Bld62003 mak rubber

BLD62003 BUILDING MATERIALS
MAK/BLD62003/RUBBER 1

 Known as Polyterpene.
 Elastic hydrocarbon polymer.
 Elastomers.
 Occurs as a milky colloidal
suspension.
 Known as latex in the sap of
plants.

NATURAL RUBBER
• The most complex agricultural
industry & requires years of
growing & processing natural
rubber.
• Combines of various knowledge
on botany, chemistry &
sophisticated machinery with
skilled people to harvest the
rubber trees.
• Includes: planting, tapping,
producing liquid concentrate,
producing dry stock, forming
sheets, producing other
products.
SYNTHETIC RUBBER
• Known as American-made
rubber.
• Made through polymerization of
monomers to produce polymers.
• Polymerization: a process where
ethylene monomer is converted
into the clear polymer
polyethylene under high
pressure at 200 degree Celsius.
• Known as: Polysoprene

 http://www.youtube.com/watch?v=CKq42J7SaWw

1. A rubber tree is tapped by cutting a thin strip of bark about
0.04 in (1 mm) deep off the tree as high up as the worker can
easily reach.
2. Later strips will be cut below the first one.
3. Each strip reaches about halfway around the circumference
of the tree and slants downward at an angle of about 30 degrees
to allow the latex to drain into a container.
4. If the latex is allowed to coagulate (thicken) naturally, each
cut will produce about 1 oz (28 g) of latex before the latex
stops flowing after a few hours.
5. A chemical may be applied to the bark to prevent the latex
from coagulating, allowing it to flow for several days.

6. The collected latex passes through a sieve to remove foreign
objects.
7. Water is added to the latex and the mixture is pumped into large
horizontal tanks containing aluminum partitions.
8. Dilute acetic acid or formic acid is added to make rubber coagulate
into slabs on the partitions.
9. The slabs are sprayed with water while they pass through a series of
rollers.
10. Excess water is removed by another series of rollers. The slabs are
packed in bales, usually weighing 225-250 lb (102-113 kg), in the
shape of cubes about 2 ft (60 cm) on each side.
11. The bales (packages) are coated with clay to prevent sticking,
bound with metal straps, and shipped to manufacturers.

 Depending on what kind of synthetic
rubber is being made, a wide variety of
manufacturing processes may be used.
 The most common form of synthetic rubber,
styrene-butadiene rubber, is usually
made in an emulsion process.

1. Various chemicals are obtained from petroleum by
fractional distillation.
2. This process involves heating petroleum to about 600-700° F
(315-370° C) and allowing the vapor to pass through a tall
vertical tower.
3. As the vapor rises through the tower, it cools. Chemicals with
different boiling points change from gas to liquid at different
points inside the tower and are collected.
4. Chemicals with very high boiling points remain in the
liquid state when the petroleum is heated and can be removed
from the bottom of the tower. Chemicals with very low boiling
points remain in the form of gases and can be removed from
the top of the tower.

5. Other chemicals are obtained by catalytic cracking. This
process involves heating petroleum to about 850-900° F
(454-510° C) under pressure in the presence of a catalyst. The
catalyst causes chemical reactions to take place. The new
mixture of chemicals are then separated by fractional
distillation.
6. Styrene and butadiene are obtained by subjecting certain
chemicals derived from petroleum to various chemical
reactions. The styrene is a liquid under normal conditions, but
the butadiene is a gas and must be stored under pressure to
keep it in a liquid form.

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Elastomers
Thermoplastic
Thermoset

 Elastomer materials are those materials that are made
of polymers that are joined by chemical bonds,
acquiring a final slightly cross-linked structure.
 Characteristics:
1. High elongation and flexibility or elasticity of these materials,
against its breaking or cracking.
2. Dimensionally stable
3. Extremely resistant to aging, temperature, pressure & chemicals
.
 Categories:
1. Thermoset Elastomers - are those elastomer materials which do
not melt when heated.
2. Thermoplastic Elastomers - are those elastomers which melt
when heated.

 Can not melt, before melting they pass into a
gaseous state
 Swell in the presence of certain solvents
 Are generally insoluble.
 Are flexible and elastic.
 Lower creep resistance than the thermoplastic
materials
 http://www.desma.biz/en/desma-news/news-
archive/browse/2.html?cHash=c75b689a24db5d2d
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• Material used in manufacture of gaskets, shoe heels
etcNatural rubber
• Used in textile industry i.e lycra clothing
• Foams & wheelsPolyurethanes
• Wheels or tires of vehicles, given the extraordinary
wear resistance.Polybutadiene
• In the manufacture of wetsuits is also used as wire
insulation, industrial belts, etcNeoprene
• Pacifiers, medical prostheses, lubricants, mold (due
their excellent thermal and chemical resistance)Silicone

 Materials that are made of polymers linked by intermolecular
interactions or van der Waals forces, forming linear or branched
structures.
 Greater the mixing of string = Greater the effort to separate the
strings from each other.
 Due to friction that occurs between each of the cords which offers
resistance to separate.
 Friction represents the intermolecular forces that holds together the
polymer.

 Polymer can take 2 types of structures (depending
on the degree of intermolecular interactions
between polymer chains.
1. Amorphous (formless) structure:
Polymer chains acquire a bundled structure – responsible for
the elastic properties of thermoplastic materials.
2. Crystal (crystal-like) structure:
Polymer chains acquire an ordered & compacted structure such
as lamellar structures.
Responsible for mechanical properties of resistance to
stresses or loads & temperature resistance of thermoplastic
materials.

 Polymers with high concentration of amorphous
(formless) structures = material have less resistance to
loads but excellent elasticity.
 Polymers with high concentration of crystalline (crystal-
like) structures = material will be very strong & even
stronger than thermoset materials but little elasticity =
the materials become more fragile.

 It may melt before passing to a gaseous
state.
 Allow plastic deformation when it is heated.
 They are soluble in certain solvents.
 Swell in the presence of certain solvents.
 Good resistance to creep.

 High pressure polyethylene as applied to rigid
material covered with electrical machines,
tubes, etc.
 Low pressure polyethylene elastic material
used for insulation of electrical cables, etc.
 Polystyrene applied for electrical insulation,
handles of tools.
 Polyamide used for making ropes, belts, etc.
 PVC or polyvinyl chloride for the manufacture of
insulation materials, pipes, containers, etc.

 Acrylates
 Cyanoacrylates
 Epoxy cured by ultraviolet
radiation
 Acrylates cured by ultraviolet
radiation

 Materials that are made by polymers joined together by
chemical bonds, acquiring a highly cross-linked polymer
structure.
 The highly cross-linked structure produced by chemical
bonds in thermoset materials, is directly responsible for
the high mechanical and physical strength compared
with thermoplastics or elastomers materials
 Highly cross-linked structure provides a poor elasticity
or elongation of thermoset.

IMAGINE:
 A set of strings mixed with each other;
 Each of these strings = polymer
 Make knots between each strings = more knots made more
ordered & rigid set of strings
 Knots represent chemical bonds.
 Thus polymers are strongly linked to each other & form
highly cross-linked polymeric structures.

GEL POINT
 Refers to the time when the material changes from
an irreversible way-viscous (sticky) liquid state to a
solid state during the curing process.
 Once has been transferred, the material stops flowing
& it can not be molded.
DISADVANTAGES
 No ability to recycle – once they are cross-linked or
cured it is impossible to return to a liquid phase
material.
 Have the property of not melt or deforming in
presence of temperature or heat to a gaseous state to a
liquid state.

 It can not melt.
 Generally do not swell in the presence of certain
solvents
 They are insoluble
 High resistance to creep

 Epoxy resins - used as coating materials, caulks,
manufacture of insulating materials, etc
 Phenolic resins - tool handles, billiard balls,
sprockets, insulation, etc
 Unsaturated polyester resins - manufacture of
plastics reinforced fiberglass commonly known
as polyester, fillers, etc

 Epoxy Adhesives
 Unsaturated polyester adhesives
 Polyurethane Adhesives by heat curing 1 component
 Anaerobic Adhesives

 Adhesive or glue as a non-metallic material which is able to
join 2 substrates using adhesion mechanisms (developed
between the adhesive and substrate) and cohesive mechanism
(developed within the adhesive itself).
 Composed by organic polymers in a liquid state when applied
and become a solid state after further curing or hardening.

Substrate = Corresponds to the material we wish to
adhesive or join, for example:
 If we bond 2 aluminum plates, each of the aluminum
plates will be the substrate, in this example both the
substrate 1 and substrate 2 are equal.
 If you want to bond a glass front of a painted aluminum
frame, we will have the substratum of glass and painted
aluminum substrate in this example the substrate 1 is
different from the substrate 2.

 Adhesion – adhesion are all the forces or
mechanisms that keep the adhesive with
each substrate,
 The term refers to all adhesion mechanisms
or forces located in a thin layer (boundary
layer) between the substrate and the
adhesive itself.

 Cohesion forces are all the forces or
mechanisms that hold the adhesive
itself.

 The adhesives materials allows joint substrates with different
geometries, sizes and composition. With the adhesive we can joint
glass, plastics, metals, ceramics.
 The use of adhesives eliminates the corrosion associated with
dissimilar metals joining with different galvanic potential, such as
the joining of steel with aluminum.
 The use of adhesive as bonding material does not produce any
deformation in the materials or substrates, eliminating metal
grinding processes (grinding and putty), reducing the manufacturing
cost and improving the aesthetics of the product.
 Does not produce any mechanical aggression to the substrate,
avoiding any damage to the structure of the material.

 Great flexibility in the product design as well as an improvement in
its aesthetics.
 Reduction of the product weight, in the case of traction vehicles
(cars, ships, locomotives) weight reduction is directly linked to
reducing energy consumption and pollutant emissions to the
environment.
 Increasing the resistance to impact and fatigue resistance using
elastic adhesive, increasing reliability and product life cycle.
 Homogeneous distribution of tensions throughout the union allowing
the elimination of stress concentrations that can lead to the
fracture of the union.

 Reduction of noise and vibration.
 Reduction in the number of components such as screws,
nuts, washers, rivets, etc necessary for the union, reducing the
manufacturing cost of the union.
 Sealing function and protection against corrosion.
 Special adhesives prepared to conduct electricity or electrical
insulator, are usually used in the field of electronics.

 Time to cure - The final strength of the adhesive bond is not
obtained immediately, unlike the case with a rivet or a screw,
you must wait a time to solidify or cure the adhesive, this
time depends on the choice of adhesive to be used, and also
sometimes it depends on the environmental conditions that
make the bonding process. If you want to reduce this waiting
time you can use a chemical booster compatible with the
adhesive.
 Resistance to temperature - Adhesives are polymer-based
materials, for this reason the adhesives and glues have an
average resistance to temperature, adhesives silicone-based
are more resistant to temperature adhesives, that kind of glues
can withstand temperatures reaching point of 800 °C.

 Ageing
i. The long-term strength of adhesive bonding is affected by various
physical and chemical actions which are in the environment, actions such as
ultraviolet light, chemical attacks on the environment, the presence of
moisture .
ii. There are adhesives that are not altered against ultraviolet light while
others break down in front of this radiation.
iii. The solution to this problem is to select an adhesive according to the
environmental conditions in later work; this will allow us to perform a
series of accelerated aging tests in order to observe the goodness of the
adhesive bond.
 Surface Preparation
i. As in the process of painting, surface preparation required prior to adhesive
application process in order to achieve good adhesion between the adhesive
and the substrate.
ii. Surface preparation that will vary depending on the materials to be
bonded, the adhesive selected and technical requirements needed to fulfill
the adhesive bond.

 Removal or disassembly
i. As in the welding or rivet process, the process of disassembly adhesive bonds can
destroy or distort the substrates joint together.
ii. being an expensive process to do, this does not happen when using techniques such
as bolting, so that those unions that require disassembly during maintenance work
during the life of the product, must perform techniques that allow easy
disassembly and assembly, such as using screws, velcro, etc.
 Safety and Environment
i. Due to the basis of the adhesives are chemical compounds, it is necessary to define
the necessary actions to prevent human exposure to these products during the
time of application.
ii. These measures will depend on the application amount and the type of the
adhesive, glue or sealant used. Also you must properly manage the waste generated
during the application process for further treatment and recycling.

 Special process
i. Like with the technique of welding, adhesive technique is a special
process, depending on the complexity and risk involved in the
union made with adhesive, and the area or sector that uses it
ii. It is necessary to have staff who deal with the design,
monitoring, verification and application with the proper skills
and capacity that can ensure the correct process of adhesive, such
as an industrial level is currently being implemented.

• Adhesive for bonding structures or
racks.
• Adhesive for bonding the front, side and
rear window glass.
• Adhesive for bonding body roof
structure.
• Adhesive for bonding side panels of the
structure.
• Adhesive for bonding the floor.
• Adhesive for bonding the cabins of the
vehicles.
• Adhesives for bonding different
elements of the equipment.

 ELASTIC
 Bond distortion
 Electrostatic energy is stored when force is
applied (Mullins effect)
 Mullins effect is where stress-strain response in
filled rubbers which typically depends on the
maximum loading previously encountered
 Polyterpene (natural rubber) has long & loose
molecular chain: zig zag or helical molecular
chains

 ELECTRICAL INSULATOR
 Synthetic rubber has a disulfide bonding, where all
electrons in the chain are occupied & no free electrons to
allow electrical ions to move
 Thus, rubber is non-electrical component in which rubber
is not able to dissolve in water
 ACID & ALKALINE RESISTANT
 Prone to pH changes
 When attacked by alkaline releasing microorganism, the
high pH will form bonds with free acidic H+ ions & harden
 For synthetic rubber, pH resistant component is added to
ensure rubber can withstand high pH changes

 Stress strain behavior of rubber can be
demonstrated through:
 Mullins effect
 Payne effect
 Hyper Elastic

MULLINS
• Stress strain
response in filled
rubbers
• Depends on the
previous maximum
load encountered
• Instantaneous &
irreversible softening
of stress strain curve
increase load beyond
maximum value
PAYNE
• Initially in formless
solid material that
undergo phases of
transformation due
to application of
strain
• Starts to crystalize
when the strain
exceeded fatigue
level
• Occurs in natural
rubber & elastomers
• Important effect on
strength & fatigue
properties
HYPER
• Derived from strain
energy density
function
• Behavior unfilled,
vulcanized elastomer
often conforms
closely to a hyper
elastic ideal

 Hardness test
 Compression test
 Rebound resilience elasticity test
 Abrasion test
 Freezing test
 Flexing fatigue test

 For quick & reliable
tensile,
compression, peel,
fatigue cycling &
constant load tests

 Rebound resilience
elasticity test: ratio of
the regained energy in
relation to the applied
energy

 Performed on materials
which are subject to
wear & tear during their
working life e.g tires,
conveyors & drive belts,
shoe soles etc

 Test the bending/
flexing durability of
rubber, plastics,
synthethic leather,
shoes etc under cold
temperatures as low
as -30 degree or -50
degree Celsius
depending on the
selected model.

 Advanced dynamic
system for
determination of the flex
properties of rubber,
leather etc in air,
temperature chamber or
liquids.

 Household or industrial products.
For examples:
 Tyres & tubes
 The largest consumes of rubber
(56% total consumption in 2005)
 44% are general rubber goods
(GRG) sector which all are products
except tyres & tubes
 Hoses, belts & dampeners
 For automobile industry
 Known as the under bonnet
products

 Gloves
 For medical, household & industrial
 Large consumers of rubber
 Made of concentrated latex

 Bearing pads
 Manufactured from the highest quality neoprene
rubber
 Conform to the most rigid specification for
highway bridges
 Widely used in building construction (beam)
 Economical, effective & require little
maintenance
 Standard thickness: .125”, .250”, .500”, .625”,
.750”, .875”, 1.00”, 1.25” and 1.5”

 RUBBER CORRUGATED PADS
 Long lasting material
 Designed for floor protection
 Creation of an anti-slip surface
 Will not separate, curl or shrink
 Clean effortlessly & quickly
 Excellent product to use in heavy
traffic area
 Available by the linear foot or
customized
 Color black or brown
 Standard widths: 24”, 36” and 48”
 Standard thickness = .125” and .259”

 PLAYSAFE RUBBER FOR
PLAYGROUNDS
 Provides safety surface that is much
more resilient than traditional wood
chips, sand or gravel materials
 Made 100% from recycled tire buffing
which are then treated with non-toxic
organic dyes to achieve a variety of
vibrant colors
 Use of organic dyes also makes it non
toxic to children, pets and our
environment

 PLAYSAFE RUBBERWALK POUR
 A seamless poured-in-place rubber surfacing
 Using a polyurethane binder & loose fill colored mulch
 The custom design application is popular for:
 Playgrounds, accessible walking trails & erosion control
 Provides a durable permeable surface that allows drainage off the surface for all weather use
 Can be installed over asphalt concrete (eliminates the need to repair cracks) or packed crusher
run

 WINDOW FRAMES
 Frames come complete with
window as well as other parts
of the frame and surround
 Manufactured from the same
grade of white UPVC
 With larger frames, steel
reinforcement is often added
for extra strength & security
 A water tight seal to concrete
& brickwork is achieved by
bedding the frame in silicone
rubber & by injecting a silicone
rubber bead along all joints

 RUBBER ANTI-VIBRATION
MOUNTS
 Rubber vibration isolating systems
have known for many years
 The dynamic properties of rubber
provides protection over wider
range of frequencies
 Used to isolate individuals items
of equipment, e.g air conditioning
& refrigeration equipment, from
main structure of the building

 SOUND INSULATION
 Noise pollution can be dealt with by using vibration
mounts
 Sound insulation can be provided by: (i) simple & heavy or
(ii) light & complex construction (rubber & plastics)
 With floating floor construction, an air gap, created by
placing a resilient material e.g rubber or foamed plastic
between the timber raft & the concrete floor can achieve
desired result

Read more: http://www.madehow.com/Volume-
5/Eraser.html#ixzz3DjpZEmxY

ADDITIONAL INFORMATION ON
SYNTHETIC RUBBER PROCESS

Bld62003 mak rubber

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