BIO-BRICK — From Waste to Worth

Section 01 — Problem Statement

Two crises. One overlooked connection.

2.4Mtons of food wasted in the UAE annually

38%of UAE food waste is bread — the #1 wasted item

8%of global CO₂ emissions come from cement & brick production

1,000°Cfiring temperature for conventional bricks

📋The UAE Building Code and Vision 2030 mandate the use of sustainable construction materials. This isn't a future trend — it's a current legal direction for the construction sector.

Regulatory Push

The UAE Building Code and Vision 2030.

💰ESG = Environmental, Social, and Governance, a framework investors use to measure sustainability. A price premium means buyers pay more for an added benefit — green-certified buildings sell for 8–12% more. The gap: developers need sustainable materials to qualify, but few exist at scale.

ESG Premium Gap

Buyers pay more for sustainable, certified buildings.

$42.75B

UAE construction market (2025) → $52.66B by 2030 at ~4.3% CAGR (Mordor Intelligence, 2026)

This market is mandated to go green — UAE Building Code 2023 and Vision 2030 require sustainable materials across new construction, while LEED and Estidama certification unlock real financial incentives for developers who comply.

Certifications Driving Demand

LEED (Leadership in Energy & Environmental Design)Global standard

Al Sa'fat (Dubai green building)Mandatory since 2016

Estidama Pearl Rating (Abu Dhabi)Mandatory for new builds

UAE Building Code 2023Sustainability mandate

UN SDG 12.3 (food waste target)Global commitment

Dubai Municipality (2010); Stonehaven (2024)

Section 02 — Solutions That Exist

We're building on proof.

Before introducing our idea, there are three independent efforts already validated that waste can be turned into practically useful materials — a world-leading university, and two pairs of young Gazan innovators working with almost nothing.

Food waste transformed into powder then pressed into solid material

Vegetable waste → dried, pulverized into powder → pressed into solid blocks. The same three-step logic RE-BLOCK applies to bread.

The Research & Process

In 2021, researchers Kota Machida and Yuya Sakai at the University of Tokyo's Institute of Industrial Science developed the world's first process for making construction material entirely from food waste — no cement required. Using Chinese cabbage, fruit peels, and other organic scraps, their compressed material reached 18 MPa flexural strength — about four times stronger than ordinary concrete in that measurement.

Their Process

Step 1Dry the food waste (vacuum-dried)

Step 2Pulverize into fine powder

Step 3Heat-press into a mold

Source: Development of Novel Construction Material from Food Waste (2021); Institute of Industrial Science, University of Tokyo

Their Use Cases

Tableware, cups & household items (as Fabula Inc.)
Furniture for partner companies
Edible emergency shelters for disaster relief
Large-scale construction — a future goal, not a current product

The Green Cake project tied for first place out of 40 competitors in the Japan Gaza Innovation Challenge. — Ezz Zanoun / Al Jazeera

The Inventors

Majd Mashharawi and Rawan Abdelatif, two Palestinian civil engineering graduates in Gaza, spent over a year developing "Green Cake" — the world's first brick made primarily from coal and wood ash instead of sand and aggregate, built to help rebuild Gaza under a construction materials siege.

Their Progress — Proof That Iteration Works

First prototype (failed test)0.2 MPa

After dozens of reformulations2.7 MPa

Current Green Cake strength3.4 MPa

Weight vs ordinary brickHalf the weight

Price vs ordinary brickHalf the price

Source: Al Jazeera, "Rebuilding Gaza from its Ashes" (Mersiha Gadzo, 2017)

Tala and Farah Mousa, founders of Build Hope

Tala (17) and Farah Mousa (15), founders of Build Hope. — TRT World

The Inventors

Tala Mousa (17) and her sister Farah Mousa (15) developed the idea while living in a displacement camp after their home was destroyed in the war. Their project, "Build Hope," won the Middle East regional award at The Earth Prize, earning $12,500 to continue their work and teach other young people in Gaza how to make the bricks.

Their Brick

Core materialCrushed concrete rubble

AdditivesClay, ash, straw, powdered glass

CostLow-cost

Use casesPavements, partitions, temporary shelters

RecognitionThe Earth Prize — Middle East regional winner

Source: TRT World, "Building Hope from Rubble"

Section 03 — Our Solution

From bread to building block.

RE-BLOCK upcycles discarded bread from UAE bakeries, hotels, and food suppliers into Bio-Brick — a sustainable construction material for non-structural, non-load-bearing applications.

🪡

What it is

A compressed bio-brick made from dried bread powder and a natural binder, cured without a kiln.

🚫

What it is not

Not a structural or load-bearing material. It does not replace foundation, column, or beam materials.

✅

Where it fits

Interior partition walls, non-load-bearing infill, insulation layers, and landscaping elements.

Collect waste bread

From bakeries & hotels

RE-BLOCK addition

→

Dry & pulverize

Into fine powder

Tokyo process

→

Mix with binder

Xanthan gum + water

RE-BLOCK addition

→

Press into molds

Cold/low-heat press

Tokyo process

→

Cure & test

QC before dispatch

RE-BLOCK addition

The Supply Base — UAE Bakeries

1,862 bakeries operating across the UAE

UAE baked goods retail market estimated at $966.7M by 2027. Sources: RentechDigital (2026); Agriculture & Agri-Food Canada Sector Trend Analysis

⚡

Energy Savings

70–90% lower firing-related energy cost

🍌

Raw Material Cost

Negative — bakeries pay us to collect

🏆

Premium Price Recovery

8–12% resale uplift on green buildings

🌿

Green Certification

Contributes to LEED & Estidama points

📈

Investor Appeal

Dual-impact, recurring B2B revenue

🏭

Lighter Material

Lower dead load, lower foundation cost

Compressive Strength

Xanthan gum-stabilized compressed materialUp to 6.86 MPa at 28 days*

Minimum required for partition/non-load use2.5 MPa

RE-BLOCK target range (bread-based)2.5–4 MPa

Thermal Conductivity

Bio-brick (organic-waste based, comparable studies)0.17–0.18 W/m·K

Hollow cement block (typical)~0.85 W/m·K

ImplicationBetter insulation than cement

Durability & Lifespan

Estimated lifespan (xanthan gum binder, indoor)25–40 years

Water absorptionModerate — indoor use recommended

Fire resistanceImproved with plastering

Validation Plan

Independent lab testingUniversity facility (planned)

StandardASTM / ISO compressive strength

Comparable precedentTokyo (18 MPa flexural), Gaza (3.4 MPa)

*Frontiers in Built Environment (2025) — xanthan gum-stabilized rammed earth, 221% strength improvement over unstabilized baseline. Lower W/m·K = better insulator. Sources: ResearchGate (2025) comparative bio-brick studies.

Cost per Brick

AED 0.80–1.20

Production cost, fully loaded

Target Selling Price

AED 2.80–3.20

Competitive launch pricing

Gross Margin

~65–70%

At target selling price

vs Hollow Block

+~AED 0.30

Small, justified premium

Why This Price Makes Sense for Launch

UAE hollow cement blocks sell for AED 2.20–2.77; solid cement bricks sell for AED 3.40–3.82. We priced Bio-Brick at AED 2.80–3.20 — just above hollow block, comfortably below solid cement — so a new, unproven material doesn't have to win on sustainability story alone; it's already price-competitive against the product it's replacing. As trust builds and certification value becomes proven on real projects, pricing can move toward the solid-cement band.

🚪

Interior Partition Walls

Primary use case — non-load-bearing dividing walls in offices, retail, and residential interiors.

🧑

Insulation Infill

Lower thermal conductivity than cement makes it a strong insulating infill layer.

🌳

Landscaping Structures

Garden walls, planters, and outdoor non-structural decorative elements.

Material	Price (AED/unit)	Strength (MPa)	Lifespan	Use Case	Green Cert.	Production Energy
Hollow cement block	2.35–2.77	~3.5	30–50 yrs	Non-structural	No	High
Solid cement brick	3.40–3.82	15–50	50–100 yrs	Structural	No	High
Fired clay brick	3.50–5.50	18–22	500+ yrs	Structural	No	Very High (1,000°C)
RE-BLOCK Bio-Brick	2.80–3.20	2.5–4*	25–40 yrs	Partition only	LEED/Estidama	10–15× less

* Target range pending independent lab validation against xanthan gum-stabilized comparable studies (up to 6.86 MPa at 28 days). Lifespan reflects indoor, non-structural use with the xanthan gum binder system.

Section 04 — Monetary Plan

Simple numbers. Clear sources.

Built on brick-level economics at our competitive launch price of AED 3.00 average.

Year 1 Revenue

AED 238K

At AED 3.00 avg price

Gross Margin

~67%

AED 1.00 cost vs AED 3.00 price

Breakeven

Month 6

Cumulative revenue covers all costs

Investment Ask

AED 110K

Equipment + working capital

Monthly Revenue vs Total Costs (AED) — 12 Months

Revenue Total Costs

Revenue

Selling price per brickAED 3.00 avg (2.80–3.20)

Pricing basisCompetitive vs hollow cement block

Month 1 bricks sold~14,500 bricks

Monthly volume growth+10% per month (B2B ramp)

Bakery Tipping Fee Income

Total UAE bakeries1,862

Assumed onboarded in Year 135 bakeries (1.9%)

Avg tipping fee per bakery/monthAED 150

Monthly tipping fee incomeAED 5,250

Annual tipping fee incomeAED 63,000

Cost per Brick (COGS)

Raw materials (bread waste)~AED 0 (tipping fee funded)

Xanthan gum binderAED 0.25–0.40

Labour (pressing + QC)AED 0.30–0.45

Utilities (dryer, press)AED 0.15–0.25

Total cost per brickAED 1.00 avg

Investor Support

Seed investment requestedAED 110,000

Equity or grant-basedOpen to discussion

Grant eligibility (non-dilutive)Khalifa Fund, MBRIF

Use of fundsSee CapEx tab

Sources: Arab Iron & Steel Union (2024); FEPY UAE block pricing (2026); Nakkeeran & Krishnaraj (2024); IMARC Group (2026). Net-zero raw material cost + investor capital funds the first 5 months of operations before breakeven.

What is CapEx?

CapEx (Capital Expenditure) is the upfront, one-time money spent on physical assets needed to run the business — machines, equipment, and setup costs. It's different from ongoing monthly expenses (like rent or salaries), which are paid repeatedly. RE-BLOCK's CapEx is the one-time AED 70,000 spent on equipment and business setup before production can start.

Total Investment

AED 110K

Full seed requirement

Equipment

AED 48K

Press, dryer, grinder, molds

Setup & Legal

AED 22K

Licensing + Dubai setup

Working Capital

AED 40K

5-month operations buffer

Equipment

Semi-auto brick pressThe machine that compresses bread powder + binder into brick shapes under pressure. The single biggest equipment cost.AED 27,500

Industrial dryerRemoves moisture from collected bread before it's ground into powder — prevents mould and ensures consistent brick quality.AED 11,500

Grain grinderGrinds dried bread into the fine powder used as the brick's main ingredient.AED 5,000

Molds & moisture sensorsBrick-shaped molds for pressing, plus sensors that check moisture content during quality control.AED 4,000

Equipment subtotalAED 48,000

Setup, Legal & Buffer

Dubai trade licenseThe legal registration that allows RE-BLOCK to operate as a business in Dubai. Required before any commercial activity.AED 8,000

Food waste handling permitA specific government permit required because we collect and process organic waste at commercial scale.AED 5,000

Legal & IP filingProtects the RE-BLOCK brand name and our specific bio-brick formulation/process from being copied.AED 6,000

Facility fit-out & safetyVentilation, safety equipment, and basic setup of the production space before it can legally operate.AED 3,000

Setup subtotalAED 22,000

Working capital bufferCash set aside to cover salaries, rent, and bills during the first 5 months — before the business earns enough on its own to break even.AED 40,000

Total investment requiredAED 110,000

Why CapEx Is Lower Than Conventional

Conventional brick plant (incl. kiln)AED 80,000–160,000 typical setup

RE-BLOCK equipment costAED 48,000

Reduction rate40–60% lower

The Reason: No Kiln

Conventional firing temperatureUp to 1,000°C

RE-BLOCK curing methodCold / low-heat press

Kiln cost eliminatedLargest line item removed entirely

A gas or electric kiln capable of firing bricks at 1,000°C is typically the single largest cost in a conventional brick plant. Because RE-BLOCK bricks are cold/low-heat pressed, that cost disappears from our CapEx entirely — this is the structural reason our equipment bill is smaller, not a rough estimate. Sources: RE-BLOCK (2025); Lontto UAE (2023).