Waste plastic destined for landfill can now be turned into sustainable homes, following a British company’s development of a new material suitable for creating load-bearing frames.

Affresol developed Thermo Poly Rock (TPR) after two years of research and development with Cardiff and Glamorgan universities, BRE and the Carbon Trust, and says that it will make building to Code for Sustainable Homes level 5 significantly cheaper.

Recycled plastics and minerals are subjected to a cold, low energy process to form TPR, which is used to make panels. These panels are then bolted together to create load-bearing frames which can then be clad using other materials, and insulated and plastered as usual.

It estimates that each house built in this way contains around 18tonnes of plastic waste. Affresol also offers portable modular buildings, built in its factory, which it says contain around four tonnes of recycled plastic.

Managing director Ian McPherson said TPR is stronger and lighter than concrete, is waterproof, fire retardant, does not rot and is great for insulation. He also estimates that a Code level 4 or 5 home built using TPR could cost 12% less than one built as standard. TPR is also recyclable at the end of its life, which is “well over 60 years”.

Mr McPherson said: “We are aiming to attain the Code 5 rating for sustainable homes – at the moment many house builders claim it is not economically viable to build homes to that standard but we are confident our product can help bridge that gap.”

Affresol is working towards hopefully taking the technology to South Africa to build affordable, sustainable homes there. The company is awaiting BRE accreditation before building 19 pilot homes in Merthyr. A detached show home is currently viewable in its Swansea factory.