How to Convert Used Textiles Into Bricks?

Used textiles can be converted into bricks through a process that involves shredding textile waste into fibers, mixing them with a bio-based ecological glue, compressing the mixture into molds, and then air-drying the formed bricks for 10 to 15 days. This process requires no heating, water, or chemical treatments, making it environmentally friendly. Such bricks, like those produced by the company FabBRICK, are sustainable building materials that reduce textile waste and energy consumption compared to traditional bricks.

Process Details for Textile Bricks

• Textile waste is first sorted by fiber type and color.

• The fabrics are shredded into small fibers.

• These fibers are mixed with a proprietary bio-based glue that acts as a binder.

• The mixture is compressed in molds for about 30 minutes.

• The shaped bricks are air-dried naturally for 10 to 15 days without the use of ovens or kilns.

Benefits of Textile Bricks

• No high heat or water use, cutting down energy and resource consumption.

• Low carbon emissions compared to standard clay or cement bricks.

• The bricks retain the natural hues of the textiles without artificial coloring.

• They have insulating properties suitable for construction purposes like partition walls and furniture.

Applications

• Acoustic panels in offices.

• Lightweight partition walls.

• Modular furniture components.

• Sustainable displays and pop-up stores.

How to Convert Used Textiles Into Bricks: A Complete, Deep Technical Guide

The world generates over 92 million tons of textile waste each year, and this number may exceed 134 million tons by 2030. Much of this material—fast-fashion garments, industrial rags, mixed fibers, carpet scraps—ends up in landfills due to contamination, fiber blends, and low economic value. Meanwhile, the construction industry consumes enormous amounts of virgin materials such as clay, sand, cement, and aggregates, leading to massive embodied carbon and environmental pressure.

An emerging solution unites these two problems: turning used textiles into construction bricks. Countries like Australia, India, and parts of Europe are already testing textile-enhanced building materials. Researchers are discovering that textile-reinforced bricks can improve insulation, reduce weight, and lower overall embodied energy.

This article provides a deep, detailed examination of the full process—from materials science to manufacturing techniques, performance metrics, limitations, and future innovations.

1. Why Convert Textiles Into Bricks?

1.1 Environmental Benefits

• Reduces landfill pressure: Textiles compact poorly and create methane as they degrade.

• Decreases consumption of virgin construction materials: Replaces sand, clay, or aggregates.

• Lowers emissions: Many textile-brick processes operate at lower firing temperatures.

• Promotes circular economy: Converts a low-value waste stream into a high-value material.

1.2 Engineering Benefits

• Improved insulation: Fibers create porous structures.

• Weight reduction: Textile bricks are lighter than traditional clay bricks.

• Shock absorption and flexural strength: Fibers act as reinforcement, like micro-rebar.

2. Understanding the Materials: What Textiles Work Best?

Not all textiles behave the same under heat, pressure, or bonding agents. Understanding fiber chemistry is essential.

2.1 Natural Fibers

• Cotton: Good thermal decomposition, forms porous micro-channels.

• Wool: Keratin structure provides resilience, but burns at lower temperatures.

• Jute/Hemp: Excellent for fiber-reinforced composites.

2.2 Synthetic Fibers

• Polyester: Melts and binds; enhances tensile strength.

• Nylon: Acts as reinforcement but may release fumes during heating.

• Acrylic: High flammability; requires controlled thermal treatment.

2.3 Mixed Fibers

Most textile waste is blended. Mixed fibers still work but require:

• Pre-sorting to avoid hazardous materials.

• Adjustments in binder ratios.

• Careful thermal control.

3. Overall Workflow: Converting Used Textiles to Bricks

The general process includes:

1. Collection & Sorting

2. Shredding

3. Chemical or Thermal Pre-treatment

4. Mixing With Binders or Clays

5. Molding or Extrusion

6. Drying & Curing

7. Testing & Quality Control

Each step has variations depending on the technology used.

4. Detailed Step-by-Step Process

4.1 Step 1: Collection and Sorting

Textiles are collected from:

• Clothing donation streams

• Industrial fabric scraps

• Carpet recycling programs

• Household waste centers

Sorting removes:

• Buttons, zippers, metals

• Plastics and contaminants

• Hazardous materials

Automated systems may include:

• Near-infrared (NIR) fiber identification

• Spectroscopy systems

• Robotic sorting arms

4.2 Step 2: Shredding

Textiles are shredded into:

• Microfibers (1–5 mm) for binder-heavy composites

• Fiber flakes (5–20 mm) for insulation bricks

• Long strands (20–50 mm) for reinforcement bricks

Industrial shredders use:

• Rotating drum knives

• High-speed tearing blades

• Granulators for fine fiber reduction

4.3 Step 3: Pre-treatment

Purpose:

• Improve bonding and mechanical strength

• Remove dyes or contaminants

• Enhance thermal behavior

Possible Pre-treatments

1. Chemical cleaning

   • Mild alkali washes remove dyes and oils.

2. Thermal stabilization

   • Pre-carbonization at 200–350°C strengthens fibers.

3. Hydrothermal processing

   • Autoclaving eliminates bacteria and moisture.

4.4 Step 4: Binder Systems (Essential Part)

Textile fibers cannot form solid bricks alone. They require binders:

Binder Options

A. Clay + Textile Mix

• Clay acts as the primary structure.

• Textiles burn away during firing, leaving pores.

• Produces lightweight, insulating clay bricks.

Typical ratio:

• 80–90% clay

• 10–20% shredded textiles

B. Cementitious Composites

• Cement bonds fibers into a strong brick.

• Lower temperature process (no firing).

• Good for structural or partition bricks.

Typical ratio:

• 60–80% sand/aggregate

• 10–20% cement

• 5–15% textiles

C. Polymer Binders

• Recycled plastic acts as binder when melted.

• Creates a waterproof, durable composite.

• Best for outdoor or landscaping bricks.

D. Geopolymers (Low-carbon binders)

• Activated aluminosilicate materials.

• High fire resistance and low CO₂ footprint.

• Works well with mixed fibers.

4.5 Step 5: Forming the Bricks

Methods include:

A. Compression Molding

• High-pressure hydraulic presses (20–100 MPa)

• Produces consistent density and shape.

B. Extrusion

• Mix is pushed through a die, then cut.

• Suitable for mass-scale manufacturing.

C. Hand Molding

• Low-tech, appropriate for developing regions.

D. 3D Printing (Emerging technology)

• Textile-aggregate pastes extruded via large-scale printers.

4.6 Step 6: Drying and Curing

Clay bricks

• Air dry 1–3 days

• Fired at 800–1050°C

• Textiles burn out → creates pores

Cement bricks

• Moist-cure at 20–40°C for 7–28 days

Polymer bricks

• Cooled after melting (no curing needed)

4.7 Step 7: Testing and Quality Control

Standards include:

• Compressive strength (ASTM C67)

• Flexural strength

• Thermal conductivity

• Water absorption

• Fire resistance

• Dimensional accuracy

5. Case Studies: Real-World Projects

5.1 RMIT University (Australia)

Researchers developed textile-incorporated clay bricks with:

• 37% increased insulation

• 20% reduced weight

• Reduced firing energy

5.2 India: Eco-Brick Initiatives

Several startups in India convert textile waste into:

• Cement-fiber bricks

• Road pavers

• Partition wall panels

5.3 Europe: Carpet-to-Brick Technology

Carpet waste is processed into:

• Polymer-aggregate composites

• Fiber-reinforced blocks

6. Performance Characteristics

Strength

• Cement-textile bricks: 5–12 MPa

• Textile-clay bricks (fired): 8–35 MPa

Insulation

• 20–40% better than traditional clay bricks due to porosity.

Weight

• 10–30% lighter.

Fire resistance

• Natural-fiber bricks: excellent after firing.

• Synthetic-fiber composite bricks: require flame retardants.

7. Challenges and Limitations

• Mixed-fiber waste complicates thermal behavior.

• Synthetic fibers can emit fumes during firing.

• Ensuring consistent mechanical performance.

• Regulation and building-code acceptance still emerging.

8. Future Innovations

Fiber-Engineered Bricks

Optimizing fiber orientation like rebar.

Carbonized Textile Bricks

Converting fibers into carbon micro-structures for strength.

AI-Driven Fiber Sorting

Robotics + spectroscopy to separate fibers at industrial scale.

Textile-Geopolymer System

Ultra-low-carbon, high-strength composite bricks.

Converting used textiles into bricks is more than a recycling technique—it’s a transformative approach to resource efficiency. With advancements in material science, binder chemistry, and manufacturing processes, textile-based bricks could become a mainstream building material.

This technology provides:

• Lower carbon emissions

• Less landfill waste

• Improved insulation

• New opportunities in sustainable construction

As global textile waste continues to rise, turning discarded fabrics into durable building materials represents one of the most promising pathways toward a circular, low-carbon future.