Breakthrough ‘plastic’ mortar could slash heat loss in buildings by 55%

A groundbreaking new mortar mix developed by scientists from Newcastle University could transform how homes are built.

By swapping out traditional sand for recycled plastic and high-tech aerogels, researchers have created a lighter, eco insulation material that reduces heat loss by up to 55%.

This innovation could mean lower energy bills, less plastic waste and a major step forward for sustainable construction.

Plastic bottles turned into high-tech building material

Instead of using conventional sand, scientists integrated shredded PET plastic from recycled bottles and combined it with silica aerogel – a material famous for its ultra-lightweight and insulating properties, even used in space technology.

This blend not only improves insulation but also makes the mortar significantly lighter while maintaining the strength needed for construction.

Publishing their results in Construction and Building Materials, the team confirmed that the mortar meets international construction standards, making it a realistic option for builders looking to improve energy efficiency in new homes.

Homes stay warmer while fighting plastic pollution

This innovative mortar could help solve two major global problems at once – energy price rises and plastic waste.

Traditional mortar allows heat to escape through gaps between bricks, but the new formula locks in warmth, potentially lowering heating bills.

At the same time, it provides a smart way to repurpose plastic waste, reducing the amount that ends up in landfills or oceans. Professor Lidija Šiller, one of the lead researchers, sees a huge opportunity: “Wouldn’t it be incredible if we could cut heating bills for new homes while tackling the plastic waste crisis at the same time? Our study shows it’s possible.”

Testing in real homes

Now that the formula has been proven in the lab, the research team is eager to take it to the next level. They are looking for industry partners to help bring this mortar to real construction projects and test its long-term benefits in actual homes.

PhD researcher Kaniaw Marof, lead author of the study, believes this could be a game-changer: “Improving insulation in masonry buildings is one of the biggest challenges in construction. Our mortar not only reduces heat loss but also makes use of materials that would otherwise go to waste.”

With growing demand for greener homes, this innovation could become a key player in the future of energy-efficient construction – where homes are not only built stronger but also smarter.