Lego-like Bricks Manufacturing Using Recycled Polyethylene (PE) and Polyethylene Terephthalate (PET) Waste in Egypt

Plastics are essential in modern civilization due to their affordability, simple manufacturing, and properties. However, plastics impact the environment as they decompose over a long period and degrade into microplastics. The construction sector has been exploring substituting conventional bricks with plastic bricks, as concrete and clay bricks consume natural resources and pollute the environment. The introduction of recycling plastic, and using plastic waste and sand mixtures to create Lego-like bricks has become a new trend. The bricks have superior properties to conventional bricks, such as a smoother surface, finer edges, easy application, crack-free, higher compression strength, almost zero water absorption, and reduced energy consumption. The study: compares the results of PE with sand and PET with sand samples to previous studies, confirms alignment, works as a control sample for PET and PE novel research, and validates the concept. Three plastic mixtures using two types of plastic waste (PE and PET) and sand were used. The plastic waste with sand was heated up to 200 °C. Plastic acts as a binder, while sand acts as a filler material. Optimized durability and cohesiveness were achieved at 30–40% plastic weight ratios. A mixture of PE and sand showed a maximum compressive strength of 38.65 MPa, while the PET and sand mixture showed 76.85 MPa, and the mix of PE and PET in equal proportions with sand resulted in 26.64 MPa. The plastic samples showed ductile behavior, with elongation between 20 and 30%, water absorption between 0 and 0.35%, and thermal conductivity from 0.8 to 1.05 W/(m/K). Carbon dioxide emissions are significantly reduced as compared to standard bricks. The CO2 per brick (kg) was 0.008 and 0.0085 in the PE; 0.0085 and 0.009 in the PET; and 0.0065 and 0.007 in the PE mixed with PET.