximately 180°C - 210°C, the shredded plastic (3mm flakes) transitions into a molten state, acting as a high-viscosity binder.
Mineral Reinforcement: Stone dust or fly ash (70% by weight) is integrated into the molten plastic matrix. The mineral particles provide the compressive strength, while the plastic provides tensile resilience and water-proofing.
Compression Molding: The mixture is subjected to high-pressure hydraulic compression (15-20 MPa). This removes interstitial air pockets (voids), resulting in a high-density (1.8 g/cmÂł) composite.
Interlocking Mechanism: The design incorporates a Digital CAD-optimized interlocking geometry, allowing for “mortar-less” construction, which further reduces cost and time.
Key Engineering Metrics:
Compressive Strength: 15-20 MPa (Class-I Brick standard is only 7-10 MPa).
Water Absorption: <0.5% (Eliminates efflorescence and dampness).
Carbon Footprint: Near-zero CO2 emissions as no kiln firing is involved.