Sand Casting from Recycled Metal: The Jua Kali Craftsmen of Nairobi

In the backstreets of Nairobi, a group of young Kenyans are turning scrap metal into stunning handcrafted products. Their process is entirely circular — every material used, from the metal itself to the fuel in the furnace, comes from waste that would otherwise be thrown away.

Sand casting from recycled metal

The process starts at the scrapyard. Old wheel rims, pistons and engine blocks are collected from the ‘Jua Kali’ mechanic workshops that line the roads around Nairobi. This scrap metal is melted down in a handmade furnace powered by waste engine oil — also collected from the same mechanics who would otherwise discard it.

Even the crucible used to melt the metal is made from recycled compressor units salvaged from old refrigerators. Nothing is wasted. Everything has a second life.

The sand moulding process

Once the metal is molten, it is poured into sand moulds. The sand itself is a by-product of the glass industry — silica extracted to make glass leaves behind a fine sand that is collected and mixed with molasses as a natural binder. The moulds are shaped by hand, giving each piece a slightly different finish and texture.

The result is a range of beautiful sand-cast metal products — bowls, figurines, bookends and decorative pieces — each one unique and each one made entirely from materials that would have ended up as waste.

Young Kenyans with a vision

The craftspeople behind these products are a talented group of young Kenyans from different and diverse backgrounds. What unites them is a commitment to recycling, a flair for design and an entrepreneurial spirit that is deeply rooted in the Jua Kali tradition — Kenya’s celebrated informal economy of outdoor craftsmen and self-taught engineers.

At Banana Box, we are proud to work with makers like these. Their products are not just beautiful — they tell a story about resourcefulness, creativity and what is possible when nothing is treated as waste.

Shop our full range of recycled metal products, or contact us to learn more about the craftspeople behind them.