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Recycled HDPE Plastic Lumber: Performance Characteristics & Bedford Technology®, LLC

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Recycled HDPE Plastic Lumber: Performance Characteristics & Bedford Technology®, LLC • About the Instructor • About the Sponsor • Ask an Expert Recycled HDPE Plastic Lumber: Performance Characteristics & Bedford Technology®, LLC. 2424 Armour Road Applications PO Box 609 Worthington, MN 56187-0609 Tel: (507) 372-5558 Fax: (507) 372-5726 Toll-Free: 800-721-9037 Email: [email protected] Web: http://www.plasticboards.com/ ©2014, 2015 Bedford Technology®, LLC. The material contained in this course was researched, assembled, and produced by Bedford Technology®, LLC. and remains its property. Questions or concerns about the content of this course should be directed to the program instructor. Slide 1 of 70 Purpose and Learning Objectives Description: Provides an overview of recycled HDPE plastic lumber and includes discussions on manufacturing processes, comparisons to wood lumber and wood/plastic composite lumber, and the composition and construction of different types of recycled HDPE plastic lumber as well as their performance attributes and applications. Purpose: Provides an overview of recycled HDPE plastic lumber and includes discussions on manufacturing processes, comparisons to wood lumber and wood/plastic composite lumber, and the composition and construction of different types of recycled HDPE plastic lumber as well as their performance attributes and applications. Learning Objectives: At the end of this program, participants will be able to: • define plastic lumber and list the types of materials used in its composition • outline three processes used to manufacture recycled HDPE plastic lumber and the differences between their end products • compare recycled HDPE plastic lumber to wood lumber and other composite lumber along various performance attributes • describe the composition and construction of different types of recycled HDPE plastic lumber and relate these to their performance and applications. Table of Contents Plastic Lumber Overview 7 Recycled HDPE Plastic Manufacturing Processes 20 Recycled HDPE Plastic Lumber vs. Wood/Composites 30 Types of Recycled HDPE Plastic Lumber 38 Green Building Programs and Testing Standards 57 Case Studies 61 Summary 68 Click on title to view Plastic Lumber Overview What Is Recycled Plastic Lumber? Recycled plastic lumber is defined as formed plastic supplied in traditional dimensional lumber sizes and manufactured using at least 50% recycled materials. Composition: Source Plastics Recycling Alternate Abbreviation Polymer Name Uses Many types of Number Image plastic are recycled; Polyethylene Polyester fibers, thermoformed sheet, 1 PETE or PET however, not all terephthalate strapping, and soft drink bottles recycled plastics Bottles, grocery bags, milk jugs, recycling bins, High-density are suitable for 2 HDPE agricultural pipe, base cups, car stops, polyethylene plastic lumber. The playground equipment, and plastic lumber highest quality Pipe, fencing, shower curtains, lawn chairs, 3 PVC or V Polyvinyl chloride plastic lumber and non-food bottles utilizes #2 HDPE— Plastic bags, six-pack rings, various containers, Low-density 4 LDPE dispensing bottles, wash bottles, tubing, and polyethylene high-density various molded laboratory equipment polyethylene. Auto parts, industrial fibers, food containers, 5 PP Polypropylene and dishware Desk accessories, cafeteria trays, plastic utensils, toys, video cassettes and cases, 6 PS Polystyrene clamshell containers, packaging peanuts, and insulation board and other Other plastics, including acrylic, acrylonitrile Bottles, plastic lumber applications, headlight butadiene styrene, 7 OTHER or O lenses, and safety shields/glasses fiberglass, nylon, polycarbonate, and polylactic acid Thermoplastics Triangle IMIDIZED MATERIALS The two categories of Best Physical Properties Above 400 ̊ F · Best Temperature Resistance High Temperature, High Load Bearing thermoplastics are semi- and Wearing Capabilities VESPEL® Good Chemical Resistance crystalline and amorphous. TECATOR™ Maintains Strength and Stiffness Their properties are shown HIGH PERFORMANCE MATERIALS HIGH PERFORMANCE MATERIALS High Service Temperatures PEEK® High Service Temperature to the right. High Strength Excellent Chemical Resistance RADEL®R PPS Hot Water and Steam Resistance High Purity ® Thermoformability ULTEM PTFE Structural POLYSULFONE PVDF Commodity plastics are (KYNAR®) produced at high volume ENGINEERINGPLASTICS ENGINEERINGPLASTICS General Purpose Structural Parts General Purpose Bearing and Wear and low cost for the most Moderate Strength PET or Structural Parts Moderate Temperature POLYCARBONATE PBT Moderate Strength and Stiffness common disposable items Good Dimensional Stability NORYL® PPO NYLON Good Chemical Resistance Good Izod Impact Moderate Temperature ACETAL and durable goods, while Easily Fabricated engineered plastic COMMODITY PLASTICS COMMODITY PLASTICS Low Temperature Good Chemical Resistance Low Strength Low Moisture Absorption properties are tailored to POLYPROPYLENE Good Bondability POLYSTYRENE Low Temperature POLYETHYLENE Good Machinabilty NORYL® PPO Low Strength specific applications and Good Formability (HDPE, LDPE, UHMW-PE) Low Cost are produced at low Low Cost volume and higher cost. Amorphous Thermoplastics Semi-Crystalline Thermoplastics • mostly transparent or translucent • translucent or opaque • low tendency to creep • good fatigue resistance • good dimensional stability • tendency to toughness HDPE is a semi-crystalline • low tendency to warp • good chemical resistance • tendency to brittleness • good sliding characteristics commodity plastic that is • low chemical resistance, easy to bond • wear resistant • sensitive to stress cracking • not easily formed/shaped durable and economical. • formable • degree of crystallinity Source Plastics: High-Density Polyethylene High-density polyethylene (HDPE) is defined as a stiff plastic resin used extensively by the food industry to mold bottles and trays. This resin is resistant to most chemicals and absorbs almost no moisture, making it an excellent building material. HDPE is more rigid and harder than LDPE, with a tensile strength four times that of LDPE. Its compressive strength is three times that of LDPE. It is commonly found in: milk jugs and juice bottles; butter and yogurt tubs; shampoo bottles; industrial containers; agricultural (water) tanks; and motor oil bottles. Source a manufacturer who does not knowingly use recycled HDPE that has come in contact with petroleum or agricultural/industrial chemicals. Source Plastics: Low-Density Polyethylene Low-density polyethylene (LDPE) is a widely used plastic, especially in the manufacturing of various containers, dispensing bottles, wash bottles, and tubing. It is translucent to opaque, robust enough to be virtually unbreakable, and at the same time, quite flexible. LDPE is a tough material that is weldable and machinable. It has very good chemical resistance, good clarity and excellent electrical/chemical use in low heat. It is commonly found in: flexible bottles; milk jug caps; bread, frozen food, shopping and clothing bags; some carpeting; and chemical containers. It is not often recycled through curbside programs, but some do accept it. Plastic lumber manufacturers do not intentionally procure LDPE material but may accommodate what LDPE is acquired. Source Plastics: Specific Weight Recycling Alternate Specific Weight It is difficult to separate recycled HDPE from Abbreviation recycled LDPE because of their specific Number Image g/cc weights. Water H2O 1.0 Water, by definition, has a specific weight of 1 PETE or PET 1.3 1.0 g/cc. When immersed in water, more dense plastics will sink (red in chart) and 2 HDPE 0.92 less dense plastics float (blue in chart). Because HDPE and LDPE have very similar 3 PVC or V 1.4 specific weights, and both float, they are not easily separated, which is why most manufacturers will use what little LDPE they 4 LDPE 0.95 have acquired. 5 PP 0.93 Note that the exact specific weight depends 6 PS 1.1 on the plastic formula used, and on the additives used. Therefore, the given values in the chart are only approximated values. 7 OTHER or O 1.1+ Source of Recycled Plastics: Post-Industrial Post-industrial waste is generated during the manufacturing process of upstream plastic products. This can be from virgin producers, molding plants, and many other plastic products. Examples of post-industrial waste include milk jug scraps from manufacturing plants, plastic lumber scraps, and the plastic lumber manufacturer’s own scraps. Post-industrial versus post-consumer content used in the manufacture of plastic lumber varies based on what the raw material availability is. Plastic for recycling is a very opportunistic buying industry. Source of Recycled Plastics: Post-Consumer Post-consumer waste is recovered from the consumer supply chain. Post-consumer waste is any item that served its original use and has been diverted from disposal in a landfill. Typical examples of recycled post- consumer HDPE include milk jugs, detergent bottles, and shampoo bottles. Most of the cost of plastic lumber is for raw materials. The more supply out there, the lower the cost. Depending on the product, significant plastic content is used. Contamination Post-industrial waste is considered “less green” than post-consumer waste; however, it is typically a “cleaner” plastic material to use due to less contamination and mixed content. Post-consumer recycled plastic is often a more contaminated supply versus post-industrial waste; it is more likely to contain cardboard, aluminum, paper fiber, other plastics, etc. A plastic lumber manufacturer may
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