YKK AP Launches 100% Recycled Aluminum Building Material "Re・AL"

YKK AP, based in Chiyoda, Tokyo, has recently commenced orders for its new product, "Re・AL" (Read-Al), an innovative aluminum building material made entirely from recycled aluminum. This new material is crafted using both post-consumer recycled aluminum and scraps generated during the manufacturing process (in-house returned materials). "Re・AL" is designed for applications such as windows and curtain walls, allowing for a measurable reduction in environmental impact during construction. By adopting this recycled aluminum product in building projects, clients can significantly improve the environmental value of the structures and contribute to lowering CO₂ emissions during manufacturing.

The Growing Demand for Low-Carbon Building Materials

In the current global shift towards decarbonization, there has been an exponential increase in demand for low-carbon building materials in the construction industry. It is no longer sufficient to only reduce CO₂ emissions during the operational phase of buildings; a comprehensive reduction across the entire lifecycle of products and buildings—from manufacturing to construction, demolition, and disposal—is essential. YKK AP aims to enhance the usage ratio of recycled aluminum, with a projected average of 60% for all residential and commercial products by 2025.

Reducing Energy Consumption with Recycling

With the launch of "Re・AL," which utilizes 100% recycled aluminum without the addition of new aluminum, YKK AP is able to minimize energy consumption associated with primary aluminum production. The product has also acquired third-party verification through the "SuMPO EPD," asserting that it can reduce CO₂ emissions by 73% compared to existing products throughout its lifecycle, from raw material sourcing and transport to manufacturing. The initial rollout will focus on custom orders for non-wooden building products like commercial windows and curtain walls, prioritizing materials that enhance environmental value.

Implementation of "Re・AL" in Upcoming Projects

YKK AP has already implemented 100% recycled aluminum windows and curtain walls in its own properties, such as the "YKK AP30 Building," completed in October 2024, and the "YKK AP Technical Center," which finished in November 2024. Notably, Mitsui Fudosan Residential has also committed to using "Re・AL" in a new condominium project set for completion on February 28, 2027, demonstrating the interest from various clients.

Quality and Functionality

Despite being made from recycled materials, "Re・AL" maintains the same quality and functionality as products made from virgin aluminum. To ensure this quality, managing the alloy components is crucial, particularly for post-consumer recycled aluminum, which requires careful sorting to eliminate impurities and differing alloy compositions. Moreover, the melting process for recycled materials can result in production losses due to oxidation and extended melting times. As such, in September 2023, YKK AP introduced a dedicated recycling furnace at their Shikoku manufacturing facility, enhancing the technology to minimize these production losses. Further collaboration with universities and other companies is underway to develop advanced recycling technologies that can efficiently produce graded recycled aluminum materials.

Environmental Benefits of Using Aluminium

Aluminum is lightweight and resistant to corrosion, but its production from bauxite ores consumes a significant amount of energy. Conversely, utilizing recycled materials reduces energy consumption. This approach allows for a remarkable 97% reduction in CO₂ emissions at the raw materials level compared to producing new aluminum. Thus, "Re・AL" contributes to carbon neutrality by significantly lowering CO₂ emissions across its lifecycle compared to existing building materials that incorporate new aluminum production.

Future Projects Incorporating "Re・AL"

One promising project of note is the proposed plan in Yoyogi 2-chome, Shibuya Ward, Tokyo. This building, set to be completed on February 28, 2027, will be constructed by Mitsui Fudosan Residential, and will feature products like "EXIMA 31" and "BGE 31" made from the "Re・AL" material.

Summary

- Name: "Re・AL"
- Applicable Products: Custom orders for residential and commercial products
- Available Areas: Nationwide in Japan
- Order Start Date: October 31, 2025
- Target Revenue: ¥1.5 billion by 2027