Production

The Resource

top view of a large construction site with multiple tall apartment buildings being build

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Endless Demand

At the Urban Age Conference in Venice it was declared that social peace and security for the whole world in the next few years depends on whether we succeed in building 1 million residential units every week at an affordable price. 2.5 billion more people will be living in cities by 2050, the vast majority in Africa and Asia. Yet, much of the infrastructure to support this urban expansion is yet to be built.

Source:Urban Age

Scarce Resource

One of the biggest problems is limited building material. Although sand is available in many places in the world, it often cannot be used to make concrete and consequently to build houses. Desert sand for example is not suitable for building houses.

Source:nature

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desert sand dunes stretching far into the horizon

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Our Solution

Polycare’s technology allows to produce Polyblocks made of durable and environmentally friendly polymer concrete. The special feature of this development allows the use of local raw materials such as desert sand or other free flowing filler – a game changer for the construction industry.

The Material

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Polymer Concrete

Polyblocks are made by polymer concrete which consists 90% filler of naturally occurring sands and 10% binder. The sands are freely available raw materials such as desert sand, overburden material from the mining industrie or even standardized sand. The binder based on an unsaturated polyester resin mixture which is produced to a large extent from recycled PET (poly- Ethylene terephthalate).

Material Benefits

The Factory

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Factory

With one dosing and mixing unit around 400 houses (60 m2 living space)
can be produced per year in a two-shift system. For a circle production 80 moulds are needed.

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Moulding

Every 30 Seconds one mould
will be filled

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Curing

20 minutes are needed
for curing.

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Demoulding

After demoulding, the Polyblocks
can be stored on pallets.

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Preparation

Moulds will be prepared and
can be filled again.

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Transport

After just 24 hours, the Polyblocks can be brought to the construction site and installed.
The blocks are already fully cured and have their final load bearing capacity

Factory in Namibia

Polycare Namibia was founded in 2019. The factory went live in February 2019 with 15 men and 15 women employed in the factory. Building with our Polyblocks belongs to the most affordable offerings in Namibia today - with significant higher quality and sustainability. Check out their website.

Deutsche Welle