building material plastic oumber

1. PLASTIC LUMBER PRODUCTS
Sonakshi Bhattacharjee |114AR0024 | Seventh semester | B.Arch.| P&A | NIT Rourkela | 2017

2. Introduction
– Plastic Lumber (PL) is a wood-like product(lumber) made from recovered plastic
or recovered plastic mixed with other materials, which can be used as a
substitute for concrete, wood, and metals.
– It is made of 100% plastic, compared to wood-plastic composite lumber.
– Made of virgin or recycled plastic.

3. Raw materials
– Raw materials required - virgin or waste plastics including :-
HDPE(High-density polyethylene) PVC (Polyvinyl chloride)

4. Raw materials
– Raw materials required - virgin or waste plastics including :-
PLA (Polylactic acid)
PS (Polystyrene)
ABS (Acrylonitrile
butadiene styrene)
PP (Polypropylene)

5. Manufacturing Process
In general, the RPL manufacturing process includes the following steps:
– Material Preparation - Sort and clean (optional), then grind the recovered plastic
material into small flakes.
– Extrusion - Homogenize and rapidly melt the flakes using heat and pressure
inside a rotating screw (extruder).
– Forming - Discharge or force the molten mixture into a mould, cool the mould in
a water bath, and eject the finished product.

6. P
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– The powder or pellets are mixed to a dough-like consistency at roughly
400 °F (204 °C) and then extruded or moulded to the desired shape.
– Additives such as colorants, coupling agents, stabilizers, blowing agents,
reinforcing agents, foaming agents, and lubricants help tailor the end
product to the target application.
– The material is formed into both solid and hollow profiles or into injection
moulded parts and products.

7. P
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– Resin, regrind, and most of the additives are combined and processed in a
pelletizing extruder.
– The new material pellets are formed in a mould and cooled.
– Testing –
– Pre-distribution testing can help determine the optimal combination of chemical
agents, design, agitation, and other flow aid strategies for the specific material in use.
– Modern testing facilities are available to evaluate materials and determine the optimal
combination of equipment components to assure the highest level of accuracy and
reliability.
– Computerized performance test reports document equipment performance.

8. Physical Characteristics
– Resistant to corrosive
substances, oil and fuels,
insects, fungi, salt spray, and
other environmental stresses
– Does not absorb moisture and
will not rot or splinter
– Weathering resistance and low
maintenance
– Can be moulded to meet
almost any desired spatial
condition
– Can also be bent and fixed to
form strong arching curves
– Can be shaped using
conventional woodworking
tools
– May slightly deform in
extremely hot weather
– Not sensitive to staining from
a variety of agents
– Doesn't need to be painted

9. Physical Characteristics
– Less stiffness and less strength
than wood under winter and
summer conditions
– Becomes brittle at low
temperatures
– Becomes soft at high
temperatures
– Less axial strength than natural
lumber under compression,
flexure, and tension
– Holds conventional wood
fasteners well
– Comparable weight to wood
– Density is between 0.64 and
0.68 g/cc
– Modulus of elasticity is very low
– Compressive properties of
plastic lumber are equal or
greater than those of wood

11. Advantages
– Won’t rot or absorb water and is
highly resistant to insect damage -
perfect for marine and other
water applications, where the
lumber is further prized by its
ability to resist shock.
– Clean, nontoxic, nonporous, and
lasts longer than wood.
– Moisture and chemical resistant.
– Graffiti resistant.
– Splinter free, does not crack.
– Requires no sanding, painting,
staining or sealing.
– Flexible, can be curved and
shaped.
– Maintenance free.
– Does not absorb bacteria.
– Recyclable.

12. Benefits to the Community
– Saves money for local governments and other purchasers by lowering long-term
maintenance costs.
– Creates additional business opportunities.
– Diverts plastic waste from landfills.
– Reduces wood waste, especially treated wood waste.

13. Disadvantages
– Costs three times as much as some wood
– More susceptible to warping and discoloration
– Can melt under a table top camping grill
– Likely to sag under a heavy load
– Increased rates of thermal expansion and contraction

14. Types of Plastic Lumber
High Density Polyethylene (HDPE) Recycled Plastic Lumber
– This type of RPL consists of up to 95 percent of HDPE (The
same material used to make plastic milk jugs).
– Advantages.
– Available in many colors. Well suited for decking and landscape
applications.
– Disadvantages.
– Much lower stiffness than wood. Also, material sorting increases labor
costs. This cost can be reduced by using automated sorting technology
instead of hand sorting.z

15. Types of Plastic Lumber
Commingled RPL
– Commingled RPL is made from mixed recovered thermoplastic (plastic
that can be remelted and remoulded). Primarily consisting of 80-90
percent polyethylene (PE).
– Advantages.
– Lowest cost because sorting is reduced or eliminated. Also well suited for
decking and landscape applications.
– Disadvantages.
– Only earth tone colors available in addition to having a stiffness much lower
than wood.

16. Types of Plastic Lumber
Wood-Filled RPL
– Wood-filled RPL is made of plastic mixed with sawdust or other recycled
fibre, usually a mix of 50 percent polyethylene (primarily low-density
polyethylene or LDPE) and 50 percent sawdust or other recycled fibre.
– Advantages.
– Fewest voids, best traction, best paintability, greater surface roughness.
– Disadvantages.
– Can absorb moisture, may have poor impact strength under low temperatures, may
not be completely insect resistant, may become discolored in outdoor applications,
may contain metal contaminants, much lower stiffness and strength than wood, can
degrade, poor flexibility.

17. Types of Plastic Lumber
Fibre-Reinforced RPL
Fibre-reinforced RPL consists of plastic mixed with chopped or
continuous strands of glass fibre.
– Advantages.
– Stiffer than other plastic lumber. Well suited for support structures.
– Disadvantages.
– Less flexible than other plastic lumber, and may irritate skin.

18. Other Combinations of Materials
– Many other combinations of materials are possible, each with different
properties, costs and applications. They should be investigated individually to
determine the best product for its intended use. Some other formulations
include:
– Glass-reinforced plastic
lumber.
– Rubber-plastic lumber.
– Mixed plastics and peanut
shells.
– Coextruded steel liner (e.g.,
metal pipe).
– Coextruded steel reinforcing
rods.
– Multiple laminations of
oriented HDPE.
– Reinforced concrete fill.
– Cross linking of PE molecules
by thermoset processes

19. Uses
– FARMING
• Manger liners
• Stalls
• Fencing
• Hog bar n floors
• Silo doors
• Curtain weights
– DECKS, DOCKS
• Deck boards
• Railing - spindles,
post caps
• Fascia boards
• Fish filleting tab les
• Swim platform
• Piling strips
• Boat bumper boards
– INDUSTRIAL
• Bumper boards
• Driveway marker posts
• Sign post
• Pallets
• Garbage Containment
• Bunk boards
• Barricades
• Packaging

20. Uses
– GOLF INDUSTRY
• Golf cart cargo areas
• Tee markers
• Trash Cans
• Water Cooler
• Fairway markers
• Sign post
• Benches
– FURNITURE/OUTDOOR
• Picnic tables
• Adirondack chair
• Benches
• Trash receptacles
• Planters
• Bird houses
• Windows
• Bumper boards
• Feed troughs
• Manure spreaders
• Milk house applications
– LANDSCAPING
• Retaining walls
• Natural area boarders
• Planters (window boxes,
tiers, and free standing)

21. Uses
– TRAILER & TRUCK BODIES
• Refrigerated unit shelving
• Runners under the body
• Side boards on trailers
• Bed liners Flooring
• Scuff boards in trailers
• Snowmobile trailers
– MISCELLANEOUS
• Ice fishing tip-ups
• Ice shanty runners
• Garden cart
• Potting bench
• Picket fence
• Lamp post
•Trellis
• Wishing well
• Mail box post

22. Testing Methods
– Recycled Plastic Lumber (RPL) Engineering Standards
o ASTM Plastic Lumber Test Methods:
o D6108-97 Compressive Properties
o D6109-97 Flexural Properties
o D6111-97 Bulk Density & Specific Gravity
o D6112-97 Compressive & Flexural Creep
o D6117-97 Mechanical Fasteners
o D 6341-98 Coefficient Of Thermal Expansion
o D6435-99 Shear Of Boards & Shapes
o E108 Residential Decking Flammability

23. Thank you
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References –
• Recycled Plastic Lumber: Research and Development, IWMB
• RECYCLED PLASTIC LUMBER FROM MIXED PLASTIC WASTE BY AMRUT V. LALWANI MANOJ V.
LALWANI NEW PLASTOMERS INDIA LIMITED Date: 24/02/07
• Development and Testing of Plastic Lumber Materials for Construction Applications. DIANE Publishing.
ISBN 978-1-4289-1323-3.