PLASTIC LUMBER

ADVANCED BUILDING MATERIALS

UNDER THE GUIDANCE OF

PROF. TUHIN SUBHRA MAPARU

SUBMITTED BY –
SONAKSHI BHATTACHARJEE (114AR0024)

DEPARTMENT OF PLANNING AND ARCHITECTURE

NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA
Contents
Introduction ............................................................................................................................ 3
Raw materials......................................................................................................................... 3
Manufacturing Process........................................................................................................... 3
Production .............................................................................................................................. 3
Physical Characteristics ......................................................................................................... 4
Advantages ............................................................................................................................. 4
Disadvantages ........................................................................................................................ 4
Types of Plastic Lumber ........................................................................................................ 5
Other Combinations of Materials........................................................................................... 5
Uses ........................................................................................................................................ 6
References .............................................................................................................................. 6
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.

Raw materials
 HDPE(High-density polyethylene)
 PVC (Polyvinyl chloride)
 PLA (Polylactic acid)
 PS (Polystyrene)
 ABS (Acrylonitrile butadiene styrene)
 PP (Polypropylene)

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.

Production
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. 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.
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.
 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.

Advantages
 Won’t rot or absorb water and is highly resistant to insect damage - perfect for marine and other
water applications.
 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.
Benefits to the Community - This saves money for local governments and other purchasers by lowering
long-term maintenance costs. It creates additional business opportunities. The plastic waste from
landfills is diverted for better purpose and reduces wood waste, especially treated wood waste.

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
Types of Plastic Lumber
o High Density Polyethylene (HDPE) Recycled Plastic Lumber
o 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.

o Commingled RPL
o Commingled RPL is made from mixed recovered thermoplastic (plastic that can be re-
melted 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.

o Wood-Filled RPL
o 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.

o Fibre-Reinforced RPL
o 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.

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.  Multiple laminations of oriented

 Rubber-plastic lumber. HDPE.
 Mixed plastics and peanut shells.  Reinforced concrete fill.
 Coextruded steel liner (e.g., metal  Cross linking of PE molecules by
pipe). thermoset processes
 Coextruded steel reinforcing rods.
Uses

FARMING
• Manger liners • Natural area boarders • Trash Cans
• Stalls • Planters (window boxes, • Water Cooler
• Fencing tiers, and free standing) • Fairway markers
• Hog bar n floors INDUSTRIAL TRAILER & • Sign post
TRUCK BODIES
• Silo doors • Benches
• Bumper boards
• Curtain weights FURNITURE/OUTDOOR
• Driveway marker posts MISCELLANEOUS
• Windows
• Sign post • Picnic tables
• Bumper boards
• Pallets • Adirondack chairs
• Feed troughs
• Garbage Containment • Benches
• Manure spreaders
• Bunk boards • Trash receptacles
• Milk house applications
• Barricades • Planters
DECKS, DOCKS
LANDSCAPING • Packaging • Bird houses
• Deck boards • Refrigerated unit shelving • Ice fishing tip-ups
• Railing - spindles, post • Runners under the body • Ice shanty runners
caps
• Side boards on trailers • Garden cart
• Fascia boards
• Bed liners Flooring • Potting bench
• Fish filleting tab les
• Scuff boards in trailers • Picket fence
• Swim platform
• Snowmobile trailers • Lamp post
• Piling strips
GOLF INDUSTRY • Arbor, Trellis
• Boat bumper boards
• Golf cart cargo areas • Wishing well
• Retaining walls
• Tee markers • Mail box post

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.