The Bio-Eco rock development

The extraction of natural rock for construction has caused severe environmental impacts, while the accumulation of agro-waste continues to pose ecological risks due to open burning and landfilling. To mitigate these problems, this study presents the Bio-Eco Rock Development (BERD), an upcycled green composite material composed of 40 wt% agro-waste, 50 wt% polyester resin, 10 wt% calcium carbonate, and a catalyst. BERD was designed to be lightweight, durable, and visually appealing. Mechanical property tests revealed that BERD reinforced with scrap wood exhibits the highest tensile strength (15.20 MPa), impact resistance (1394.94 J/m²), and flexural strength (40.24 MPa), making it suitable for structural and load-bearing applications. Moreover, macadamia nutshells and tea leaves improved flame resistance due to their inherent lignin and tannin content, respectively. These results suggest BERD’s high potential as a sustainable alternative to natural rock in applications such as countertops, flooring, and wall panels. Given its strength, fire resistance, and eco-friendly composition, BERD is recommended for implementation in green building materials, especially in regions facing both stone mining-related pollution and agricultural waste surplus. The adoption of BERD can promote circular economy practices by transforming agro-waste into value-added construction materials.