A sustainable solution to surfboard waste is making waves in the construction industry. Designed and manufactured in Haiku, Hawaii, Surf Block is a new type of Insulated Composite Concrete Form (ICCF) made from 85% recycled Expanded Polystyrene (EPS) foam—primarily sourced from discarded surfboards. This innovation diverts thousands of cubic yards of waste from local landfills while offering a high-performance, disaster-resistant alternative to conventional building materials.

Sustainable innovation for the built environment

Surf Block’s core value lies in its circular material approach. Traditional Insulated Concrete Forms (ICFs) rely on virgin EPS, but Surf Block reclaims waste EPS from the surf industry, particularly local board shapers. By blending this recycled foam with cement and proprietary binders, the blocks serve as permanent formwork that also insulates the structure, eliminating the need for separate framing and insulation. This greatly reduces the use of concrete—by around 30% compared to typical builds—and minimizes the need for imported construction materials, which is especially valuable on an island like Maui.

Energy-efficient and disaster-resilient

With a thermal insulation capacity up to three times greater than standard wood-framed walls, Surf Block significantly lowers energy demand. Users have reported a 30%–70% reduction in HVAC use, which directly translates to lower utility bills and a lighter load on Hawaii’s energy grid. The blocks are also vapor-permeable and resistant to mould, pests, and termites—important features in tropical climates.

Structural integrity is another key benefit. Surf Blocks are engineered to withstand high-stress environments, including 240+ mph hurricane winds and seismic events up to magnitude 8.0. Once assembled and filled with rebar and concrete, they form a monolithic post-and-beam structure that resists fire for over four hours without igniting.

Applications and relevance for designers

This innovation is particularly relevant for architects, interior designers, and landscape architects seeking durable, low-impact solutions for residential or small-scale commercial projects in coastal or climate-vulnerable areas. The aesthetic flexibility, high thermal mass, and acoustic insulation qualities of the blocks make them suitable for various applications, while also aligning with sustainable design goals. Additionally, product and packaging designers may draw inspiration from Surf Block’s circular approach to waste reuse and local material sourcing.

By transforming surfboard waste into strong, insulating building components, Surf Block Maui offers a compelling example of material innovation that supports both environmental stewardship and community resilience.

Source & photos: Surf Block Maui