Asbestos cement corrugated (ACC) roofing sheets are widely used in low-cost construction for their durability, affordability, and structural performance. In Global South countries, people with low socio-economic status are conditioned to accept living under ACC sheets, despite growing awareness of asbestos-related health risks. Despite this need, no such alternative has been developed and structurally validated. The aim is to develop and evaluate a waste-based corrugated composite that meets ACC's structural benchmark through minimally processed, low-cost manufacturing. The novelty lies in a framework linking material formulation, corrugation optimisation, performance benchmarks, manufacturing, and roofing assembly through density as the governing variable across all stages. Using this framework, a lignin phenol formaldehyde-bound composite was developed via compression hot pressing that satisfies the primary structural benchmark required to replace ACC. This research provides practical evidence that the slow violence of ACC roofing in vulnerable communities can be countered.