Bld62003 mak plastics

PLASTIC
BUILDING MATERIALS (BLD62003)
BACHELOR OF QUANTITY SURVEYING (HONS.)
BLD62003/MAK/PLASTIC
1

• INTRODUCTION TO PLASTICS.
• PROPERTIES & CHEMICAL COMPOSITION OF PLASTICS.
• FORMING PROCESSES (Explanations & Videos)
• TESTING PROCESSES.
• APPLICATION OF PLASTIC MATERIALS IN CONSTRUCTION.
• ONLINE QUIZ! SELF-ASSESSMENT
• TUTORIALS
2

WHAT IS PLASTIC?
• Derived from GREEK word
“PLASTIKOS” = able to be shaped
or molded.
• A PLASTIC material is any of a
wide range of synthetic or semi-
synthetic organic solids that can
be shaped or molded into any
form: some are naturally occurring,
but most are man-made.
3

WHAT IS PLASTIC MADE OF?
• The raw material is OIL.
• Produced from petrochemical products.
• There are some other raw materials that can be used:
coal, natural gas, various organic materials such as
sugar and oils.
4
PLASTIC
GRANULES

WHAT IS PLASTIC?
• A substance that contains natural or synthetic high
molecular organic material
• A petrochemical product-derived from petroleum
• Can be liquefied thus cast in specific molds
• Can imitate the appearance of wood, glass, metal
etc
• Decorative items and accessories have been
eventually being replaced by plastics instead of glass
to lowered the manufacturing cost
• Appearances are similar to glass but there are great
differences between their properties.
5

PROPERTIES OF PLASTIC
• Non-load bearing materials.
• Not subject to corrosion. Therefore always be a replacement for
some other materials.
• Degraded by sunlight exposure. Hence, reduce mechanical
strength.
• Flammable unless treated.
• Inexpensive to produce.
• Lighter than other materials of comparable strength e.g wood,
metal (iron or steel) etc.
• Low density materials: from 0.9-2.2g/cm.
• Polythene & polystyrene are among the lightest.
• Low tensile strength e.g the resistance to pulling force is weak.
• 20% of plastic production used in building industry. E.g: 40%
PVC (Polyvinyl chloride – has high embodied energy content)
used in pipes, cladding, electrical cable insulation, windows,
doors and flooring.
6

• Elongate up to 500% without fracturing
• Low compressive strength yet glass-fiber-reinforced
plastics resist compressive force more than steel
• Hardest plastic is softer than the softest metal yet the
penetration resistant can be enhanced by
reinforcing glass fibers
• Resistance impact varies e.g. rigid polymers i.e.
polystyrene and acrylics are brittle and fracture easily
• Flexible plastic e.g polyvinyl and polyethylene have
high impact strength
• Low melting temperatures but high coefficient of
expansion
7

• Deforming capacity: Materials like iron cannot be
deformed as easy as plastic. Hence plastic is more
flexible.
• Atmospheric resistance: Resists to humidity, high and
low temperatures.
• Chemical resistance: Chemically inert, hence substances
like soap , water acid can be stored in plastic containers.
• Recyclability: Plastic can be re-used.
• Impermeability to light, water and gases.
8

• Composed of repeating units of short carbon compounds
called ‘monomers’ that link together to form a larger
molecule called a ‘polymer’
• Various types of monomers can be combined in many
different arrangements to make infinite variety of plastic –
which all have different chemical properties.
9

CHEMICAL COMPOSITION
• The manufacture of plastic involves: polymerization of
ethylene monomer (colorless gas) - @ high pressure
200 degree Celsius – converted into – clear polymer
polyethylene or polythene
10

ARRANGEMENT OF MONOMERS
11
• LINEAR POLYMERS
• BRANCHED POLYMERS
• CROSS-LINKED POLYMERS
• NETWORK POLYMERS

CLASSIFICATION OF PLASTIC
12
THERMOPLASTICS
• Can be heated and
shaped many times.
• Will soften when is
heated and can be
shaped when hot.
• Will harden when cooled,
but can be reshaped
because it has no link
between polymer chains.
• Example: ABS
(acrylonitrile
butadienestyrene), Nylon
(polyamide), acrylic
(polymethyl methacrylate),
uPVC (polyvinyl chloride),
polystyrene, polypropylene
and cellulose acetate
THERMOSETTING
• Can only be heated and
shaped once.
• If re-heated they cannot
soften as polymer chains
are interlinked.
• Fixed molecular structure
that cannot be reshaped by
heat or solvents that are
joined by adhesives.
• Example: Epoxy resin,
melamine formaldehyde,
polyester resin and urea
formaldehyde.
ELASTOMER
• Elasticity
• Plastic in which hellical /
zig-zag molecular chains
are free to straighten
when the material is
stretched and recover
when the load is taken
away
• Example: natural rubber,
neoprene.

THERMOPLASTIC
• Linear or slightly branched molecules
• Do not chemically bond with each other when
heated
• Can be heated, cooled, softened and hardened
repeatedly like candle wax
• Can be remolded and reused
13

THERMOSET
• Consists of chain molecules that chemically bonded, or cross-linked
with each other when heated.
• Cannot be remolded once cured.
• Used to make heat-resistant products
• Example: a) phenol formaldehyde: decorative laminates; b) melamine
formaldehyde: laminates for working surfaces and doors, molded electrical
components, WC seats; c) urea formaldehyde: decorative laminates; d)
glass-reinforced polyester (GRP): cladding & roofing panels, cold water
tanks, spa baths, garage doors, decorative tiles and panels.
14

THERMOPLASTIC vs THERMOSET
15

ELASTOMER
16
• Natural rubber added with
sulfur to ensure that elastomer
materials return to its original
form when applied stress is
removed
• Also known as elastomeric
• Example:
a) Rubber: floorings, door seals,
anti-vibration beatings
b) Neoprene: glazing seals, gaskets
c) Elastomer: glazing seals,
gaskets, single-ply roofing
systems
d) Butyl rubber: sheet liners to
water features and land-fill
sites
e) Nitrile rubber: tile & sheet
flooring

COMPARISON BETWEEN
THERMOPLASTIC &
THERMOSET
17

THERMOPLASTIC
• These are made from polymers without
cross-linking between their chains.
• The intermolecular forces between the
chains are relatively weak (compared to
thermosets with covalent cross-links).
• The attractive forces in the thermoplastics
can be broken down by warming.
• The chains are able to move over each
other and the polymer can be deformed.
• On cooling, the weak forces between the
polymer reform and the thermoplastic
holds its new shape.
• Examples of thermoplastics are polythene
and nylon.
THERMOSET
• These polymers have lots of cross-
linking between the different polymer
chains.
• These cross-links make the chains
much stronger than in thermoplastics.
• The attractive forces cannot be broken
by warming.
• The chains cannot move relative to
each other and the polymer cannot
change shape.
• If heated, the polymer just chars and
burns. Bakelite is an example of a
thermoset.
18

THERMOPLASTICS
• They will burn when excessive
heat is applied because their
melting point is simply too high to
reach.
• The materials degrade and
decompose before they can reach
temperatures high enough to melt.
• Commonly utilized in automated
equipment and high volume
applications.
• Thermoplastics are easier to work
with than thermoset materials.
• They can also be easily stripped if
an application requires.
THERMOSET
• Irreversibly molded.
• Thermosets are great solutions
for high temperature
applications or for circuits at
risk for overload.
• High temperature ratings make
them more likely to function if an
application overheats suddenly.
19

HOW PLASTIC IS MADE OF?
20
• The melted plastic is poured into a mold.
• When the plastic becomes cooler, it takes the shape.BLENCH
• Air or gas is injected into a plastic mass to form
bubbles in order to make it lighter.
• Eg: mattresses, sponges, bike helmets.
SKIM
• The plastic is passed through the rollers called
calenders until it becomes into thin sheets.
• Eg: files
CALENDER
• Plastic is given shape by introducing it into a mold
by either high or low pressure.MOULDING

PRODUCTION PROCESSES
THERMOPLASTICS
• Raw materials
(gas, liquid,
powder,
granules)
• Formed into
extrusion or
sheet.
• Reformed into
finished product.
THERMOSETTING
PLASTICS
• Partially
polymerized
material; or
• Directly from
resin and
hardened mix.
FOAMED
PLASTICS
• Blown with
internally
generated gas; or
• Produced by a
vacuum process.
21

TYPICAL MANUFACTURING PROCESS
• Conveys petroleum to a refinery
• Refine raw oil and natural gas into ethane, propane & other
petrochemical products
• Break ethane & propane into ethylene & propylene in a high
temperature furnace
• Ethylene can be converted into clear polyethylene under high
pressure at 200 degree Celcius (polymerization process)
• Combine ethylene or propylene with catalyst in a reactor to
produce “fluff”, a powdered material.
• Combine “fluff” with additives in a continuous blender
• Melt the polymer in an extruder
• Cool the melted plastic
• Cut the product into tiny pellets in a pelletizer
• Send to customer
22

PLASTIC FORMING PROCESSES
23
FORMING
PROCESSES:
EXTRUSION
INJECTION
MOULDING
BLOW
MOLDING
VACUUM
FORMING
COMPRESSION
MOULDING

EXTRUSION FORMING PROCESS
• Plastic pellets are placed in a feed
hopper which feeds into the
system.
• A turning screw pushes the plastic
into the barrel where heaters
increase the temperature and a
melted polymer is obtained.
• The melted plastic is forced
through a shaping die.
• Depending on the particular shape
of this element, a continuous shape
is formed and pulled out of the
extrusion machine.
• Solidification by cooling.
24

EXTRUSION FORMING PROCESS
25
TYPICAL DIAGRAM OF EXTRUSION FORMING PROCESS
Using this processing it is possible to produce a wide range of different
forms of plastic, such as tubes, sheets and films, structural parts, etc.

RESULT OF EXTRUSION PROCESS
26

INJECTION MOULDING PROCESS
• Plastics pellets flows, due to gravity,
from the feed hopper onto a turning
screw.
• It is converted into a melted plastic by
the action of heaters situated along the
barrel.
• The screw moves the molten plastic
forward, forcing the plastic through a
gate into the cooled mold.
• The mold is opened once the plastic has
solidified and the piece is pushed from
the mold by automatic ejector pins.
• After we get the manufactured piece,
the mold is closed and clamped and the
process begins again.
27

INJECTION MOULDING PROCESS
28
TYPICAL DIAGRAM OF INJECTION MOULDING PROCESS

INJECTION MOLDING
ADVANTAGES
• High production rates
are possible.
• (A typical cycle time for a
3mm thick part would
about 40 seconds)
• Injections molding allows
you to produce products
with a good finish to a
good consistent quality
DISADVANTAGES
• Very expensive
to set up - the
tools (the dies or
molds) are
produced to a
high degree of
accuracy and
surface finish
29

COMPRESSION MOULDING
• In compression moulding, plastics
pellets, sometimes called
moulding powder, are placed in
the feed hopper and pushed to
the gate by the action of the
turning screw.
• It is heated and compressed
while it passes through the
barrel.
• After the gate, the molten charge
is quickly transferred to a press
where it is moulded while still
hot.
• The part is removed after
sufficient cooling.
30

EXTRUSION BLOW MOLDING
• Plastic grocery bags, bottles and
similar items are made using
this processing.
• As in compression processing,
plastic pellets are melted and
the plastic is forced through a
gate into the blow pin camera.
• The plastic substance is
expanded and cooled by being
made to flow around a
massive air bubble.
• After a few seconds, the mould
is opened and the
manufactured product is
ready.
31

VACUUM FORMING
32
• Vacuum forming is used to make
simple moulds using thin sheets of
thermoplastic.
• High impact polystyrene sheet is
what is used in school (HIPS). PVC
can also be used.
• A mould is created from wood or
epoxy resin and this is placed on
the table (platten) of the vacuum
forming machine.
• The sheet plastic is heated until it
becomes soft.
• The table with your mould on is
lifted into position and a vacuum
is used to draw the plastic over the
mould.
• Vacuum forming only works with
thin plastics and moulds with no
undercuts.
• The plastic can then be trimmed
to the required shape

VACUUM FORMING
• Vacuum forming is a popular
deforming process.
• Vacuum forming works by
removing air, thereby creating
a partial vacuum underneath
a soft and flexible
thermoplastic sheet and
allowing atmospheric
pressure to push the plastic
down onto a mold.
• The vacuum forming process
may start with a ‘blow’ that
stretches the plastic or it may be
started by raising the mold, on
the plate, to create a draping
form.
33

SHORT VIDEO ON PLASTIC FORMING
PROCESSES
34

TESTING OF PLASTIC
35
TESTING
Tensile
Flammability
Hardness
IMR
Cold Bend
SEM

TENSILE TESTING
• Measures force to break a specimen, plastic and the
extent to which specimen stretches or elongates to the
breaking point.
• Produce a stress-strain diagram to determine tensile
modulus.
• Depends on temperature
• Using extensometer
• Results are:
• A) tensile strength at yield and break
• B) tensile modulus
• C) strain
• D) elongation & % elongation at yield
• E) elongation & % elongation at break
36

FLAMMABILITY TESTING
• Determine rate of burning
• Used for production control, QC and
materials comparison
• Cannot be used as a criterion for fire
hazard
• Procedures:
a) Place a specimen either horizontal or
vertical in a test chamber
b) Apply a flame form a Bunsen burner for
a specified time
c) Measure the time or distance the flame
spreads.
37

HARDNESS TESTING
• Hardness is tested by forcing a round
rod into the plastic surface
• Conducted on a Rockwell hardness tester
or a Shore durometer tester
• The test results in each case are a measure
of how far the indenter penetrates into the
sample
• Procedures:
a) Place specimen on a hard flat surface
b) Indentor pressed into the specimen
making sure it is parallel to the surface
c) Read the hardness within 1 second or as
specified by customers
38

IMR TESTING
• IMR is a testing where few labs
possess the capability to analyze
both metals and plastics at one
time.
• Produce testing and failure
analysis.
39

OTHER TESTING
OXYGEN INDEX TESTING
• Determines minimum
concentration of oxygen
in an oxygen/ nitrogen
mixture that supports a
flaming burn in
specimen
COLD BEND TESTING
• Measures plastic resistance
to cracking when being bent
in a cold environment
• Evaluates plastics insulation
on electrical wires
• Specimen is placed in a cold
chamber i.e freezer for 4
hours then examined for
cracks
40

OTHER TESTING
SCANNING ELECTRON
MICROSCOPY (SEM)
• Evaluates surface
irregularities or fracture
• Measures thickness
• Coats specimen with gold,
place in vacuum chamber
for computer monitor
reviewing and take
Polaroid photos for
permanent record.
41

PLASTIC IN CONSTRUCTION
• Plastics are used in a growing range of application in the
construction industry.
• Can be designed and engineered to respond to particular
design conditions. For instance they may especially require
to be durable, strong or waterproof to suit a particular
project.
• The possibility of these materials are ever growing and our
natural resources are in short supply, and hence they could
increasingly be important in reducing the amount of raw
materials used.
42

EDEN PROJECT
43
• The Eden Project is a visitor
attraction situated in Cornwall
United Kingdom.
• These artificial biomes house
thousands of plant species
collected from all over the
world.
• This structure consists of
hundreds of hexagonal and
pentagonal cells that are made
by plastic (ETFE – Ethylene
tetrafluoroethylene) that are
supported by steel frames.
• These plastic cells help the
dome withstand high
temperature and also allows
light into the spaces.

WATER CUBE
44
• Was built in 2008 to
house the water events
for the Olympics games
in Beijing.
• Cells are plastic,
framed with steel and
concrete.
• The material is
transparent, and fills
the space with light.

KUNSTHA, US
45
• This is an art
museum located in
Austria.
• Its formwork is
reinforced concrete
box that is covered
in blue plastic,
creating an organic
shape.
• At night the lights
are carefully lit to
exaggerate the
unusual shape.

ECOARK
46
• The EcoArk building is a
movable fashion pavilion.
• The structure features walls
made entirely of plastic
bottles called POLLI-Bricks.
• Just a small amount of silicone
is used to make a bond
between the bottles.

XILE TUNNEL
47
• Xile is a plastic tunnel that connects two dark, industrial halls in
Belgium.
• The tunnel is strikingly bright, foldable, expandable and
environmentally friendly which can be used indoors or outdoors.

PLASTIC HOUSE POLAND
48
• This is a house situated in Poland
that is clad entirely in Thermopian –
a plastic material typically used in
roofing applications and favored for
its high thermal and insulating
properties.

PLASTIC HOUSE
IN JAPAN
49
• The architect who
designed this house
does not believe that
we should allow the
choice of modern
materials to mislead
us, and hence this
house features two
materials commonly
used in traditional
japanese archirecture
–bamboo and rice
paper.
• The plastic urethane
panels used were
chosen for their
flexibilty and visual
qualities which are
similar to the
traditional rice paper.

EXHIBITION BOOTH – PVC PIPES
• This exhibition design was showcased at the Danish design
centre, Copenhagen.
• It was constructed using PVC pipes and acted as a stage for the
exhibits.
50

PLASTIC PRODUCTS
51

THERMOPLASTIC - PRODUCTS
• Soft polythene (low density): DPC (damp proof course),
DPM (damp proof membrane), vapor checks, roof DPM
• Rigid polythene (high density): cold water tanks, cold
water plumbing
• Polypropylene: pipework and fittings, drainage systems,
water tanks, WC cisterns, DPCs, fibers in fiber-reinforced
concrete
• Polybutylene: hot & cold water pipework & fittings
• Rigid polyvinyl chloride (PVC-U): rainwater good,
drainage systems, pipe and fittings, underground services,
window and door frames, conservatories, garage doors,
translucent roofing sheets
• Medium rigid polyvinyl chloride (PVC-UE): claddings,
soffits, fascia, window boards
52

• Soft polyvinyl chloride (PVC): tile & sheet floor
coverings, single-ply roofing, cable insulation,
electrical trunking systems, tensile membrane
structures, glazing to flexible doors, door seals,
handrail coatings, vinyl-film finishes to timber
products
• Chlorinated polyvinyl chloride (CPVC): hot water
systems, door and window frames
• Ethylenetetrafluoroethylene (ETFE): inflated
systems for translucent wall and roof membranes
• Polymethyltetrafluoroethylene (PTFE): sealing tape
for plumbing, tensile membrane structures, low-
friction movement joints
53

• Polymethylene methacrylate: baths, shower trays,
kitchen sinks, glazing, roof lights, luminaires
• Polycarbonate: vandal – resistant glazing, spa baths,
kitchen sinks
• Polystyrene: bath and shower panels, decorative
expanded polystrene tiles
• Copolymer: pipe and fittings, rainwater goods, drainage
systems, shower trays
• Nylons: electrical conduit and trunkings, low-friction
components: hinges, brush strips for sealing doors and
windows, carpet tiles & carpets, shower curtains
54

THERMOPLASTIC PRODUCTS:
PUSH-FIT PLASTIC FITTINGS
55
• Whilst the bulk of the
materials used are
thermoplastics, such as PVC
(polyvinyl chloride), ABS
(acrylonitrile butadiene
styrene terpolymer) and
polypropylene, without the
use of rubber O-rings and
compression gaskets push-
fit systems would be
impractical.

POLYTHYLENE PIPES
• With potable water distribution,
polyethylene pipes are now widely used.
• Pipes are available in diameters from a
nominal 8 mm bore up to 1000 mm and
above, made from specially developed
grades of MDPE (medium density
polyethylene) which meet a range of
water industry specifications .
• One advantage of plastic pipes over more
traditional materials is that in the smaller
diameter sizes they are available in
continuous lengths of up to 100m or even
250m in some cases.
• This reduces the number of joints needed
and hence the number of potential leaks.
56

PLASTIC PIPES
57
• Plastic pipes have a
smoother bore than
their metal
counterparts, flow
rates can be
increased and scale
formation is reduced.
• Plastic pipes also
offer advantages in
corrosion resistance.

58
• For underground potable
water distribution pipes
are coloured blue.
• This enables the contents
of a buried pipe to be
immediately identified on
a construction site.
• Above ground black
coloured polyethylene is
used to ensure adequate
UV stability.

CROSSLINKED POLYETHYLENE
• Cross-linked polyethylene (PEX) is made from
normal polyethylene by, for example, crosslinking it
using a peroxide catalyst.
• The cross-linking raises the thermal stability of the
material under load. Thus, the resistance to
environmental stress cracking, creep, and slow
crack growth are greatly improved over
polyethylene.
• PEX pipe is approved for potable hot- and cold-
water plumbing systems and hot-water (hydronic)
heating systems in all model plumbing and
mechanical codes across the U.S. and Canada.
• PEX piping systems are durable, provide security
for safe drinking water, and use reliable
connections and fittings. There are currently about
ten domestic producers of quality PEX piping.
59

ROOFING SYSTEM
60
• Corrugated plastic sheeting has
been used for roofing in
conservatories and buildings
where transparent panels have
been required.
• However, in more recent times
double and triple walled
polycarbonate sheeting has
become increasingly used.
• This provides not only diffuse
daylight for illumination but also
heat insulation and hence reduced
heating costs.

THERMOSET PRODUCTS
• EPOXY RESIN
• MELAMINE LAMINATED BOARDS
61

ELASTOMER - PRODUCTS
62
Neoprene rubber flange gaskets
Butyl rubber sheet liner

EXAMPLE: ELASTOMER MODIFIED ASPHALT
WATERPROOFING MATERIAL
• Both have the reliability of original asphalt
waterproof, and also have elasticity of the rubber
• Good resistance to high and low temperature
performance, it can adapt to all the year round;
• Waterproof layer with high strength, durability,
resistance to chromium, tear resistance, fatigue
resistance;
• With good extensibility and high ability to bear
cracks at the base plane;
• Remain good performance at low temperatures,
even in cold weather;
• The lap joint can use hot melting method, the
seam sealing is reliable.
• Scope of application
• Applicable to industrial and civil architecture
roofing and underground waterproofing
engineering, the paint is suitable for low
temperature environment of building waterproof
project.
63

ADVANTAGES OF PLASTIC
• Corrosion resistance
• Good thermal and electrical insulators (has high
resistance to heat & protects electric cable cores etc)
• Easily mold into desired shapes
• Variety of choices: appearances, colors &
transparencies
64

DISADVANTAGES OF PLASTIC
• Non-biodegradable – Take long time to decay. (Biodegradation
of plastic takes up to 500-1000 years)
• Cost of recycling – It can be very costly.
• Environmental damage – release toxic gases over time and after
burning.
• Less dimensional stability over a period of time – Creep effect
: the deformation under load over time of plastic makes them not
suitable for heavy equipment yet some reinforced plastic resins
are sued for light-machine bases
• Aging effect – Becomes brittle over time.
65

PLASTIC RECYCLING
• Convert waste or reused plastic into reusable useful products.
• There are 4 types of recycling
•Primary Recycling
•Secondary Recycling
•Tertiary Recycling &
•Quaternary Recycling
66

PLASTIC RECYCLING
PRIMARY
• Products are
recycled into
products of the
same type.
• Eg: aluminum
cans to aluminum
cans.
• Also known as
closed-loop
recycling.
SECONDARY
• The reused
products are
converted to
different end
products.
• Eg: tyres into
other rubber
products.
TERTIARY
• The structural
breakdown of the
material into their
raw core
components and
then turning it
into a completely
new products
QUARTENERY
• The plastic is
burnt in order to
use the heat it
produces as an
energy source.
67

OVERVIEW
PLASTIC RECYCLING
68

OVERVIEW
BLD62003/MAK/PLAST
PLASTIC RECYCLING
69

OVERVIEW
PLASTIC RECYCLING
70

PLASTIC IN INDUSTRY
71

TUTORIAL QUESTIONS
• Plastics are classified into thermoplastics,
thermosetting plastics and elastomers. With the aid of
a diagram, explain the extrusion forming process of
plastics (10 marks).
• Describe 3 different characteristics of thermosetting
plastics and thermoplastics (9 marks).
73

REFERENCES
• http://www.nobelprize.org/educational/chemistry/plastics/
readmore.html
• http://www.the-
warren.org/GCSERevision/resistantmaterials/rm%20plast
ic%20forming.htm
• http://www.petervaldivia.com/technology/plastics/fabricat
ion-of-plastic.php
74

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