Development of sustainable green polymer concrete incorporating recycled HDPE and marine composite fiberglass for enhanced mechanical strength

This study developed polyester polymer concrete incorporating r-HDPE (detergent bottles) and r-fiberglass wastes. Five compositions (C1-C5) with varying filler ratios were fabricated via hand lay-up with CSM reinforcement and tested per ASTM standards. Composition C3 (polyester 50 wt%, sand 40 wt%, r-fiberglass 5 wt%, CSM 5 wt%) achieved optimal balanced performance: tensile strength 56 MPa (+18%), flexural strength 332.91 MPa (+85%), impact strength 5.82 J/mm 2 (+19%), water absorption 0.31% (-56%) versus baselines. These results demonstrate effective waste valorization producing durable green bricks exceeding cementitious materials, advancing sustainable construction via locally abundant waste streams. These results highlight the potential of recycled materials for sustainable green bricks with excellent water resistance and surface durability, suitable for structural repairs and green building facades. This approach diverts waste from landfills, reduces raw material dependence, and cuts carbon emissions versus Portland cement, advancing climate action.