UPCYCLING in CONSTRUCTION - A Circular Economy Concept
- jaehorbacz
- Oct 4
- 4 min read
While working on our Eco-Friendly Home project, discussed in a recent blog, we researched and learned a lot about the use of RECYCLING and UPCYCLING materials. This weeks blog touches on what we discovered about the use of Upcycled Materials in the construction industry.
Transforming waste into sustainable building materials is becoming increasingly popular. More manufacturers are exploring ways to transform waste materials, by-products, or unwanted products into items of higher quality or value, often enhancing their usefulness, beauty, or durability beyond the original form.
Unlike recycling, which breaks items down into basic components for remanufacturing, upcycling retains the original material’s structure, repurposing it without significant degradation. This approach plays a crucial role in reducing landfill waste, conserving resources, and supporting sustainable living by extending the useful life of existing materials throughout various industries, including construction.
Many of the key features in upcycling within the construction industry leverage creativity to repurpose discarded or unused items, such as turning worn-out t-shirts into tote bags or old furniture into unique décor, resulting in products with increased practical or aesthetic value. The goal is to minimize waste and reduce consumption of new raw materials, which decreases environmental impact by lowering pollution, energy usage, and greenhouse gas emissions. Individuals, businesses, and communities create upcycled products, encompassing a wide range of items from art and furniture to everyday household and construction materials.
Upcycling differs significantly from recycling in its process and outcomes:
Examples in Construction and Beyond include
Turning glass jars into planters or lanterns
Creating furniture, art, or home goods from shipping pallets or reclaimed wood
Repurposing old clothing into quilts or bags
Crafting products from plastic bottles, such as bird feeders or plant pots
Several major US based manufacturers and niche companies have pioneered the integration of upcycled materials in construction products:
Holcim US Inc.: Incorporates recycled concrete aggregates and green concrete blends.
CEMEX USA: Offers low-carbon concrete with recycled and upcycled materials.
Heidelberg Materials North America: Uses industrial byproducts like fly ash and slag.
Owens Corning: Manufactures insulation and roofing systems from recycled glass.
Trex Company: Produces decking and outdoor products with up to 95% recycled content.
Specialized companies like Repurposed Materials Inc., Modern Mill, GreenFiber, and ECORE International further advance the use of surplus, recycled, and upcycled materials in construction, supporting circular economy principles by diverting waste from landfills.
A significant focus is on upcycling plastic waste into building materials such as decking, structural lumber, composite panels, tiles, and community structures. Companies like Trex, Upcycled Inc., Modern Mill, and ECORE International transform post-consumer or post-industrial plastics into durable products that are water-resistant and weatherproof, offering sustainable alternatives to virgin plastics. Numerous U.S. suppliers produce roofing and siding panels made with recycled plastic, including:
Brava Roof Tile: Synthetic roofing tiles from recycled polymers.
EcoStar Roofing: Slate and shake tiles from recycled rubber and plastic.
Roofeco Smart System: PVC-free synthetic roof tiles.
DuraLight Plastics: Corrugated and flat roofing panels.
NewTechWood and EcoPanels USA: Composite siding and cladding panels from recycled plastic bottles and wood fibers.
These materials are designed for long-lasting performance with qualities like high-impact resistance, UV protection, fire resistance, and eco-friendly manufacturing.
Other popular upcycled materials for the construction industry include:
Reclaimed Wood: Used for flooring, cabinetry, beams, and decorative features.
Recycled Steel: Common in structural framing and cladding.
Upcycled Plastics: Found in roofing, siding, wall panels, and fencing.
Recycled Concrete and Asphalt: Used as aggregates in new construction.
Reclaimed Glass: Incorporated into windows, tiles, and decorative finishes.
Upcycled Bricks & Masonry: Made from recycled concrete and other materials.
Shipping Containers: Repurposed into modular buildings.
Reclaimed Metal Waste: Melted for new building components.
The question comes arises when considering the cost and lifecycle benefits of upcycled materials. Are they cost-prohibitive or cost effective?
Upcycled construction materials generally cost 15-30% less than virgin materials, especially for aggregates, metals, wood, and glass. They offer lower embodied energy, reduced carbon footprints, and require less raw resource extraction. Although virgin materials often provide tighter consistency, most upcycled materials meet construction standards with equivalent or even longer service lives and lower maintenance costs. Upcycled materials generally have lower environmental impacts, with lifecycle assessments showing up to 50% emission reductions compared to virgin products. Furthermore, maintenance and replacement costs for upcycled materials tend to be equal or less.
Lifecycle Cost Comparison
In conclusion, Upcycling significantly advances sustainable construction by diverting waste from landfills and reducing environmental impacts. The growing availability and quality of upcycled building materials, combined with cost and lifecycle benefits make these products as increasingly favored choices in modern building practices. By embracing upcycling, the construction industry can support circular economy concepts that prioritize reuse, reduce resource consumption, and foster innovation in sustainable building solutions.
We challenge the AEC community to research and consider UPCYCLING materials use for projects in the future.
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