frequently asked questions

Are ByBlocks available for purchase?

In limited supply at the moment but pre-orders for certain amounts are available in the US.

Have ByBlocks been tested?

Yes. ByBlocks have undergone initial independent testing for compression (PSI), R-value, and shear strength. They have already been used in various projects including the construction of retaining walls in New Zealand and California, withstanding severe environmental exposure and multiple earthquakes, without showing any visible signs of stress or degradation.

As we continue to make improvements, however, ByBlocks will undergo additional testing to ensure we meet all US and international standards for building materials.

What types of unsorted plastic can the Blocker process?

The ByFusion-patented Blocker processes all types of plastic (#1 to #7)—individually or mixed, clean or contaminated—except for 100% polystyrene (#6) and other “foam-based” plastics.

What are the dimensions of the Blocker?

The Community Blocker occupies two standard 20-ft. self-contained shipping containers. The Industrial Blocker is completely customizable to meet the plastic volume demands of any size operation and is intended to be factory floor-mounted.

Does the Blocker require any special soundproofing?

No. The noise decibel levels are equal to an idling diesel truck – sound levels are fairly low, but personal protection is required.

How much water is used during the process?

Water usage varies by model, with an average use of approximately 2–3 liters per ByBlock.

Blockers have the capability to recycle as much as 50% of the waste water. We will continue to innovate new ways to increase the amount of water we can repurpose.

Do Blocker operators need special training and what are the safety hazards?

ByFusion service engineers will train and certify local operators during installation. A foreman with a background in basic mechanical systems and repairs is recommended.

Although designed for user ease and safety, the ByFusion Blocker is an industrial machine so proper health and safety procedures should be followed at all times. Before operating the Blocker, a safety and emergency management plan must be designed and implemented to comply with local regulations.

Does the ByFusion process use any chemicals or glues?

No. Our proprietary process only used steam and compression. We never add any chemicals, fillers or additives to ByBlock.

What is the fire-resistance rating of a ByBlock?

Our upcoming plans include a full array of ASTM fire rating tests based on internationally-accepted standards —stay tuned for more to come!

How much plastic waste can be processed?

The amount of waste that can be processed is dependent of the size of the waste stream. Each customer goes through an evaluation to determine the amount of plastic they produce, so we can provide a Blocker system to suit their needs. An Industrial Blocker system can produce enough ByBlocks per day to build a single family home.

Can ByBlocks be cut?

Yes. ByBlocks can be cut using a band saw or radial arm saw with a minimum 120+ tpi 12-in. blade. You can also cut them with a handsaw.

What type of energy is required to operate a Blocker?

Our Blocker systems require electricity, water, and a fuel source such as diesel, natural gas, or LPG. Part of our continuing development is toward the use of biofuels.

How many people are needed to operate a ByFusion system?

The number of workers required to run a Blocker system depends on the size of the application. Generally, our Community Blocker can be operated by only two people.

If no glues or adhesives are used, what holds ByBlocks together?

ByBlocks are made in such a way that the block below fits into the block above, thus locking them into position. Threaded rods are fastened into your footer or slab. Each ByBlock is then placed over the threaded rods and dropped down into position. After your designated height is achieved, washers and nuts are threaded onto the rod above the top plate and post-tension is applied, pulling the wall assembly into one unit.

Can ByBlocks be painted?

Yes. As the material is plastic, it would require a specific primer to ensure proper adhesion.

What is the size of a ByFusion Blocker system?

Our standard ByFusion Community Blocker system is contained in two standard 20-ft. shipping containers. On-site, these would be placed side-by-side for easy connection and setup. Adequate space is required around the machine for safety and ease of moving materials. Each ByFusion system requires a site inspection to provide all the necessary information regarding machine location, safety, and work flow.