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CHAPTER I

The Problem and Its Setting

1.1 Background of the Study

Chicken Feathers are considered as a waste product of the poultry industry. Tons

of waste feathers are generated each year by poultry processing plants, creating a serious

solid waste problem (Parkinson, 1998; Schmidt, 1998). The Philippines, on the other

hand, has well-attained self-sufficiency in poultry, an abundant producer of poultry

products generating for about 800 million broilers annually regardless of continuous rise

in population, the supply continues to meet the consumer demands (Bansal and Singh,

2016). With the arising large scale of Chicken Feathers, it has come to a point that the

disposal of such wastes became difficult and expensive. Usually, feathers are roasted or

treated at raised temperature and pressure. After drying, it is ground to make powder for

further use as a feed supplement for livestock. This process is quite expensive and

contains protein with low nutritional value (Ekta and Rani 2012). Disposal methods such

as burning, or burying are also occasionally used but they are not environment friendly

(Valtcho and Zheljazkov, 2005). Meanwhile, in today's scenario, fiberglass is commonly

used as reinforcement in commercial plastic roofing. Since plastic roofing is exposed to

weather, the material greatly needs a type of glass that has high melting point capable

enough to withstand Ultraviolet rays through the test of time. Apparently, for this matter,

glass with higher melting point induces higher cost (E. Jarquio, 2007).

The innovative way of using plastic as a roofing material has a wide selection of

material based on plastic; all of which differ in mechanical property and global
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abundance. One of the most common plastic materials is the vinyl chloride also known as

vinyl. Vinyl is a very versatile plastic among thermoplastics in use today. It is produced

by the fusion or polymerization of vinyl chloride monomer, a gas yielded by the reaction

of ethylene, a colorless flammable gas with oxygen and hydrochloric acid. The properties

of vinyl material compared to other polymer of plastics are exceptional at some points

making it more applicable for roof construction setting (Whelan et al., 1990).

However, considering plastic alone isn't necessary. Excellent coupling of fiber

reinforcement to the vinyl matrix is required for good retention of tensile strength.

Addition of glass fibers results in a significant decrease in coefficient of linear thermal

expansion. When properly formulated and managed for weather resistivity, the vinyl and

glass fiber excel in good color retention, impact retention, and outstanding dimensional

stability (Summers et al., 1999). Overall, utilizing glass fiber yields great stabilization

and a perfect balance in performance and aesthetic. Conversely, fiberglass needs to be

regel-coated about every five years and can result in airborne fibers which may be an

issue to asthma sufferers (Amer et al., 2018).

Chicken feather, on the other hand, can be a more durable and substantial material

than fiberglass. It is affordable and economical due to chicken feathers being a waste

product in the poultry industry. Using chicken feather fiber will make a sufficient and

easily attainable product in the market. Chicken feathers are mostly made up of keratin

usually seen in claws and nails making it very sturdy. It is water and moisture resistant,

so it has minimal swelling due to water content. The fiber has good thermal and acoustic

properties that make it tough and resilient to weathering. Chicken feather fiber has a very

low density making it lightweight. Lastly, chicken feather, being mostly keratin, has a
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very long degradation period making the product long lasting (Ramos et al., 2007).

Despite the advantages, chicken feather fiber also has downsides compared to fiberglass.

Chicken feather fiber has significantly lower mechanical properties namely the tensile

and flexural properties compared to fiberglass (M. Zhan, R. P. Wool, 2016).

With that, another variable was added to the design to compensate for the

mechanical properties of the chicken feather fiber. Nylon, a cousin of plastic, has also

one of the highest flexural and tensile strength of the plastic family. It is also very durable

and can withstand weathering as much as chicken feathers. Its surface area is also almost

the same as PVC making the binding process much easier. It is inflammable but rather

has a low resistance to heat with a lower melting point just like plastic. This is where the

heat and water absorption of the chicken feather plays a significant role making the

combination efficient and reliable. Nylon is a useful plastic for applications that

require both a plastic material as well as a high melting temperature. Nylon can be

adapted to a wide variety of uses because of the many different variants in production and

the adjustable material properties of these variants resulting from the different materials

nylon can be combined with (Song et al., 2005).

Corrugated green roofing was then chosen for the overall design of the product.

Corrugated form is expected to be very flexible in the corrugation direction and stiff in

the direction perpendicular to the corrugation. Mechanical properties of the corrugated

composites in the longitudinal and transverse directions were evaluated through tensile

and flexural tests. It was confirmed that the corrugated composites have ultra-anisotropic

characteristics (i.e. stiff in the longitudinal direction and flexible in the transverse
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direction), and the capacity to extend and deform flexibly in the transverse direction

(Yokozeki et al., 2005).

The study will be designed to produce corrugated vinyl plastic roof using chicken

feather fibers and nylon mesh as partial replacement to fiberglass that will have the

positive characteristics such as flexibility, lightweight and thermal resistance. Chicken

feather fibers have the property to enhance the thermal resistance and reduce the density

of the material due to its light weight. Moreover, to enhance its flexural property,

incorporation of nylon will be considered. Nylon has been known to have high flexural

and tensile property, hence its application as reinforcement to various composite studies.

1.2 Objectives of the Study

1.2.1 General Objective

The main objective of the study is to characterize the properties of

Corrugated Vinyl Plastic Roofing using chicken feather fibers and nylon mesh as

partial replacement to fiberglass.

1.2.2 Specific Objectives

1. To determine the linear density of chicken feather fibers.

2. To determine the tensile strength of chicken feather, nylon and

fiberglass.

3. To determine the physical properties of corrugated vinyl plastic roofing

using chicken feather fibers and nylon mesh as partial replacement to

fiberglass such as water absorption and flammability.

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4. To determine the mechanical properties of corrugated vinyl plastic

roofing using chicken feather fibers and nylon mesh as partial replacement

to fiberglass such as tensile strength and flexural Strength.

5. To determine the suitable mix design among the proposed design mixes

for the corrugated vinyl plastic roofing using chicken feather fibers and

nylon mesh as partial replacement to fiberglass.

1.3 Scope and Delimitation of the Study

This research will be focusing on the determination of the physical and

mechanical properties of plastic roofing using chicken feather fibers and nylon mesh as

partial replacement to fiberglass. The chicken feather to be used is limited only to one

variety, Broiler chicken or 45-day old chicken feather. Nylon mesh, on the other hand,

will be limited only to one type; Nylon 66. The prototype development is to be conducted

using compression molding conforming to ASTM 4703-16 (Standard Practice for

Compression Molding Thermoplastic Materials into Test Specimens, Plaques, or Sheets).

Physical property characterization includes flammability and water absorption

while the mechanical property characterization covers the determination of tensile and

flexural strength of the product. The physical and mechanical property characterization

will be conducted in accordance with the standard procedures as stated in ASTM D570 -

98 (Standard Test Method for Water Absorption of Plastics), ASTM UL 94 (Standard

Test for Flammability of Plastic Materials for Parts in Devices and Appliances), ASTM

D790 - 17 (Standard Test Methods for Flexural Properties of Unreinforced and

Reinforced Plastics and Electrical Insulating Materials) and ASTM D638 (Standard Test

Method for Tensile Properties of Plastics).

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Seven specimens will be used in every test. Also, the specimens will be limited

only to plain shape due to the unavailability of tests for corrugated shape specimens.

The fabricated plastic roofing is primarily intended only for low slope roofing.

1.4 Significance of the Study

The study evaluated the potential of chicken feather fibers and nylon mesh as

partial replacement to fiberglass with polyvinyl as the main polymer. This study can

provide understanding on the property characterization of the oriented plastic roofing and

its production as an alternative to conventional roofing. Specifically, this study will be

beneficial to the following:

For the poultry industry, this study would help reduce the arising number of

chicken feather waste. Instead of burning and burying it through a landfill, chicken

feather fiber can be utilized by using it as a reinforcement, which would result to a

cheaper but a standard conforming roofing material.

For the engineering, this study would serve as a reminder that innovation does

not always need to be expensive, sometimes it comes with having a healthy surrounding.

For the government, it is important to assume, at the national level to create

techniques for the use of this waste as it can bring significant changes in industrial

policies of domestic materials for a greater scientific development and sustainability in

the Philippines.

This research is also beneficial to the environment. It would not only reduce the

demand for fiberglass as the main reinforcement in the production of plastic roofing but
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also suggests a more effective way of eliminating of feather wastes produced by the

poultry industries.

This would also be an instrument that would help future researchers. This

research will be a guide for them whenever they will conduct a research related to this

topic. This study was the researchers' contribution to the utilization and development of

agricultural wastes as construction materials.

1.5 Conceptual Framework

Figure 1.1 illustrates the conceptual framework of the study. It shows the flow of

the study which is divided into three categories: the input, the process and the output. The

input of the study shows the initial preparations required before conducting the research

such as gathering of materials, preparation of equipment etc. The process of the study, on

the other hand, includes the preparation of materials, the production of test samples and

the testing of the samples. Lastly, the desired output of the study is to characterize the

physical and mechanical properties of the sample.

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INPUT PROCESS OUTPUT

Problem 1. Preparation of Results of Physical

Fiberglass
Chicken Feather Fiber
(CFF)
Knowledge/Concept
Corrugated Vinyl Roofing
using CFF and Nylon
Mesh as Partial
Replacement to Fiberglass
Resources Requirements
Vinyl Resin
Nylon Mesh
Chicken Feather Fiber
(CFF)
Fiberglass
Pigments
Hardware/Machine
Requirements
Universal Testing Machine
Oven Dryer
Squeegee
Electronic Weighing Scale
Cavity Machined Mold
Conditioning Rack
Samples Property Testing
Gathering of Chicken Water Absorption
Feather Flammability
Bleaching and cutting of
Chicken Feather Results of Mechanical
Preparation of Nylon Mesh Property Testing
Testing of Materials Tensile Strength
Flexural Strength
Mix Design
a. Fiberglass-Nylon-
Chicken Feather Fiber with
constant amount of vinyl
Production
Laying
Polishing
Trimming
Physical Property Tests
Water Absorption
Flammability
Mechanical Property Tests
Tensile Strength
Flexural Strength

Figure 1.1 Conceptual Framework of the Study

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1.6 Definition of Terms

Absorption – describe the process of absorbing or soaking up something.

(https://www.merriam-webster.com/dictionary/absorption)

Anisotropic – having a physical property which has a different value when

measured in different directions.

(https://www.merriam-webster.com/dictionary/anisotropic)

Corrugated – (especially of sheets of iron or cardboard) having parallel rows of

folds that look like a series of waves when seen from the edge.

(https://dictionary.cambridge.org/us/dictionary/english/corrugated)

Density – defined qualitatively as the measure of the relative “heaviness” of

objects with a constant volume. (https://www.britannica.com/science/density)

Durability – assurance or probability that an equipment, machine or material will

have a relatively long continuous useful life without requiring maintenance

(https://dictionary.cambridge.org/us/dictionary/english/durability)

Ethylene – a colorless flammable gaseous unsaturated hydrocarbon that is found

in coal gas, can be produced by pyrolysis of petroleum hydrocarbons.

(https://dictionary.cambridge.org/us/dictionary/english/ethylene)

Fiber – a thread or a structure or objects resembling a thread

(https://dictionary.cambridge.org/us/dictionary/english/fiber)
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Fiberglass – a form of fiber-reinforced plastic where glass fiber is the reinforced

plastic. (https://dictionary.cambridge.org/us/dictionary/english/fibreglass)

Flammable – capable of being easily ignited and of burning quickly

(https://www.merriam-webster.com/dictionary/flammable)

Flexibility – ability to bend or stretch

(https://dictionary.cambridge.org/us/dictionary/english/flexibility)

Flexural Strength – the ability of the material to withstand bending forces

applied perpendicular to its longitudinal axis.

(https://www.trenchlesspedia.com/definition/2742/flexural-strength)

Hydrophobic – “the fear of water”. Hydrophobic molecules and surfaces repel

water. Hydrophobic liquids will separate from water

(https://biologydictionary.net/hydrophobic/)

Keratin – any of various sulphur – coating fibrous proteins that form the

chemical basis of epidermal tissues.

(https://www.merriam-webster.com/dictionary/keratin)

Linear Density – also known as the mass density, is defined as the mass of the

object per unit of length. (https://www.aqua-calc.com/what-is/linear-density)

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Mechanical Property – characteristics that indicate the elastic or inelastic

behavior of a material under pressure (force), such as bending, brittleness,

elongation, hardness, and tensile strength.

(https://www.merriam-webster.com/dictionary/mechanical%20property)

Melting Point – temperature at which the solid and liquid forms of a pure

substance can exist in equilibrium. As heat is applied to solid, its temperature will

increase until the melting point is reached.

(https://www.britannica.com/science/melting-point)

Mesh – an openwork fabric or structure; a screen made of wire mesh

(https://www.merriam-webster.com/dictionary/mesh)

Mix Design – a process of selecting suitable ingredients and determining their

relative proportions to produce concrete of having precise minimum workability,

strength and durability as economical as possible.

(https://www.thefreedictionary.com/mix+design)

Modulus of rupture – frequently abbreviated by MOR, (sometimes referred to as

bending strength), is measure of a specimen’s strength before rupture. It can be

used to determine a wood species’ overall strength.

(https://www.wood-database.com/wood-articles/modulus-of-rupture/)

Moisture – liquid diffused or condensed in relatively small quantity.

(https://www.merriam-webster.com/dictionary/moisture)
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Moisture Content – is the quantity of water contained in a material, such as soil

(called soil moisture), rock, ceramics, crops, or wood.

(https://en.wikipedia.org/wiki/Water_content)

Molecular Structure – the location of the atoms, groups or ions relative to one

another in a molecule, as well as the number, type and location of covalent bonds.

(https://www2.chemistry.msu.edu/faculty/reusch/VirtTxtJml/intro3.htm)

Nylon – any of numerous strong tough elastic synthetic polyamide materials that

are fashioned into fibers, filaments, bristles, or sheets and used especially in

textiles and plastics.

(https://www.merriam-webster.com/dictionary/nylon)

Plastic – a synthetic material made from a wide range of organic polymers such

as polyethylene, PVC, nylon, etc., that can be molded into shape while soft and

then set into a rigid or slightly elastic form.

(https://www.merriam-webster.com/dictionary/plastic)

Pigment – something’s color is its pigment. Technically, all living things have a

natural pigment, but it is more generally applied to skin color.

(https://www.vocabulary.com/dictionary/pigment)

Polymerization – any process in which relatively small molecules, called

monomers, combine chemically to produce a very large chainlike molecule, called

a polymer. (https://www.britannica.com/science/polymerization)
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Reinforcement – something designed to provide additional strength, as in a weak

area. (https://www.merriam-webster.com/dictionary/reinforcement)

Shear Strength – is a material’s ability to resist forces that can cause the internal

structure of the material to slide against itself. Adhesives tend to have high shear

strength (https://www.corrosionpedia.com/definition/1026/shear-strength)

Single Fibre – single fibres are most often prearranged into structures making

them easier to handle and ready for further use.

(https://www.sciencedirect.com/topics/engineering/single-fibre)

Specific Gravity – Specific gravity, also called relative density, ratio of the

density of a substance to that of a standard substance.

(https://www.britannica.com/science/specific-gravity)

Swelling – expansion of clay minerals in rocks and soils that caused by the

chemical attraction of water to certain clay minerals. Layers of water molecules

can be incorporated between the flat submicroscopic clay plates.

(https://www.civilengineeringx.com/construction/swelling/)

Tensile Strength – The ability of a material to withstand a pulling (tensile) force.

It is customarily measured in units of force per cross- sectional area

(https://www.corrosionpedia.com/definition/1072/tensile-strength)

Thermal Expansion – is the tendency of matter to change in volume in response

to temperature alterations.

(https://www.britannica.com/science/thermal-expansion)
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Vinyl – is a strong plastic used for making things such as floor covering and

furniture (https://www.collinsdictionary.com/dictionary/english/vinyl)

Weathering – alteration of rocks due to action of surroundings such as wind

(https://www.merriam-webster.com/dictionary/weathering)