Building Greener, Cheaper Homes in Florida: The Lego-Like Construction Revolution

A Miami company is using recycled materials to create innovative, affordable, and hurricane-resistant Lego homes and apartment buildings in Palm Beach County.

The first stage of construction of a first-of-its kind apartment building in Palm Beach County. It was built with blocks made of recycled glass, plastic and other materials that fit together like Lego pieces. A Miami company that developed the systems says it can lead to cheaper, greener buildings. RENCO

Imagine living in a building made from blocks that fit together like a giant Lego set. Sounds like a dream, right? Well, for some South Florida residents, that dream has already become a reality. A groundbreaking apartment complex in Palm Beach County is being built using innovative new blocks that are assembled just like a toy kit – but don’t be fooled; these blocks are far stronger and more durable than any Lego piece.

Developed by a Miami company called RENCO, the new Lego system promises a cheaper, greener way to build homes and businesses, especially in hurricane-prone Florida. Instead of traditional concrete blocks, these blocks are made from recycled materials like glass, plastic, resins, and limestone powder. What makes them unique is how they’re put together: workers follow color-coded diagrams, not blueprints, to snap the blocks into place and then secure them with glue. It’s like building a house without the hassle of cutting, hammering, or heavy machinery.

Faster, Cheaper, and More Sustainable Building

So, how does this new building method help? First off, it’s much faster. RENCO President Kenneth Smuts shared that building a three-story, 96-unit apartment complex took just eight weeks, thanks to the simple and efficient assembly process. In comparison, a traditional construction project using concrete could take months. The speed of construction not only saves money but also reduces labor costs. Since fewer workers are needed, and less equipment is required, developers can pass those savings onto buyers and renters.

The apartment complex on 4290 Lakewood Road is built from a brand new recycled material on the market. Ashley Miznazi

Another major benefit of these new blocks is their sustainability. Rather than relying on concrete, which is one of the biggest contributors to global carbon emissions, RENCO’s blocks use recycled materials that would otherwise end up in landfills. And since Florida homes are often vulnerable to termites, the use of wood in construction is avoided, making the buildings more durable.

What’s Inside These Revolutionary Blocks?

The blocks themselves are made from a mix of recycled glass, plastic, and calcite (a type of limestone powder), fused together under heat to create a solid, long-lasting material. Tests have shown that these blocks are not only hurricane-resistant but also immune to issues like rust, rot, and even termites. This makes them an ideal choice for Florida’s humid and storm-prone environment.

They’re also 75% lighter than traditional concrete blocks, making them easier to handle and quicker to assemble. This also means less waste, since the blocks are cut to fit without requiring excess material or creating debris that would typically fill up dumpsters on construction sites.

Building for the Future: More Than Just Homes

Color-coded design plan for Palm Springs apartment complex. RENCO

The RENCO team believes their innovative building system has the potential to help solve housing challenges, especially for working-class families. The new Lakewood apartments, built in Palm Springs, are affordable, with two-bedroom units renting for $2,000 a month and three-bedroom units for $2,500. These units are priced to cater to local families, making them a valuable addition to the area. By reducing the overall cost of construction, RENCO hopes that this building method can be scaled up to help address the growing need for affordable housing in Florida and beyond.

In the future, RENCO aims to build structures up to eight stories high, which is perfect for apartment complexes and workforce housing. With plans for a new manufacturing facility opening soon in Jupiter, Florida, RENCO is preparing to meet the growing demand for these green, efficient building materials.

Kenneth Smuts shows how the blocks made from recycled plastic, glass and stone stack. Ashley Miznazi

The Bigger Picture: Sustainability and Cost in Construction

While cement has been the backbone of construction for decades, it’s also responsible for a significant portion of global carbon emissions—around 8%, according to the U.S. Department of Energy. RENCO’s approach offers a solution by providing a more eco-friendly alternative that doesn’t compromise on strength or safety.

RENCO built their first apartment complex in Palm Beach with a new material they say is stronger, greener and cheaper than conventional building methods like concrete. RENCO

Although these blocks aren’t designed to replace concrete entirely (a foundation still requires traditional materials), they offer a promising alternative for the majority of the structure. By using recycled materials and simplifying the construction process, RENCO’s system could become a game-changer in Florida’s booming construction market, where speed and sustainability are in high demand.

Looking Ahead: The Future of Construction

Kenneth ​​​Smuts, the president of RENCO, shows an exposed part of the building that shows how the blocks stack together like LEGOS and are reinforced by steel beam decking. Ashley Miznazi

RENCO’s innovative building system is getting industry attention and winning awards, thanks to years of testing and development. Although it took eight years and $20 million to get to this point, the company is confident that their product will be the future of construction, especially in hurricane-prone areas like Florida.

With developers increasingly looking for sustainable, cost-effective ways to build, RENCO’s blocks could be the key to meeting the growing demand for affordable, eco-friendly housing. And with the expansion of manufacturing facilities, these Lego-like building blocks might just be the next big thing in construction.