Innovative solution developed for concrete flooring waste

Clevaco, a New Zealand-based company, has developed the Cleva Pod system, a circular solution to the major waste issue in construction and demolition.

Some flooring contractors use polystyrene blocks as space savers in concrete flooring. Concrete is poured over the blocks to form the floor. This is known as waffle pad floorings, which reduces the amount of concrete required and cuts costs. The disadvantage of this method is that the concrete binds to the polystyrene. When a building is demolished, the concrete and steel reinforcements cannot be separated from the polystyrene for recycling. Instead, the floor materials end up in landfills.

The system developed by Clevaco co-founders Andrew Minturn and Grant Brown replaces the polystyrene blocks with pods made from recycled and waste plastic. The plastic pods can be separated during demolition, and the concrete and steel recycled. Undamaged leftover plastic pods can be used again. Plastic from damaged pods can be recycled.

This innovative solution not only reduces environmental impact but also saves costs, with potential savings of $40,000 to $50,000 in demolition, cartage and dumping fees. The pods are stackable and lightweight, reducing transport costs.

In 2024, Clevaco was awarded the Tāmaki Makaurau Zero Waste Innovation Award for the Cleva Pod system.

Andrew Minturn and Grant Brown started developing the Cleva Pod system ten years ago in a garage. The two Clevaco founders are talking to large companies in the construction industry that want to use more sustainable products like Cleva Pod.