SEMESTER 4 – BMC

MODULE 1 REVISION – PLASTICS

LECTURE 1

MODULE 1 : PLASTICS

TOPICS COVERED : THERMOPLASTICS & THERMOSETTING

PLASTICS, RESINS, FABRICATION OF PLASTICS,
POLYMERIZATION & CONDENSATION-APPLICATION OF
PLASTIC IN BUILIDNG CONSTRUCTION – PROPERTIES
AND ARCHITECTURAL USE OF PLASTICS.

STRUCTURAL PLASTICS, REINFORCED PLASTICS AND

DECORATIVE LAMINATES, PLASTIC COATINGS

FRP-FIBRE REINFORCED POLYMER

NO DRAWINGS, ONLY THEORY (5 MARK & 10 MARK QNS)

 REPEATED UNIVERSITY EXAM QUESTIONS

5 marks

1. Discuss the properties of plastics and its usage in

building construction.
2. Explain the usage of FRP in building construction.
3. What is FRP?
4. What are the advantages of PVC?
5. What are the properties of Thermoplastics?
6. What are the applications of plastics in building
construction?
7. What are the limitations of plastic as a
construction material?
8. Explain the properties of plastic as an engineered
material.
9. Enumerate the types of plastics used in building
construction.
10. Distinguish between Polymerization and condensation
of plastics?
 REPEATED UNIVERSITY EXAM QUESTIONS

1o marks

11. Discuss the properties and applications of

polycarbonates in buildings.
12. Describe in detail about structural plastics and
reinforced plastics
13. Explain the different methods of Fabrication of
Plastics.
14. Explain in detail the application of plastics in
building construction.
 PLASTICS : DEFINITION & COMPONENTS

 Plastic is defined as a material that contains as an

essential ingredient an organic substance of large
molecular weight. It is also defined as polymers of
long carbon chains that are built from relatively
simple units called monomers through a chemical
polymerization process.
 POLYMERS & POLYMERIZATION

The structure of polymers.

 Polymers are large molecules made up of many smaller
molecules. 'Poly' means many and 'mer' means units.
These smaller units are called monomers (mono = one,
mer = unit) and are joined together through
polymerisation to form polymers.
 A polymer contains hundreds of thousands of
monomers.
 Polymerisation, which means the linking of monomers
to form polymers results from two kinds of chemical
reaction called condensation and addition.
 In a monomer atoms are joined by double bonds, and
these must be broken and new bonds created between
adjacent atoms to form the long chain molecules of a
polymer through polymerisation.
 If the chains run parallel to each other the
structure is said to be crystalline (made of
crystals). This contrasts with the disorder of
tangled chains in an amorphous (shapeless)
structure.
 Many polymers have both crystalline and amorphous
regions, and the proportion of crystalline and
amorphous regions in a polymer depends on its
chemical composition, molecular arrangement and how
it has been processed.
 Crystallisation is one of the two principles that
have been used to produce strong, stiff polymers
(e.g. polythene and nylon), the other is the
formation of strong bonds between the chains which
is a process known as cross linking.
 Polymers such as bakelite and urea formaldehyde have
many strong cross links which do not soften with
increased heat, but set once and for all after their
initial moulding.
 This is how we get the ‘set’ in thermosetting. These
plastics remain comparatively strong until over
heating leads to a breakdown of the cross links and
chemical decomposition.
 By contrast, in thermoplastic polymers only weak
forces hold the chains together and these materials
can be softened by heating and if necessary
remoulded.
 Polymerization & condensation (QN 10)

 What is Polymerization? (also known as addition

polymerization)

 Addition polymerisation is the addition of one monomer to

another monomer to form long chain polymers. This process
does not produce any by-products. Hence, the molecular
weight of the polymer will be an integral multiple of
monomer’s molecular weight.
 The monomers involved in these reactions must be
unsaturated (double or triple bonds must be present).
 During the reaction, unsaturated bonds open up and form
covalent bonds with adjacent monomer molecules to form
long chain polymers.
 There are three types of mechanisms in addition
polymerisation, namely; free-radical mechanism, ionic
mechanism, co-ordination mechanism.
 Polymers produced by the addition polymerisation process
are called addition polymers.
 Examples of addition polymers include polyvinyl chloride
or PVC, poly(propylene), poly(tetrafluoroethene) or
TEFLON, etc.
 Polymerization & condensation (QN 10)

 What is Condensation? (also known as

condensation polymerization)
 Condensation polymerisation is the process of
intermolecular condensation of two different monomers to
form a large chain of polymer molecules.
 In this process, linking of every two monomer molecules
will result in a simple molecule such as HCl, ammonia,
water, etc., as a by-product.
 Hence, the molecular weight of the polymer will be the
product of the degree of polymerisation and the molecular
weight of the repeating unit.
 The polymers resulted due to condensation polymerisation
are called condensation polymers.
 Bakelite, nylon and polyester are some common examples of
condensation polymers.
 ADDITION CONDENSATION
POLYMERIZATION POLYMERIZATION
Monomer must have at least
 Monomer must have at least
two similar or different
a double or triple bond.
functional groups.

 Addition of monomer results Monomers condense to give a

in a polymer. polymer.

By-products : This
By- products : This
polymerisation results in by-
polymerisation doesn’t produce
products such as water, HCl,
any by-products.
CH3OH, NH3, etc.

Molecular weight of the Molecular weight of the

resulting polymer is an resulting polymer is not an
integral multiple of monomer’s integral multiple of monomer’s
molecular weight. molecular weight.

The reaction results in high The molecular weight of the

molecular weight polymers at polymer increases steadily
once. with the reaction.
 ADDITION CONDENSATION
POLYMERIZATION POLYMERIZATION
 Addition polymerisation Condensation polymerisation
produces thermoplastics. produces thermosets.

Addition polymerisation Condensation polymerisation

results in homo-chain results in hetero-chain
polymers. polymers.

 Examples : Polyethylene, Examples : Bakelite, nylon,

PVC, etc. polyester, etc.
 THERMOPLASTICS & THERMOSETTING PLASTICS
(QN 5)

 Polymers fall into two distinct groups,

thermosetting plastics and thermoplastics.
 Thermosetting polymers are converted into their
final form by heat and once set cannot be softened
by further heating.
 Thermoplastics however are softened and become fused
or 'plastic' by moderate heating and then harden
again on cooling. This process can be repeated many
times without radically altering the thermoplastic
properties.
 THERMOPLASTICS

 These plastics can be softened by heating and

hardened by cooling any number of times without
changing the properties of the material.
 It is thus possible to shape and reshape these
plastics by means of heat and pressure.
 One important advantage of this variety of plastics
is that scrap obtained from old and warnout articles
can be effectively used again.
 Properties :
1. Softens and liquefies on heating and hardens
up to cooling.
2. Retains shape after manufacture.
3. Suitable for recycling.
4. Can be reshaped by heat.
5. It may melt before passing to a gaseous
state.
6. Allow plastic deformation when it is heated.
7. They are soluble in certain solvents.
8. Swell in the presence of certain solvents.
 Examples and applications of thermoplastic
plastic materials:

 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.
 Examples of thermoplastic adhesives:
1. Acrylates
2. Cyanoacrylates
3. Epoxy cured by ultraviolet radiation
4. Acrylates cured by ultraviolet radiation
 THERMOSETTING PLASTICS

 These plastics are either originally soft or liquid

or they soften once upon heating, they harden
permanently.
 When they are heated in the temperature of 127
degree centigrade to 177 degree centigrade , they
set permanently and further application of heat does
not alter their form of soften them.
 But at temperature of about 343 degree centigrade,
the charring occurs. The thermo setting plastics are
durable, strong and hard.
 They are mainly used in engineering applications of
plastics.
Properties :
 Permanently hard on heating above a certain
temperature.
 Undergoes chemical changes during manufacture.
 Cannot be melted and reshaped.
 Little potential for recycling.
 EXAMPLES AND USES

 Polyester fibreglass systems: sheet molding compounds

and bulk molding compounds)
 Polyurethanes: insulating foams, mattresses, coatings,
adhesives, car parts, print rollers, shoe soles,
flooring, synthetic fibers, etc. Polyurethane polymers
are formed by combining two bi- or higher functional
monomers/oligomers.
 Bakelite, a phenol-formaldehyde resin used in
electrical insulators and plasticware
 Urea-formaldehyde foam used in plywood, particleboard
and medium-density fiberboard
 Melamine resin used on worktop surfaces.
 Epoxy resin used as the matrix component in many fiber
reinforced plastics such as glass-reinforced plastic
and graphite-reinforced plastic
 FABRICATION OF PLASTICS (QN 13)

 The processing of raw materials into usable forms is

termed fabrication or conversion. An example from
the plastics industry would be the conversion of
plastic pellets into films or the conversion of
films into food containers.
 COMPOUNDING

 The first step in most plastic fabrication procedures

is compounding, the mixing together of various raw
materials in proportions according to a specific recipe.
 Most often the plastic resins are supplied to the
fabricator as cylindrical pellets (several millimetres in
diameter and length) or as flakes and powders. Other forms
include viscous liquids, solutions, and suspensions.
 Mixing liquids with other ingredients may be done in
conventional stirred tanks, but certain operations demand
special machinery.
 Dry blending refers to the mixing of dry ingredients prior
to further use, as in mixtures of pigments, stabilizers,
or reinforcements.
 However, polyvinyl chloride (PVC) as a porous powder can
be combined with a liquid plasticizer in an agitated
trough called a ribbon blender or in a tumbling container.
 This process also is called dry blending, because the
liquid penetrates the pores of the resin, and the final
mixture, containing as much as 50 percent plasticizer, is
still a free-flowing powder that appears to be dry.
 FORMING

 The process of forming plastics into various

shapes typically involves the steps of
melting, shaping, and solidifying.
 PLASTIC FABRICATION-PROCESSING
TECHNIQUES

 Because of the properties of polymers it is possible

to mould them and change their shape using a number
of different repetitious manufacturing processes.

 The most important of these are extrusion, injection

moulding, blow moulding, vacuum forming, extrusion
blow moulding, rotational moulding, calendaring,
foaming and compression moulding.
 EXTRUSION

 Extrusion is a process that

can be compared to squeezing
toothpaste out of a tube.
Thermoplastic granules are
forced through a heated
barrel and the fused polymer
is then squeezed through a
die that is the profile of
the extruded component.
 The extrusion is cooled by
water or air as it leaves
the die and is finally cut
to the required length. The
shape of the die can be
varied from a simple hole
with a centrally supported
core to produce tubes such
as pipes, to very complex
sections for curtain tracks
or hollow window frames.
 BLOW MOULDING

 Blow moulding is a
simple process where
compressed air is
introduced underneath
a warmed sheet of
thermoplastic
material forcing the
material into a mould
cavity, or allowing
it to expand freely
into the shape of a
hemisphere.
 It is a good way of
forming large domes,
which when made out
of clear acrylic
sheet are often used
in shop displays.
 Vacuum forming

 This is a very common manufacturing process used, for

example, to make a range of plastics packaging. Think of the
boxes sandwiches come in, or the inner in a chocolate box, or
your acrylic bath.
 It is really the opposite of blow moulding. Instead of the
warmed plastic sheet being forced into a mould by air
pressure, in vacuum forming the air is drawn out from under
the softened plastic sheet, so it is forced over or into a
mould by atmospheric pressure.
 Vacuum forming is a very common and effective way of
producing complex shapes in thermoplastic sheeting.
 Extrusion blow moulding

 This is a combination of
extrusion and blow moulding
and is often used where the
article to be made has a
narrow neck, such as a
bottle.
 The plastic material is first
extruded as a tube shape into
an open die. The die is then
closed to seal the ends of
the tube and air is blown in
forcing the plastic tube to
take up the shape of the die
cavity.
 As the material is extruded
first and then blow moulded,
the process is known as
extrusion blow moulding.
 Injection Moulding

 This process is one of

the most common of all
plastics manufacturing
processes.
 The polymer, in granule
form, is heated until
fused and forced into a
closed mould.
 Because of the viscous
thick, syrupy) nature
of the fused polymer,
very high pressures are
needed to make it flow,
which means that the
machine and mould have
to be very strong to
withstand the forces
involved.
 Rotational Moulding
 Rotational moulding is used to
produce hollow thermoplastic
products such as drums, storage
tanks and litterbins.
 A carefully calculated amount of
plastic is placed in a closed
mould that is heated in an oven
and rotated slowly around both a
vertical and horizontal axes.
 The plastic material fuses and
sticks to the hot mould surface,
building up the required
thickness.
 The mould is then gradually
cooled by air or water while
still rotating.
 The mould is opened, the finished
product removed and the mould
reloaded and closed for the next
cycle. The time it takes to make
one of the product is known as
the product’s cycle time.
 FOAMING

 Plastic foams used in packaging and the upholstery

industry can be produced by using blowing agents
that are mixed with the base polymer.
 When heated these agents release gas which form
bubbles in the plastic.
 Another method is to inject compressed nitrogen gas
into molten plastics during the moulding process.
 A third method is to freeze a gas within the
plastics granules which then expands due in the heat
of the moulding process.
 CALENDERING

 Calendering is used to
produce plastic sheeting
and products such as floor
tiles, coated fabrics and
coverings for car
interiors.
 Fused thermoplastic is
extruded on to heated
rotating rollers that
squeeze the material into a
continuous sheet or film.
 The film is cooled by jets
of air or water, before
being cut to suitable
lengths or loaded onto
rolls.
 Compression moulding

 Compression moulding is one of the

oldest manufacturing technologies
associated with plastics and was
used in 1854, for example, by Samuel
Peck to make picture frames from
shellac mixed with wood flour.
 The process is almost always used
with thermosetting plastics.
 A carefully weighed amount of
thermosetting polymer is placed into
a preheated lower mould cavity.
 The mould is then closed by the
placing of the upper half and
subjected to further heat, and
pressure provided by a press, often
of several hundred tons capacity.
The pressure and heat causes
polymerisation and the flow of the
plasticised material within the
mould.