PROJECTS

Framework
The construction sector is under increasing pressure to improve resource efficiency, reduce the carbon footprint of construction materials and processes, and accelerate the adoption of circular economy principles. Heavy reliance on conventional materials, such as cement, ceramics and steel, coupled with the significant generation of construction waste, a shortage of skilled labour and low recovery rates for certain plastic waste streams, highlights the need to develop more efficient, circular construction solutions that are better suited to the sector’s current challenges.
In this context, the recovery and valorisation of recycled polypropylene through the development of advanced composites incorporating mineral fillers and plant-based additives offers significant potential for creating new materials for modular construction systems. Combining recycled and renewable raw materials with industrially scalable manufacturing processes could help reduce the consumption of natural resources and enable the development of construction solutions with a lower environmental impact, without compromising the applicable performance and safety requirements.

Main objective
The main objective of the REBLOCK project is to develop and validate a modular construction system based on sustainable blocks manufactured from recycled polypropylene compounded with mineral fillers and plant-based additives, while meeting an integrated set of requirements relating to mechanical performance, hygrothermal and acoustic performance, reaction to fire and durability.
The project therefore aims to establish an optimised composite formulation; develop and validate the geometry and functionality of the modular blocks; demonstrate the feasibility of pilot-scale production; and assess the system’s performance under conditions representative of its intended future use. This will establish the technical and commercial foundations required to bring the solution to market.

Project activities and expected results
The REBLOCK project has a total duration of 30 months, with activities planned in accordance with the following structure:

Activity 1 – Preparatory Studies
This activity aims to map international trends and competitors, anticipating opportunities and threats for the project; define requirements and functional specifications to ensure legal and technical compliance with European standards and those of other target markets; plan and establish validation methodologies for the composites and prototypes; and prepare the infrastructure required to carry out testing and simulations.

Activity 2 – Composite Optimisation
The main objectives of this activity are to select different sources of polypropylene, minerals and additives, and optimise the composite formulations; manufacture laboratory-scale composite prototypes; and rigorously characterise the material developed, thereby generating the technical evidence required for the subsequent stages of the project.

Activity 3 – Development of the Construction System
This activity focuses on modelling and simulation studies to optimise the geometry of the system’s basic units; the integration of additional functionalities into the modular construction system; the development of laboratory prototypes for functional validation studies; and the prospective life cycle assessment of the system.

Activity 4 – Pilot Production and Testing in a Relevant Environment
This activity aims to manufacture pilot batches of the blocks to assess the suitability of the manufacturing method, its potential for industrial scale-up and the quality of the composite developed; test the system in real structures under different climatic and usage conditions; conduct technical tests in a relevant environment to validate the performance of the final material; and assess the life cycle of the final product, identifying and quantifying the environmental impacts associated with its various stages.

Activity 5 – Market Readiness
This activity aims to consolidate the results obtained from the various testing campaigns to support the process of affixing CE marking to the new construction system; prepare technical data sheets and standardised installation procedures; and develop the commercial and market strategy by defining business models, target audiences and potential customers, with a view to maximising market acceptance and the success of the solution.

Activity 6 – Dissemination and Promotion
This activity aims to develop and implement an integrated communications plan; disseminate the technical and scientific results at national and international events; and promote the project at both commercial and institutional levels.

OPERATION SHEET