Revolutionizing Construction EcoFriendly Mortar with Recycled Plastic & Aerogel
Estimated Read Time: 3 Minutes
The Highlights
- Newcastle University researchers have developed a new mortar mix using recycled PET plastic and silica aerogel.
- The mix meets international standards and could reduce heat loss in buildings by up to 55%.
- It offers a sustainable alternative that could lower energy bills and cut down plastic waste.
- Real-world testing is the next step as the team seeks industry collaboration.
A Breakthrough in Sustainable Construction
The construction industry is continuously looking for innovative ways to improve sustainability, reduce energy consumption, and minimize environmental impact. A research team at Newcastle University has made a significant breakthrough by developing a mortar mix that incorporates recycled plastic and silica aerogel, offering superior insulation while repurposing plastic waste.
By replacing sand with silica aerogel and PET plastic particles from shredded plastic bottles, the researchers created a mortar mix that is lighter, stronger, and more thermally efficient than traditional mortar. This new formulation not only improves energy efficiency in buildings but also helps reduce the vast amount of plastic waste that ends up in landfills.
How It Works
The key to this innovation lies in the use of silica aerogel, a material known for its high insulation properties, and recycled PET plastic, which provides additional structural benefits. After testing seven different formulations, the team found the optimal mix:
- 7% untreated silica aerogel replacing natural sand
- 3% recycled PET plastic
The plastic particles were washed, dried, and integrated into the mix to create a mortar that reduces thermal conductivity by up to 55% compared to conventional mortar while maintaining the necessary strength for masonry construction.
Meeting Industry Standards
A major achievement of this research is that the new mortar mix complies with international construction standards, including:
- BS-EN 413-1:2011 (European standard for masonry mortar)
- ASTM C270-10 (American standard for mortar for unit masonry)
- AS 1012/AS 3700 (Australian standards for concrete and masonry structures)
This means it is not just a theoretical breakthrough—it is a practical, real-world solution for sustainable construction.
Benefits for Energy Efficiency & Sustainability
The new mortar mix provides multiple benefits, including:
- Lower Energy Bills – Reduces heating and cooling costs by improving insulation in masonry structures.
- Waste Reduction – Offers a second life for plastic waste, reducing landfill accumulation.
- Sustainable Building Practices – Supports environmentally friendly construction without compromising strength and durability.
What’s Next?
Professor Lidija Šiller, one of the study’s lead authors, emphasizes the potential of this discovery:
“Wouldn’t it be wonderful to reduce heating bills for all new buildings while also significantly reducing plastic waste in the world?”
The research team is now looking for construction industry partners to test the mortar mix in real-world projects. Their next step is to secure funding to build a demonstration home using this innovative material, which will provide direct evidence of its energy savings and economic feasibility.
The Future of Sustainable Construction
As the demand for eco-friendly, energy-efficient buildings continues to rise, solutions like this recycled plastic and aerogel mortar could play a crucial role in the future of construction. By collaborating with industry partners, this innovation could soon become a widely adopted method for reducing carbon footprints in new developments.
Are you interested in sustainable construction solutions? IOC Construction stays ahead of the latest trends and technologies to bring cutting-edge, environmentally friendly solutions to every project. Contact us today to learn more about how innovation can shape the future of construction.
Reference: Kaniaw Marof and Lidija Šiller, “Enhancing thermal insulation in cement mortar with silica aerogel and recycled PET plastic,” Construction and Building Materials, 467 (2025) 140320. DOI: 10.1016/j.conbuildmat.2025.140320
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