EBML 2103

TAKE HOME EXAMINATION

SEPTEMBER 2020

EBML2103

ENGINEERING MATERIAL

NO. MATRIKULASI : 840526146509001

NO. KAD PENGNEALAN : 840526146509
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PART A QUESTION 2
1.0 INTRODUCTION OF THERMOPLASTIC
A thermoplastic, or thermo-softening plastic, is a plastic polymer material that becomes
pliable or moldable at a certain elevated temperature and solidifies upon cooling. Most
thermoplastics have a high molecular weight. Examples of thermoplastic materials are
polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyamides, polyesters, and
polyurethanes. High-temperature thermoplastics include polyetherether ketones, liquid
crystalline polymers, polysulfones, and polyphenylene sulfide. The following essay focusing
on the three processing methods used to form thermoplastics. Each method will be elaborated
using two suitable applications. The conclusion will determine by comparing these methods.
On an atomic level, as the temperature is raised, auxiliary holding powers are
decreased by expanded sub-atomic movement so the overall development of nearby chains is
encouraged when stress is applied. Irreversible corruption results when the temperature of a
liquid thermoplastic is raised direct at which sub-atomic vibrations become savage enough to
break the essential covalent securities. In addition, thermoplastics are moderately delicate.
Most straight polymers and those having some expanded structures with adaptable chains are
thermoplastics. These materials are regularly created by the concurrent use of warmth and
weight.
2.0 PROCESSING METHODS TO FORM THERMOPLASTICS
The processing stages, for example, warming, moulding and cooling would typically be
attempted as a straightforward occasion or a rehashed cycle. The principal processing
methods for thermoplastic polymers are, injection moulding, extrusion, blow moulding and
thermoforming.
2.1 INJECTION MOULDING PROCESS
This is the most generally utilized procedure for manufacturing thermoplastic materials. In
the processing cycle, plastic granules from a hoper are taken through an opening in the
infusion chamber onto the outside of a pivoting screw drive, which conveys them forward
toward the form. The rotation of the screw powers the granules against the warmed dividers
of the chamber, making them liquefy because of the warmth of pressure, grinding and the hot
dividers of the chamber. At the point when adequate plastic material is softened at the form
end of the screw, the screw stops and by unclogged like movement infuses a "shot" of
dissolved plastic through a sprinter entryway framework and afterward into the shut shape
pits. The screw shaft keeps up tension on the plastic material took care of into the form for a

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brief timeframe to permit it to become strong and afterward is withdrawn. The shape is water-
cooled to quickly cool the plastic part. At last, the shape is opened and the part is catapulted
from the form with air or by spring-stacked ejector pins. The shape is then shut and prepared
for another cycle.
2.1.1 INJECTION MOULDING APPLICATIONS
Injection moulding is used to create many things such as wire spools, packaging, bottle caps,
automotive parts and components, toys, pocket combs, some musical instruments (and parts
of them), one-piece chairs and small tables, storage containers, mechanical parts (including
gears), and most other plastic products available today. Injection moulding is the most
common modern method of manufacturing plastic parts; it is ideal for producing high
volumes of the same object.
2.2 EXTRUSION PROCESS
Extrusion measure is essentially an infusion embellishment of a thick thermoplastic through
an open-ended die, like the extrusion of metals. A mechanical screw or drill pushes through a
chamber the pelletized material, which is progressively compacted, melted and formed into a
continuous charge of viscous fluid. Extrusion happens as this liquid mass is constrained
through a bite the dust hole. Cementing of the expelled length is facilitated by blowers or a
water splash not long prior to going to a moving transport.
2.2.1 EXTRUSION APPLICATIONS
Common applications of extrusion process are Insulated coating for wires and cables,
monofilament for rope, bristles and synthetic textile fibres. Pipes and tubing used for hoses,
water, gas, sewers and drains are also another type of applications which gone through
extrusion process.
2.3 BLOW MOULDING AND THERMOFORMING PROCESS
Blow moulding and thermoforming of sheet is another important processing methods of
thermoplastics. In blow moulding, a parrison which is a cylinder or tube of heated plastic is
placed between the jaws of a mould. The mould is closed to pinch off the ends of the
cylinder, and compressed air is blown in, forcing the plastic against the walls of the mould. In
thermoforming, a heated plastic sheet is forced into the contours of a mould by pressure.
Mechanical pressure may be used with mating dies, or a vacuum may be used to pull the
heated sheet into an open die. Air pressure may also be used to force a heated sheet into an
open die.
2.3.1 BLOW MOULDING AND THERMOFORMING APPLICATIONS.

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Many of the parts storing fluids in automotive industry use blow molding. Cooling system
overflow containers, windshield washer fluid bottles, and even fuel tanks are commonly
made with blow molding. larger fluid containers like barrels to transport and store water, oil,
or anything else liquid. Those are made with blow molding. Other than that, larger fluid
containers like barrels to transport and store water, oil, or anything else liquid used for
industrial bulk storage are made with blow molding.
3.0 CONCLUSION
Thermoplastics are materials which soften when heated and can then be formed whilst soft.
After cooling they becoming rigid take up the applied form. The softening and forming
processes are reversible. Thermoplastics are probably the most widely used type of polymer.
The group includes most of the “commodity” plastics such as polyethylene, PVC,
polypropylene, nylons (polyamides) and polystyrene. Below table illustrate the differentiate
between several thermoplastic processing methods.

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PART A QUESTION 3
1.0 INTRODUCTION
Timber from well-managed forests is one of the most sustainable resources available and it is
one of the oldest known materials used in construction. It has a very high strength to weight
ratio, is capable of transferring both tension and compression forces, and is naturally suitable
as a flexural member. Timber is a material that is used for a variety of structural forms such
as beams, columns, trusses, girders, and is also used in building systems such as piles, deck
members, railway sleepers and in formwork for concrete. Timber can be differentiate into
duo category which is hardwoods and softwoods. Timbers also categorized based on its
appearance and strength grading. Density and moisture condition are the main influence of
the timber properties. This essay explain the macrostructure of wood, moisture in timber and
its defects and lastly timber composite as an alternative construction material will be
discussed.
2.0 MACROSTRUCTURE OF WOOD
Wood is a composite material that comprises fundamentally of an intricate exhibit of
cellulose cells strengthened by a polymeric substance called lignin and other natural mixes.
The strength of wood is exceptionally anisotropic with its elasticity being a lot more
prominent toward the path corresponding to the tree stem. A common trunk cross-part is
shown in below figure.

As shown on the above figure, section A is the outer skin of the tree known as outer bark. it is
a dry dead tissue that giving general assurance against outside components. The inner bark as
pointed in section B is the inner skin or layer that covering the cambium layer. The inner bark

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is a moisture, delicate material that conducts food synthesized by the leaves to all developing
pieces of the tree. Section C is the thin layer between sapwood and inner bark known as
cambium layer. The cell in this layer is accountable for the thickness development of the tree.
Sapwood is in the section D is the cutter annual rings between heartwood and cambium layer.
Sapwood involving the more youthful development containing living cells which store
nourishments and direct dampness from the roots to the leaves. This zone of wood is typically
lighter in shading than the inward heartwood and differs in thickness from roughly 30mm in
Western red cedar and Douglas to the thickness in overabundance of 75mm in maples, white
debris and a few pines. Section E, is the inner annual rings surrounding the pith is known as
heartwood. Heartwood containing inner layers with the cells biting the dust and the excess
food stores going through synthetic change to deliver substances, for example, tannin, a drab
shapeless mass. The principle capacity of the idle heartwood tissue is to give mechanical
inflexibility to the tree. The inner most central portion of core of a tree is called a pith as
pointed in the section F. Pith comprising the core of the tree about which the first wood
growth takes place. Pointed in the section G, is the growth ring, in a cross section of the stem
of a woody plant, the increment of wood added during a single growth period. In temperate
regions the growth period is usually one year, in which case the growth ring may be called an
“annual ring.” These rings are the consequence of patterns of development and rest, where
changes happen in the tissues framed between the start and the finish of the developing
season. As a rule, tissues framed toward the start of the period that direct dampness and
conduction vessels become more modest with proportionately thicker dividers. The thin
radial fiber extending from pith to cambium layer know as rays as pointed in section H. Its
containing tight groups of tissue running radially across the development rings. Their
motivation is to store and lead food to the different layers between the essence and their bark.
3.0 MOISTURE IN TIMBER
One of the main qualities of timber that influences its utilization and on-location execution is
its moisture content. This is a significant factor in timber use and the innovation of limber
revolves around the proficient techniques for controlling the dampness substance of timber.
The moisture condition of timber in the living tree is alluded to as the green condition.
Natural timber may contain approximately 20% percentage of water by its weight. In
contradictorily, dry timber usually contains less than 19% of water level by its weight. This
phenomenon called as hygroscopic nature of timber. The free water in its cell cavities and
hygroscopic moisture in the cells wall is two type of moisture that found in timber. Fiber

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saturation point is the dampness content (in percent) of the timber when the cell dividers are
soaked with water and the cells cavity contains no water. Any drying beneath the fiber
immersion point brings about shrinkage Unexpected and quick drying of wood brings about
the expulsion of water from cell dividers and the subsequent shrinkage causes breaking. On
the off chance that a dry bit of wood is kept in a soaked air, timber ingests water from air up
to around 15 percent of its weight. This water goes into the cell dividers which will in general
grow. The measure of water assimilated relies on the moistness of the air thus does the
growing. Wood dried and fabricated in one atmosphere will therapist, swell and twist
whenever utilized in another atmosphere. The determination of moisture content can be
calculated by the following formula.
Ww−Wd
Moisture contain % = .
Wd
3.0 TIMBER DEFECTS
Defects can create in timber at different occasions, some happening normally during
development while others result from the cycles engaged with their change and preparing. All
these can influence the nature of wood created, either by lessening its solidarity or harming
its appearance. Most common defects in timbers are knots, slope of grain , seasoning defects,
fungal decay, reaction of the wood, wane, distortions, insect damages and cracks. The defects
details has been simplify for a better understanding as per below table.
Knots The roots of the small branches of the tree. Harmless
Slope of grain A piece of lumber is said to have slope of grain when the fibers do
not run parallel to its main axis.
Seasoning defects Seasoning is the process of drying lumber (either in a kiln or air
drying) to an appropriate level of moisture for woodworking and
other commercial uses
Fungal decay A wood-decay fungus is any species of fungus that digests moist
wood, causing it to rot
Reaction of the wood Reaction wood in a woody plant is wood that forms in place of
normal wood as a response to gravity, where the cambial cells are
oriented other than vertically.
Wane Wane is one of the most easily identifiable aspects in the lumber
grading process.
Distortions Deformations in sawn timber, usually referred to as warp, can be a
consequence of primary stresses in the log, so-called growth

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stresses
Insect damages The insects can easily destroy sapwood and flight holes throughout
one or more faces of a timber that spans a room or roof are
generally attributable to that form of attack
Cracks Shakes are nothing but cracks which separate the wood fibers
partly or completely. Ring shakes are similar to cup shakes, but
they completely separate the annual rings

4.0 CONCLUSION
Introduction of wood composite in construction is that because it is man-made, it can be
designed for specific qualities or performance requirements. It can be made into different
thicknesses, grades, sizes and exposure durabilities, as well as manufactured to take
advantage of the natural strength characteristics of wood and sometimes results in a greater
structural strength and stability than regular wood. As a result, it can be used in a diverse
array of applications, from industrial scale to small home projects, and enable more design
options without sacrificing structural requirements.
Composite wood is also easy to work with using regular tools and can be efficiently
cut, fastened and drilled using basic skills. It is easily malleable and can be molded into
almost any desired shape. Plywood, for example, can be easily bent to create a curved
surface, without compromising its strength. It can also be manufactured into large panel sizes
meaning that builders don’t have to install numerous smaller pieces.
The ability of wood composites to be tailored to specific uses, together with their
strength properties and affordability, makes them a viable solution to reducing the need for
solid wood. They have been successfully applied in all forms of building, from small home
projects to industrial construction work, and as technology surrounding their manufacture
only advances, the future looks bright.

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PART B QUESTION 1

1.0 INTRODUCTION
Concrete is the most widely used construction material in the entire world. Rather than
existing as an independent material, concrete is a mix of various materials. These materials
include cement, water, fine aggregate, and crushed stones or gravel. Sand and gravel or
crushed stones are examples of fine aggregate and coarse aggregate, respectively. Numerous
popular structures and high rises are built utilizing concrete. Focal points of concrete
incorporate the capacity to be cast, is affordable, sturdy, heat proof, remembers for site
manufacture, high in compressive strength, high imperviousness to fire, high protection from
cyclic and weakness stacking just as requiring little support.
2.0 CONCRETE PRODUCTION MATERIALS
Primarily Concrete is made out of three materials of cement, water and aggregate. In addition
an extra material known as admixture can be added to accomplish certain properties. The
accompanying subsections expound the constituent materials of concrete and its influence in
the quality of concrete produced.
2.1 CEMENT
Cement is the main fixing in concrete and goes about as a coupling material since it has glue
and firm properties. The most widely recognized mix utilized in creation cement is limestone,
clay and sand. These materials are handled in a turning heater called an oven where
temperatures arrive at 1500°C. Cement when blended in with water shapes a glue which
solidifies and ties the total together and structures a hard and strong mass called concrete. The
cement utilized for construction is known as Portland cement. Other cement besides Portland

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are also widely used such as Slag cement, Pozzolanic cement and High Alumina BS EN
14647:2005.However, usage of Portland cement contributes majority in building sector.
According to Neville (2005), there are different types of Portland cement. An excellent
basic type of cement which are widely used known as Ordinary Portland Cement (OPC).OPC
is well known cement compound due to its properties has 0 sulphate in its soil and
groundwater.
Rapid-hardening Portland cement (RHPC) is another type of cement is famous for its
finest compared to OPC.RHPC develop strength faster than OPC, yet both will be in the same
durability after several months. RHPC is greater than OPC to a small extent.
Sulphate-resisting Portland (SRPC) cement known as low tricalcium aluminate content.
This type of cement has a minimal usage in building sector due to its higher in cost due to its
special composition of the raw material.
White Portland cement (WPC) and Low heat Portland Cement (LHPC) is another duo types
of cement used in construction. The former has least content of iron which allow grey-green
color to its properties. The latter consider in a larger structure usage and its normally
available upon special request.
2.2 WATER
Water is accountable for the hydration responses with the cement and impacts the strength
advancement and sturdiness of the solid. Water additionally greases up the outside of totals
and, consequently, impacts the functionality and compaction of concrete during the plastic
stage.
Customary drinking water can be utilized for getting ready cement. All in all, water is
required for, chemical response with concrete ,water of the blending is required for substance
response, workability, and facilitates blending, putting and compacting of the new concrete.
Water of hydration is the measure of water expected to finish the compound response in the
concrete. For the most part the water is around 25 percent of the heaviness of cement.
The impact of a high water-cement proportion on the strength of cement is that the
higher the water to solidify proportion, the lower the strength of the solid (gave that there is
adequate water to completely hydrate the concrete and accomplish great functionality for
setting the solid); the lower the water-concrete, proportion, the better the solid as far as
strength and toughness. Water should be liberated from specific synthetic compounds
harmful to solidify and the nature of water should be only adequate for the substance
response needed for the usefulness of the solid.

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2.3 AGGREGATE
Aggregate is the granular material of sand rock, squashed stones, squashed impact heater slag
or development and destruction squander. It is utilized with an establishing medium to deliver
either concrete or mortar. Aggregate is viewed as modest contrasted with concrete and it is
conservative to blend however much as could reasonably be expected. Aggregate mostly
possesses 70 to 80 percent of the volume of concrete and, hence, impact its properties. It will
improve the volume strength and wear opposition than hydrated cement paste alone. They are
granular materials, inferred generally from characteristic natural stone such as crushed stone
or natural gravel and sands albeit artificial materials, for example, slags, extended clay and
shale are utilized in lightweight concrete.
British Standards (BS) categorized aggregate into three types. Heavyweight aggregate
which give a powerful and prudent utilization of cement for radiation protecting and for
weight covering of lowered pipelines; and Density range from 4000 to 8500kg/m3 which
relies upon the total sort, measurements and level of compaction. Normal aggregate which
suits for most purposes generally comprises of different blends of natural sands, gravel and
stones and of various sizes of squashed rocks. The density range from 2300 to 2500kg/m3.
Lightweight aggregate are utilized to make lightweight cement. Lightweight aggregate can
be handled regular materials for models extended day or extended shale, prepared side-effects
for instance frothed slag or sintered pummeled fuel debris or natural materials.
3.0 CONCLUSION
Admixtures are added to concrete batch immediately before or during mixing concrete.
Concrete admixtures can improve concrete quality, manageability, acceleration, or retardation
of setting time, among other properties that could be altered to get specific results. Many, not
to say all, concrete mixes today contain one or more concrete admixtures that will help your
pouring process driving down cost while increasing productivity, The cost of these
admixtures will vary depending on the quantity and type of admixture being used. All of this
will be added to the cubic yard/meter cost of concrete.
Admixtures set retarding concrete admixtures are used to delay the chemical reaction
that takes place when the concrete starts the setting process. These types of concrete
admixtures are commonly used to reduce the effect of high temperatures that could produce a
faster initial setting of concrete.
Accelerating concrete admixtures are used to increase the rate of concrete strength
development or to reduce concrete setting time. Calcium chloride could be named as the most

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common accelerator component; however, it could promote corrosion activity of steel
reinforcement.
Air entrained concrete can increase the freeze-thaw durability of concrete. This type of
admixture produces a more workable concrete than non-entrained concrete while reducing
bleeding and segregation of fresh concrete.
Water-reducing admixtures are chemical products that when added to concrete can
create a desired slump at a lower water-cement ratio than what it is normally designed.
Water-reducing admixtures are used to obtain specific concrete strength using lower cement
content.

PART B QUESTION 2
1.0 INTRODUCTION
Recycling is a process of changing waste materials into reusable material to avoid waste of
potentially useful materials, reduce the consumption of fresh raw materials, reduce energy
usage, reduce air pollution (from incineration) and water pollution (from landfilling) by
reducing the need for "conventional" waste disposal and lower greenhouse gas emissions.
Recycling is a key component of waste reduction and is the third component of the "Reduce,
Reuse and Recycle (3R)".
There are many byproducts that have been reused to be utilized for as construction
materials. The iron-metal slag used to make mineral fleece protection and fly debris used to
make concrete are instances of modern reused/recycle materials. There are many byproducts
that have been reused to be utilized for as construction materials. The iron-metal slag used to
make mineral fleece protection and fly debris used to make concrete are instances of modern
reused/recycle materials. The following section will be focusing the four types of waste that
have been recycled to reuse as construction materials.
2.0 INDUSTRIAL WASTE
The age of industrial waste is expanding at high rates for as far back as many years and the
disposal in landfill has been the most utilized alternative. The introduction of mechanical

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side-effects in cementitious materials has been applied for quite a long time. Likewise, given
the significant CO2 outflows related with the Portland cement manufacturing measure,
various investigates have been embraced to see choices utilizing environmentally-sustainable
crude materials
For instance, coal fly ashes and bottom ash from power stations and impact heater slags
from steel processing plants have been effectively utilized in concrete and brick making
either as valuable cementitious materials or aggregate. Tire and plastic are different instances
of mechanical waste that become a significant ecological issue in all around the world. The
common raw materials for plastic and tire creation are petroleum, which is likewise the
petroleum derivative with the best commitment the overall energy creation in the world.
Consistently a huge number of tires are disposed of, discarded or covered everywhere on the
world leading to an intense danger to nature ecology. Studies indicated that there is a
promising future for the utilization of waste tire rubber as an partial substitute for aggregate
in cement concrete
The utilization of pyrolysis innovation to plastic and tire squanders permits the change
of dangerous waste into conservative important items .Scrap tires has been utilized as a fuel
in the concrete assembling measure (Davies and Worthington, 2001). The chance of reusing
modern squanders as total for concrete has likewise been accounted for brawl et al., 2000).
Other mechanical squanders that have been reused are glasses and rubber crumb. Various
investigations on adding glasses and crumb rubber into Portland concrete cement have
additionally been reported.
3.0 AGRICULTURE WASTE
Utilization of agriculture waste, for example, rice husk ash, straw from the stems left after
harvesting of cereal grains, oil palm shell (OPS), coconut shell ash and sugarcane in concrete
and brick have been reported. The yearly creation of solid waste from the palm oil industry
from the three fundamental makers of oil palm Malaysia, Indonesia and Thailand is around
90.5 million tons.
Rice husk is one of the agricultural wastes. Around the world, roughly 61 million tons
of rice paddy is produced every year. A normal 20% of the rice paddy is husk, giving a yearly
complete creation of around 132 million tons. Most of the husk produced from processing of
rice is either dumped as waste or burnt causing environmental problems. Sugarcane is another
horticultural waste that can possibly be concrete substitution material. Sugarcane bagasse is a
fundamental substance of the sugar business, which is utilized as a fuel source for sugar

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creation. Bagasse can be used as a raw material for paper making. The ash produced by
burning transforms the silica content of the ash into amorphous phase and provides
pozzolanic reactivity that lead to densification of cement matrix structure.
4.0 CONSTRUCTION WASTE
The construction sector requires amounts of materials (such as gravel and sand) derived
mainly from natural resources and generates high quantity of wastes. The reusing of these
wastes are considered as a significant strides towards sustainable construction application.
The wastes from destruction works have been utilized as aggregate which is known as
recycled aggregate
Reused concrete aggregate utilized for development can ease total lack issue and diminish
both air contamination and ecological footprint.
The utilization of concrete aggregate, for example, from obliterated waste or structures
could not only contribute to the solution of waste disposal but to the conservation of natural
resources which are scarce these days. It has been perceived that solid fabricated utilizing
reused aggregate concrete could have mechanical properties equivalent to the regular total
cement given that the parent concrete is of acceptable quality.

5.0 WASTEWATER SLUDGE

Numerous regions in the world are encountering issues in the expanding disposal of
municipal solid waste. Debris from treatment plants of sludge from city wastewater have
been presented as concrete or sand substitution in cement. Burned sewage sludge debris has
been utilized partially in making concrete as fine aggregate Pre-treatment (calcination)
plating sludges have been included concrete.
Paper sludge ash (PSA) contains a high extent of natural matter, as cellulose, just as
inorganic mixes, for example, muds and calcium carbonate . In the event that burning
happens in the scope of 700-750°C, dirt minerals in the paper sludge, for example, kaolinite
will be changed into metakaolinite (MK) and the PSA will carry on as a pozzolanic material
(Frias et al., 2008). It indicated that it is conceivable to produce feasible 20% PSA and with
powdered extended polystyrene mortar in consistence with significant norm as delivering,
workmanship and putting materials.
6.0 CONCLUSION

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Implementation of Site Waste Management Plan (SWMP) provides a framework and efforts
towards a sustainable built environment. SWMPs provide a useful framework for the
sustainable resource and waste management of construction waste, offering environmental,
social and financial benefits. The aim of their implementation on site is to increase the
resource efficiency of materials through recycling, reusing or recovering products before they
are disposed, and reducing environmental problems, such as illegal dumping and open
burning.
There are many proven benefits of construction waste management plans for
contractors, such as cost and time savings, increased productivity on site, good corporate
social responsibility and the ability to control the quality and ensure the safety of project sites
as a result of a clean site environment.

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