In a significant breakthrough towards addressing Hawaii’s housing crisis, an innovative solution has emerged from the very industry that put the islands on the map: surfing.
A local firm has pioneered a process that transforms discarded polystyrene foam from surfboards into building materials for affordable, disaster-resistant homes.
David Sellers, an amateur surfer and professional architect, conceived this idea nearly a decade ago when he came across polystyrene foam waste in a dumpster near his office in Haʻikū, Maui.
This sparked his curiosity about the potential of recycling this material, specifically how many homes could be constructed from it.
Sellers adapted existing Insulating Concrete Form (ICCF) technology to create ‘Surf Blocks,’ which consist of 85% recycled expanded polystyrene (EPS) foam, thus giving new life to an otherwise discarded resource.
Hawai’i Off-Grid Architecture & Engineering, led by Sellers, has been manufacturing Surf Blocks for two and a half years.
As Sellers points out, Hawaii is grappling with limited space and resources, alongside landfills that are rapidly reaching capacity.
With a Green Grant from Maui County, the initiative is poised to recycle substantial amounts of EPS foam from landfills, decrease dependence on imported materials, and encourage local businesses.
“Surfing was born in Hawaii,” Sellers emphasized. “Shaping boards is still a part of daily life here. Creating building materials from local waste is not just environmentally responsible; it’s crucial. It allows us to reduce imports, cut emissions, and build in a truly place-based manner.”
Designed to be stacked similarly to Lego bricks, Surf Blocks form walls that are reinforced with steel rebar and filled with concrete, ensuring they remain structurally sound.
These blocks are lightweight yet strong, offering superior insulation and exceptional sound-dampening properties.
Additionally, Surf Blocks are resistant to mold, pests, and mildew, and most significantly, they are highly resilient against natural disasters, including hurricanes, earthquakes, and fires.
Houses constructed using Surf Blocks utilize only about one-third of the concrete required for traditional breeze block construction, significantly reducing material costs while supporting environmental objectives.
This alternative is particularly valuable given the soaring construction costs in Hawaii— the highest in the United States.
Moreover, it provides a pragmatic approach to the growing affordability crisis wherein only one in five households is projected to afford a single-family home by 2024, especially in light of the 2,200 homes that were rendered unsalvageable by the Lahaina fires.
The project has garnered attention not only for its positive environmental impact but also for its potential scalability.
As the inaugural home constructed entirely from Surf Blocks nears completion, plans are already underway to broaden the use of this innovative material across the island.
Looking ahead, the next challenge involves making surfboard manufacturing more sustainable. Presently, boards are made from fiberglass and virgin polystyrene, which generates considerable waste.
Francisco Goya, a former world windsurfing champion with decades of experience in shaping boards, has acknowledged the complexity involved in this transition.
“It’s everywhere in our manufacturing, in our thoughts – how to reduce waste and find greener materials,” Goya remarked. “We are committed to our efforts, but the challenge remains.”
While striving for greener surfboards is crucial, recycling surfboard waste into resilient homes may represent an ideal solution, addressing the intertwined issues of housing and sustainability in Hawaii— one wave at a time.
image source from：traveltomorrow
