Sustainability is not just important; it's crucial in today's world. While its long-term impact on our planet is undeniable, a well-directed focus on sustainability can also provide immediate benefits to our finances. Spain is aware of this and the construction sector has long been concerned about achieving sustainable, efficient and quality construction that is accessible to all budgets, which is why the first and only Autoclaved Aerated Concrete factory in Spain, built by Baublock, has caused great excitement and has been received with great enthusiasm. 

Baublock blocks – an old material reformulated to improve the economy of the future

Baublock blocks, used in exterior walling and interior partitioning solutions, result in energy-efficient A-class buildings. Their precise geometrical dimensions and final finish result in faster and cheaper building works due to higher performance. In addition, they are 100% recyclable to produce new blocks.

The whole world is concerned about the health of the environment and is working hard to protect it. Spain is home to ten of the best construction companies in the world and this sector is one of the main drivers of the country. Clearly the possibilities of AAC in Spain and its contribution to a new era of sustainable construction are very tangible. Baublock provides an innovative approach that assists the efforts for decarbonisation. Thanks to its chemical properties, the blocks absorb CO₂ throughout their life cycle with 77kg per m³, i.e. they are permanent carbon sinks. Also noteworthy is the fact that their production is energy efficient, requiring up to 4 times less energy than traditional brick production.

AAC is known worldwide, especially in harsh climatic zones where thermal insulation has always been a matter of survival and comfort. In more benevolent climates such as the Iberian Peninsula, the construction sector has not been as concerned with this type of insulation, but environmental responsibility and the energy crisis make it necessary to pay more attention.

AAC has a high thermal insulation capacity thanks to its thermal inertia. In addition, Baublock has also made a great effort to obtain the best raw materials (which are available in Spain) and the most suitable machinery from the best European suppliers, to improve this quality even further. Undoubtedly, buildings constructed with Baublock will provide significant savings for both Spanish developers and builders, as they will no longer have to invest heavily in traditional insulation. In addition, savings are provided to the end buyer, as thermal losses are reduced, resulting in energy savings in both winter and summer, which will undoubtedly have a direct impact on the economic situation of the household. This is the key to the success of this new material in Spain.

The factory

If this company stands out for anything on the national construction scene, it is for being the only factory of Autoclaved Aerated Concrete. This material is truly sustainable and energy efficient from its own production, as it follows a circular model of waste-free production, thanks to the innovative facilities built over more than three years. During this time, Baublock has managed to combine the knowledge and technology of professionals from different parts of the world to end up building what is possibly the most advanced factory of this material in the whole of Europe. 

The new four-hectare factory will manufacture 200,000 cubic metres a year in its first stage, or 1,000,000 square metres of walls, and 600,000 cubic metres when it reaches its maximum production level.

It is an efficient plant that respects the environment, uses renewable energy systems for self-consumption and has a zero impact as it does not generate any type of waste.

But Baublock is not stopping at these points and continues to study systems and improvements that contribute to true sustainability in the manufacturing process.

The CEO

Flor Zafra Herrera, a young woman with a law degree from the University of Cordoba, is the driving force behind this innovative project located in Puerto de Santa Maria, Cadiz, where more than 30 million Euros have been invested.

Baublock walked through Zafra's door as a client of her law firm four years ago, but the impressiveness of the project, the possibility of participating in the improvement of a sector as important as the construction industry, making the sustainability of new buildings a reality, absorbed all her time and attention. With extensive experience in industrial sectors such as renewable energies, Zafra was dazzled by Baublock and put in all her effort and passion. In February 2022, she accepted the position of CEO of the company. In June 2023, just a year and a half later, Zafra's work was recognised with the CEO of the Year Award for Innovation and Sustainable Construction, granted by the newspaper La Razón, which acknowledged the social impact of her work.

With great human resources and a great technical team, Zafra has materialised the dream of Baublock's investors, and after almost four years of tireless effort, the "FUTURE OF CONSTRUCTION" is now a reality.

Conclusion

From the company's CEO: "Baublock's work would be meaningless if it didn't directly benefit ordinary people. Fortunately, it does! Baublock blocks make it possible to build houses faster, have a healthy indoor environment, free of damp and microorganisms, and reduce electricity bills considerably.

Baublock has a clear mission in Spain: to provide sustainable, economically competitive and technically advanced solutions through the use of AAC in the construction and refurbishment of all types of buildings in the country. The use of this material will have a clear impact on the economy of all those involved in the construction process, including the final owners.”