A Welsh based company has developed a low cost, quick to build modular home system made from recycled materials. After working with Cardiff and Glamorgan universities for two years, Affresol Ltd developed a new material called Thermo Poly Rock (TPR) from recycled plastics and minerals. The Building Research Establishment (BRE) and the Carbon Trust were also involved in developing the unusual construction material. Funding has been provided by the assembly government's single investment fund, and Finance Wales, a provider of commercial funding to businesses in Wales and a subsidiary company of the assembly government, also provided investment. Ian McPherson, managing director, commented "Every country in the world has issues with waste and we now have an opportunity to turn waste into an enduring housing resource that is 100% recyclable" he added that TPR was stronger and lighter than concrete, waterproof, fire retardant, did not rot and had excellent insulation properties.

The components are factory built which reduces on site waste. Frames can be built quickly to order, therefore reducing the design to erection time scale. The material is very strong and is totally waterproof so the erection process is not dependant on weather conditions, which leaves it suitable for year round construction.

TPR is a very “dense” material and the frames are panelled both externally and internally so as to provide optimum sound proofing. The TPR™ panel design has many advantages, one of which is that unlimited quantities of insulation can be placed in the panels. The material is therefore sound resistant and very energy efficient. The recommended walling system has a “U” Value rating of 0.15. Additional quantities of insulation inside the panels will reduce the “U” Value rating even further..On average, each modular house requires 18 tonnes of selected waste material that would have otherwise gone to landfill.

As it is a modular system the buildings have excellent design flexibility. They can be built to almost any design (subject to planning controls) and due to the lightweight (but very strong) components, they are easy to transport. This makes them popular for difficult to reach locations. Designs can extend to multi storey construction, flats and hospitals etc.

Economy Minister Ieuan Wyn Jones said the "new sustainable process" had exciting potential for construction and for "green jobs". "It is precisely the kind of business we aim to promote... designed to ensure the Welsh economy is fit for the future and ready to compete in high value markets" he said.

The company estimated the life of the houses at more than 60 years and said the TPR elements were recyclable at the end of that period.

This week domestic heating and water system company Worcester Bosch ordered the first modular building from Affresol for its Worcestershire plant. Worcester Bosch said supplying the company with plastic from recycled boilers would enable it to achieve a zero waste policy. At present, the Swansea based company employs seven people but said it hopes to treble this number in a year.

It is awaiting BRE accreditation before building 19 homes in Merthyr as its pilot project.