mortar minimizes heat loss” title=”Demoulded and dried cement mortar mixes in the shape of the prism (40x40x160 mm). Credit: Construction and Building Materials (2025). DOI: 10.1016/j.conbuildmat.2025.140320″ width=”800″ height=”319″/>
Revolutionizing Mortar with Sustainable Materials
Researchers from Newcastle University have created a new type of mortar that combines recycled plastic and silica aerogel, significantly enhancing its insulation properties while addressing plastic waste issues. This novel building material is poised to lower energy costs associated with heating and cooling, making it a sustainable choice for modern construction.
Published Research Findings
This groundbreaking study has been documented in the journal Construction and Building Materials. The research team modified traditional cement by substituting sand with silica aerogel along with recycled PET plastic, resulting in a lighter mix that delivers superior thermal insulation capabilities. Silica aerogels are renowned for their exceptional insulating qualities, increasingly utilized across various sectors including construction and aerospace.
Significantly Reduced Heat Loss
The innovative mortar blend demonstrated an impressive reduction in heat loss—up to 55% less than conventional mortars—while maintaining structural integrity necessary for masonry work. It complies with international standards such as BS-EN 413-1:2011, ASTM C270-10, AS 1012/AS 3700, making it a viable option for eco-conscious construction practices aimed at achieving energy efficiency.
Tackling Thermal Bridging Challenges
This newly formulated mortar addresses thermal bridging issues commonly found between bricks during wall assembly processes where gaps may occur due to traditional methods of application. By filling these spaces effectively, this product may significantly enhance overall energy conservation within buildings.
The Insight from Leading Researchers
Professor Lidija Šiller from Newcastle University’s School of Engineering underscored the importance of their findings: “Our formulation harnesses recycled PET plastic waste to create effective cement-based mortars that mitigate environmental impact,” she remarked. “Imagine if we could lower heating expenses in all new constructions while simultaneously curtailing global plastic waste.”
Diverse Formulations Tested
The researchers examined seven unique formulations against standard mortars, finding that one particularly effective combination consisting of 7% untreated silica aerogels alongside 3% recycled PET yielded notable performance benefits.
The PET used was derived from shredded plastics such as bottle materials; these were coarse fragments ranging between 2.5 – 3.5 mm after they were washed thoroughly and air-dried for approximately 24 hours post-production.
A Comprehensive Analysis Conducted
Critical aspects like setting time, flowability (which assesses workability), density specifications, compressive strength, and thermal conductivity were measured rigorously throughout testing phases. The results confirmed a possible improvement on thermal conductivity by up to an impressive margin when compared to standard samples available on the market today.
An Outlook Towards Real-World Applications
Study co-author Kaniaw Marof highlighted a pivotal focus on enhancing thermal efficiencies within masonry structures which directly relates to minimizing heating/cooling demands essential for occupant comfort—a primary concern among today’s architects and builders alike.
“Crucially,” Marof stated, “the modification techniques applied during our research facilitated better integration of silica aerogel particles into both the cement binder matrices as well as incorporating collected PET materials.” The team hopes further extensive evaluations will take place under real-life operational conditions soon enough.
Paving Paths Forward With Collaborations
“We now can confidently meet all British standards required pertaining towards implementation concerning this novel heat-retentive compost,” stated Professor Šiller regarding future advancements slated beyond laboratory settings involving collaborative partnerships aimed at actual home builds using their specialized formulation.” Such efforts could yield invaluable data showcasing potential economic advantages observed through enhanced energy efficiencies.”
