Section 02 · The process
The purpose built fusion press takes mixed, unwashed, unsorted plastic and fuses it with steam and pressure alone. What comes out is a standardised building block. This is the entire chain.
Stage 1
Waste stream
Municipal + industrial plastic
Stage 2
Fusion press
Shred, heat, compress
Stage 3
Block yard
Cure, palletise, dispatch
Stage 4
Build site
Insulated dwelling
01
Municipal trucks are weighed and routed to a diversion apron ahead of the tipping face. Plastic rich loads never reach the landfill cell.
02
A picking line staffed by local reclaimers separates plastics from organics, glass and metal. Reclaimers become salaried operators, not scavengers.
03
Mixed plastics, all seven resin types, no washing required, film and rigid together, are shredded to a uniform flake.
04
The fusion press applies steam, heat and compression. The polymers bond to each other. No mortar, no binder, no additive, no offtake chemistry.
05
Blocks exit at full form, cool in the yard and are palletised. Output is dimensionally consistent and immediately stackable.
06
Engineers set wall runs, rebar spacing and openings. Blocks are notched to thread onto vertical steel like oversized bricks.
07
Community build teams stack walls in days, not months. Cladding, roof and services follow standard construction practice.
The block
Composition
100% recovered plastic waste
All resin types, mixed, unwashed.
Thermal
High insulating value
Warm in winter, cool in summer, the opposite of sheet metal.
Resilience
Water, rot and pest resistant
Does not absorb damp, does not feed mould.
Fire
Dense mass, no cavity
Removes the sheet and timber fire path that makes settlement fires spread.
Performance figures to be confirmed by our own test programme and SANS structural certification during the pilot phase.