STUDIES ON EVALUATION OF STRUCTURAL PROPERTIES

OF MIXED MULTI-LAYERED RECYCLED PLASTIC

LUMBER
Project report submitted

to

MANIPAL ACADEMY OF HIGHER EDUCATION, MANIPAL

For Partial Fulfillment of the Requirement for the
Award of the Degree

of
BACHELOR OF TECHNOLOGY
in
CIVIL ENGINEERING
by
UPASANA SURYA KIRAN

Under the Guidance of

External Guide Internal Guide

Prof. NAJEEB MOHAMMAD
Prof. PRASANNA KUMAR M
SHARIFF
Assistant Professor, Department of Assistant Professor, Department of
Civil Engineering, IIT Bombay Civil Engineering, MIT Manipal

DEPARTMENT OF CIVIL ENGINEERING

2023
M
 STATEMENT OF THE ORIGINAL REPORT SUBMITTED

The project report titled, “STUDIES ON EVALUATION OF STRUCTURAL PROPERTIES

OF MIXED MULTI-LAYERED RECYCLED PLASTIC LUMBER” contained in this draft
has not been previously submitted to meet any requirements for carrying out the project work at
this / any other higher education institutions. To the best of my knowledge and belief, this project
report contains no materials previously published or written by another person except where due
references are made.

Upasana Surya Kiran

 ACKNOWLEDGEMENT

“Each person holds so much power within themselves that needs to be let out.
Sometimes they just need a little nudge, a little direction, a little support, a little
coaching, and the greatest things can happen.” I have made efforts in this project.
However, it would not have been possible without the kind support and help of many
individuals and the institute. I would like to extend my sincere thanks to all of them.

I am highly indebted to Prof. Najeeb Mohammad Shariff, Assistant Professor, Dept.

of Civil Engineering, IIT Bombay for providing the kind opportunity through the
prestigious IRCC RESEARCH INTERNSHIP AWARDS 2022-23 and introducing
me to this interesting topic of structural domain and his guidance and constant
supervision as well as for providing necessary information regarding the project & also
for his support in completing the project.

I would like to express my gratitude to all the professors of the Department of Civil
Engineering, IIT BOMBAY, for their kind co-operation and encouragement which
helped me in the completion of this project.

I would like to express a special vote of thanks to the HOD, Dept. of Civil Engineering,
Indian Institute of Technology, Bombay Prof. Deepankar Choudhury for his support
throughout the duration of my research project. I would like to express my gratitude to
the Director of IIT Bombay, Prof. Subhasis Chaudhuri, for giving me this wonderful
opportunity to work at IIT Bombay.

I would like to express my gratitude towards Prof. Prasanna Kumar, Assistant

Professor, Department of Civil Engineering, MIT, Manipal (Internal Project guide)
for his kind co-operation, guidance and motivation which helped me in the completion
of this project.

I would like to express my special thanks of gratitude to our Director, Manipal Institute
of Technology, Manipal, Prof. Commander Anil Rana as well as our HOD of Civil
Engineering, Prof. Purushotham G. Sarvade who gave me the golden opportunity to do
this project titled, “Studies on Evaluation of Structural properties of Mixed Multi
Layered recycled plastic lumber” which also helped us in doing a lot of research and I
came to know about so many new things, I am really thankful to them.

i
 ABSTRACT
KEYWORDS: Plastic, recycled, mechanical properties, plastic lumber.

Severe burdening of landfills due to non-degradable plastic waste deposition is a major

environmental hazard. Although there have been initiatives to use recycled plastic as a
building material, it has been successful only as a non-structural material or as a partial
replacement of aggregate in concrete. Further, the present design standards do not
discuss the use of recycled plastic as a construction material.

In this study, an experimental program has been carried out to evaluate the mechanical
properties of recycled plastic lumbers (RPL) developed using mixed multi-layered
plastic (MLP). First, the specific density and coefficient of thermal expansion of RPL-
MLP are evaluated. Compression, tension, flexure, and shear tests are also carried out
on the RPL-MLP using displacement-controlled and load-controlled testing machine.
All tests are carried out using pertinent ASTM standards. MLP exhibits excellent
deformation capability, although the ultimate failure is a brittle mode. The report also
discusses the challenges involved in testing such a material and ideas to improve its
structural performance. It can be concluded that RPL-MLP lumber can be used in low
stress building applications.

ii
 TABLE OF CONTENTS
Page
ACKNOWLEDGEMENT i
ABSTRACT ii
LIST OF TABLES v
LIST OF FIGURES vi
ABBREVIATIONS xi
NOTATIONS xii

CHAPTER 1 INTRODUCTION 1

CHAPTER 2 LITERATURE REVIEW 3

2.1 Preliminary Literature Review 3
2.2 Research Gap 8

CHAPTER 3 PROBLEM STATEMENT AND OBJECTIVES 9

CHAPTER 4 EXPERIMENT METHODOLOGY 10

4.1 Tension Tests 10
4.1.1 Significance and Use 10
4.1.2 Apparatus 10
4.1.3 Procedure 11
4.2 Coefficient Of Linear Thermal Expansion And Specific Gravity 11
4.3 Compression Tests 12
4.3.1 Significance and Use 12
4.3.2 Apparatus 12
4.3.3 Procedure 12
4.4 Flexural Tests 13
4.4.1 Significance and Use 13
4.4.2 Apparatus 13
4.4.3 Procedure 13
4.5 Shear Tests 15
4.5.1 Significance and Use 15
4.5.2 Apparatus 15
4.5.3 Procedure 15
4.5.4 Calculations 16

CHAPTER 5 RESULTS AND ANALYSIS 17

5.1 Tension Tests on RPL Members 17
5.2 Specific Gravity on RPL Members 22
5.3 Thermal Expansion Co-efficient on RPL Members 23
5.4 Compression Tests on RPL Members 24
5.5 Flexural Tests on RPL Members 29
5.6 Shear Tests on RPL Members 34
5.7 Compression tests on HDPE 43
5.8 Tension Tests on HDPE 48
5.9 Specific Gravity on HDPE 51
5.10 Coefficient of linear thermal expansion determination on HDPE 53
iii
 TABLE OF CONTENTS
5.11 Flexural Tests on HDPE 53
5.12 Shear Tests on HDPE 57

CHAPTER 6 COMPARISONS AND CONCULSIONS 63

CHAPTER 7 SCOPE FOR FUTURE WORK 66

CHAPTER 8 REFERENCES 67

ANNEXURE 1 CONFERENCE CERTIFICATE 70

ANNEXURE 2 POSTER PRESENTATION AT IIT BOMBAY 71

ANNEXURE 3 CONFERENCE PAPER 72

iv
 LIST OF TABLES

Table Title Page

5.1 Determination of Specific Gravity 22

5.2 Determination of Linear coefficient of thermal expansion 24

5.3 Compression Test Results 29

5.4 Flexural Test Results 34

5.5 Shear Test Results 43

5.6 Compression Modulus and Compressive Strength 47

5.7 Bulk Density Calculation for 5 specimens 52

5.8 Linear Coefficient of Thermal Expansion on HDPE 53

5.9 HDPE – Flexural Strength and Displacement 57

5.10 HDPE Shear Strength of Specimen 52

6.1 RPL Vs HDPE Comparison of Properties 63

v
 LIST OF FIGURES

Figure Title Page

Four-point loading Demo figure through the relevant ASTM Code 14

4.1
Dimensions of the Type-3 Dog-Bone shaped specimen in
17
5.1 accordance with relevant ASTM Code

5.2 Dog-Bone shaped specimen prepared inhouse 18

Three Nos. of Dog-Bone shaped specimen with rectangular mild

steel plates attached with them to avoid crushing of the specimens 18
5.3
during testing

5.4 Side View of failed specimen after conducting tensile test 19

5.5 Failure pattern of Dog – Bone shaped specimen 19

5.6 Failed Specimen while conducting the Test 20

5.7 Load-Displacement (Tensile tests) 21

5.8 Stress Strain Curve (Tensile test) 21

5.9 Squared Prism shaped specimens 23

5.10 RPL cube for compression 25

5.11 Failure pattern of the RPL cube in compression 25

5.12 Stress strain graph for compression of all 3 specimens 26

5.13 Load-Displacement Graph for first specimen in compression 27

5.14 Load-Displacement Graph for second specimen in compression 27

5.15 Load-Displacement Graph for third specimen in compression 28

5.16 Compression cube placed in UTM Machine 28

vi
Figure Title Page

5.17 Specimen failed in compression 29

Specimens kept in joist and plank position respectively of

5.18 30
dimensions 600 mm ×120 mm × 30 mm.
Load-Displacement graph for the first specimen kept in plank
5.19 30
position
Load - Displacement graph for the second specimen kept in plank
5.20 31
position
Load-Displacement graph for the third specimen kept in joist
5.21 31
position.
Load-Displacement graph for the fourth specimen kept in joist
5.22 32
position

5.23 Load-Displacement graph for 2 nos. of specimens in plank position 33

5.24 Load-Displacement graph for 2 nos. of specimens in joist position 33

5.25 Flexural Testing 34

Front view of Shear Punch tool box with dimensions mentioned in

5.26 35
inches

5.27 Plunger to facilitate the failure of specimens. 35

5.28 Load-Displacement Graph for first specimen in shear 36

5.29 Load-Displacement Graph for second specimen in shear 36

5.30 Load-Displacement Graph for third specimen in shear 37

5.31 Load-Displacement Graph for fourth specimen in shear 37

5.32 Load -Displacement Graph for fifth specimen in shear 38

5.33 Combined stress strain graph for shear of 5 specimens 38

5.34 Combined Load-Displacement graph for shear of 5 specimens 39

vii
Figure Title Page

5.35 Dimensions of shear punch toolbox 39

5.36 Shear punch tool setup 40

5.37 Side view of Punch shear toolbox 40

5.38 Shear specimen prepared in accordance with relevant ASTM code 41

5.39 Failure pattern of shear specimen 41

5.40 Top view of shear punch tool setup 42

5.41 Shear test in progress 42

5.42 HDPE Cube for Compression 44

5.43 Failure Pattern of the HDPE Cube in Compression 44

5.44 Stress-Strain Plot of HDPE 45

5.45 Load-Displacement Graph for First Specimen in Compression 45

5.46 Load-Displacement Graph for Second Specimen in Compression 46

5.47 Compression Cube HDPE Placed in UTM Machine 46

5.48 HDPE Specimen failed in Compression 47

Dimensions of the Type-3 Dog-Bone Shaped Specimen in

5.49 48
Accordance with relevant ASTM Code

5.50 Dog-Bone Shaped Specimen Prepared In-house 48

Dog-Bone Shaped Specimen with Rectangular Mild Steel Plates

5.51 Attached with them to Avoid Crushing of the Specimens During 48
Testing

5.52 HDPE Tensile Test Conduction 49

viii
Figure Title Page

5.53 Failure pattern of Dog-Bone shaped specimen 50

5.54 Load-Displacement (Tensile tests) – HDPE 50

5.55 Stress-Strain Curve for HDPE Tensile Test 51

5.56 Squared Prism Shaped Specimens 51

5.57 HDPE Specimen Kept in Plank Position 54

5.58 HDPE Specimen Kept in Joist Position 54

5.59 Failure Pattern of Specimen in Plank Position for HDPE 55

5.60 Failure Pattern of Specimen in Joist Position for HDPE 55

Load Vs Displacement Curve for HDPE Specimen kept in Plank

5.61 56
Position
Load Vs Displacement Curve for HDPE Specimen kept in Joist
5.62 56
Position

5.63 Shear HDPE Specimen before Testing 57

5.64 Shear Test Conduction 58

5.65 Failure Pattern of HDPE specimen in Shear 58

5.66 Load Vs Displacement Graph for First HDPE Specimen 59

5.67 Load Vs Displacement Graph for Second HDPE Specimen 59

5.68 Load Vs Displacement Graph for Third HDPE Specimen 60

5.69 Load Vs Displacement Graph for Fourth HDPE Specimen 60

5.70 Load Vs Displacement Graph for Fifth HDPE Specimen 61

ix
Figure Title Page

Combined Load Vs Displacement Graph for HDPE Shear

5.71 61
Specimens

5.72 Combined Stress-Strain Curve for HDPE Shear Specimens 62

6.1 Bar Chart Showing Properties Comparison 64

6.2 Specific Gravity Comparison 65

x
 ABBREVIATIONS

HDPE High Density Polyethylene

LCCA Life Cycle Cost Analysis

MLP Multi-Layered Plastics

PET Polyethylene Terephthalate

RCC Reinforced Cement Concrete

RPL Recycled Plastic Lumber

UTM Universal Testing Machine

WPC Wood Plastic Composites

xi
 NOTATIONS

𝛼
Coefficient Of Linear Thermal Expansion

𝜀𝑝𝑘 Strain At Peak Stress

𝜀𝑡𝑝𝑘 Strain At Peak Tensile Stress

𝜀𝑡𝑢 Tensile Strain at Ultimate

𝐸𝑐𝑜𝑚𝑝 Modulus of Elasticity, MPa

𝐸𝑓𝑙𝑒𝑥 Flexural Modulus, MPa

Lo
Initial Length of the specimen in mm

L Length at a given temperature of the specimen in mm

T Temperature, K

xii
 CHAPTER 1
INTRODUCTION

Plastic is one of the most useful manufactured materials to date. However, they are non-

biodegradable and often lead to environmental pollution [1]. Upscaling of plastic and reuse is

not very common, especially with domestic plastic waste. To reduce the impact on landfills

and use plastic waste in a useful manner, some up-scaling of plastic in the form of recycled

plastic lumber (RPL) has been attempted in the past [2]. The use of RPL has been successfully

demonstrated in manufacturing outdoor furniture which are subject to low stresses [3].

Recycled PET (Polyethylene Terephthalate) is used as geotextiles, roof insulations and apparel

[4]. Recycled plastic tiles have also been recently used in the construction of pavements in

Bengaluru, India [5]. Recycled plastic aggregate has been extensively used in the

manufacturing of sustainable concretes [6]. However, the quantity of recycled plastic

consumed in concrete is only a fraction and hardly solves the problem at hand. One of the major

drawbacks of RPL has been to maintain consistency in the material properties. Further, low

compression and flexural modulus and low density seem to limit their applications in load-

resisting structural forms. RPL inherently exhibits a visco-elastic behaviour leading to

increasing deformations under sustained loads [7]. It is known that the properties of RPL are

dependent on the thermal treatment they are subjected to. When RPL is subjected to higher

temperatures, it has shown lesser strength in comparison to specimens subjected to cooler or

sub-zero temperatures [8]. RPL is also susceptible to fire, as it has very low fire rating.

Nevertheless, RPL has been used in marine pilings and corrosive environments and has shown

durable performance [9]. Despite the drawbacks, RPL can potentially become an alternate

structural construction material on a large scale through engineered solutions. The absence of

standard codal provisions limits its use at a commercial scale. Recycled plastic lumber

manufactured using multi-layered plastics (RPL-MLP) (collected through domestic waste) can

1
be engineered as a sustainable material for developing structural members. To test the efficacy

of this material, it is important to ascertain its mechanical properties.

In the present study, mixed multi-layered recycled plastic sourced from domestic waste are

studied. The lumber elements are manufactured by commercial plastic manufacturers in

Mumbai. The mechanical properties such as compression strength, compression modulus,

flexural strength, flexural modulus, tensile strength, tensile modulus, shear strength, coefficient

of thermal expansion, specific density and exposure to high temperatures are studied through

experiments.

2
 CHAPTER 2
LITERATURE REVIEW

2.1 PRELIMINARY LITERATURE REVIEW

The earliest records of plastic lumber's characteristics and processing may be found in the early

1970s, when processing methods for the material were created in Europe and Japan [10]. Since

post-industrial plastic scrap was the only affordable supply of plastic at the time, it made up

the majority of the plastic lumber that was produced. However, the plastic lumber sector did

not originally enjoy any kind of major expansion.

The standard extrusion and injection procedures are the foundation of the Klobbie intrusion

system, which was created in the 1970s. It is made comprised of a cooling water tank, numerous

rotating moulds, and an extruder. In the extruder, the plastic material is combined, melted, and

then pressed into one of the moulds. After the mould has been filled, the carousel turns so that

a new mould may be filled. The full mould is then cooled by being placed in the chilled water

tank before being ejected. Linear profiles and thick wall mouldings may be created using this

method [11].

Technologies created starting in the 1980s include Superwood (Ireland), Advanced Recycling

Technology (Belgium), and Hammer's Plastic Recycling (United States). The ET/1 (Extruder

Technology 1) equipment created by Advanced Recycling Technology is an adiabatic extruder

that can handle mixed waste plastics of various densities to create posts, rods, stakes, boards,

etc. In contrast to the Klobbie technique, Hammer's Plastic Recycling's method produces linear

profiles like planks in addition to thick wall sections like pallets, animal feeders, and bench

brackets. Other techniques, such the Reverzer process used by Mitsubishi Petrochemical to

produce large cross-section products, have been developed for the continuous extrusion of

profiles under refrigeration. There have also been earlier compression moulding efforts, like as

3
the Recyclo-plast method used in Germany to create thick wall components including pallets,

benches, and grating [12].

The development of wood-plastic composites (WPC) to replace wood with recycled plastic

lumber in decking and fencing came about in the 1990s as a result of the aforementioned efforts

in equipment design. Under the direction of Professor Eloisa Biasotto Mano, the Institute of

Macromolecules of the Federal University of Rio de Janeiro launched the first line of

university-level research in the 1990s, pioneering investigations on plastic recycling for the

creation of plastic timber. The Centre of Excellence in Recycling and Sustainable Development

at the same institute created a laboratory size plastic recycling machine and pilot scale

equipment in 2009.

Even though the technology to acquire recycled plastic timber has advanced, the building sector

was unable to employ it in the early 1990s, especially for structural purposes, due to a lack of

standardisation. A set of ASTM standards that were initially applicable to plastic lumber

produced from high-density polyethylene (HDPE) were developed by the Plastic Lumber Trade

Association [14].

The structural characteristics of recycled plastic/sawdust timber decking boards were

thoroughly investigated [15]. Standard 2 by 6 plastic lumber planks were evaluated in the

related study endeavour at -23.3 C and 40.6 C to imitate winter and summer circumstances,

respectively. The permitted strength and stiffness for design would be determined by the high

temperature values since it was noticed that the strength and stiffness at high temperatures was

lower than at low temperatures. The plastic lumber's high temperature modulus was 5.79, 1.03,

and 1.12 GPa in compression, flexure, and tension, respectively, while it was 5.31 MPa in shear

strength. The compressive, flexural, and tensile strengths of the plastic lumber would be

equivalent to those of timber lumber in the winter. Plastic lumber has a lower modulus in

compression, flexure, or tension than timber lumber for testing that simulate summer weather.

4
When a building is loaded, the low modulus causes more internal deflections, which in some

circumstances may render plastic timber unsatisfactory. Duraboard® plastic lumber is a

superior option for compression members than most other plastic lumber materials because its

compression modulus is higher than that of other plastic lumber products. The Duraboard® is

a subpar option for tensile members due to its relatively low tensile strength. Most of the time,

plastic lumber has sufficient stiffness and flexure strength, but the size of the components must

be bigger than if hardwood lumber were used. Plastic lumber may be used in structural

applications despite not being as rigid and sturdy as hardwood lumber. Simple strength and

stiffness values for the plastic lumber must be used by the designer when creating the

construction.

In order to demonstrate the utility and application of plastic lumber made from pure HDPE and

its composite with wood for various purposes, efforts have been made to experimentally

evaluate its mechanical properties [16]. The experiment took into account several

circumstances. The initial production and testing of pure plastic lumber and wood plastic

composite timber takes place at room temperature and below. Bending, tensile, and impact

strength were assessed under each circumstance. Eight samples were prepared for each test in

accordance with international standards, and the tests were carried out using accepted testing

equipment. The outcome demonstrates that pure plastic lumber has superior weight carrying,

tensile load resistance, and impact load resistance properties at room temperature. The

specimen was suspended at two places and had a weight applied to it in the middle to assess

the specimen's ability to carry a load.

According to the values obtained from results of the bending test, specimens 1 and 2 of the

HDPE plastic lumber behaved under loading at 14.61 N/m𝑚2 and 14.7 N/ m𝑚2 , respectively.

The wood composite has very limited capacity to resist the tensile force, similar to the bending

test. The pure HDPE timber value at room temperature is designated by the curve in their study

5
as being around 42 N/mm2. The tensile test showed the two types of lumber's elastic behaviour

and tensile load bearing capabilities. The outcome of WPC timber is little impacted by

temperature. This leads us to the conclusion that under certain tensile loading conditions, pure

HDPE lumber exhibits a considerable value difference from WPC lumber and has

demonstrated itself to be more capable of withstanding tensile loads. At room temperature, the

impact test specimens for pure HDPE timber are 2.5 Kg/m and 2.67 Kg/m. 0.5Kg/m and

0.5Kg/m for WPC timber. However, the proportional variables revealed a notable distinction

between the two species of timber. Compared to WPC lumber, HDPE lumber has a greater

potential to absorb energy. By increasing its strength capabilities, HDPE plastic lumber may

be utilised for structural purposes in addition to furniture goods, it was determined in the end.

Numerous methods, including as production procedures, matrix pattern selection, composite

material selection, wood plastic composition % selection, etc., may be used to increase the

plastic's strength capacity while avoiding moisture content in the material. Plastic lumber is

also technically and economically possible since the creation of wood plastic composites

employs basic technology and both waste plastic and wood.

Investigations have been done to solve problems with RPL's long-term performance and

durability [17]. Although many elements influence long-term performance, it is widely

recognised that the effort is concentrated on four main ones: creep deformation under sustained

load, external weathering impacts, thermal expansion, and hygrothermal cycling brought on by

freeze-thaw. According to the hygrothermal cycling and weathering studies, these elements are

not anticipated to have an impact on RPL constructed mostly from recycled HDPE. The LCCA

of RPL constructions in comparison to those made of more conventional materials like wood

is one of the durability evaluation's major effects. Compared to pressure-treated wood, RPL

constructions are anticipated to last far longer, need less care, and have no negative

environmental effects. RPL can therefore be justified as a superior material option for some

6
constructions based on a life cycle perspective. This is particularly valid for applications such

as home decks, marine docks, and other waterfront structures.

Another experimental study was carried out to ascertain the relationships between recycled

plastic lumber's mechanical properties and design considerations, taking into account the

feedstock's composition, member sizes, service temperatures, service stress levels, loading

durations, and loading orientation. To find out how these diverse elements affected the strength

and stiffness of plastic timber, a thorough experimental investigation was conducted. A

comprehensive creep test programme using 2x4 and 2x6 plastic lumber members at various

stress levels was used to build an empirical creep model, which was based on the results of the

tests that were carried out over a period of 1000 hours. It was determined that the manufacturer,

i.e., the resin mix used as feedstock, the member size, and the direction of loading, all affect

the mechanical characteristics of plastic lumber. The findings of the creep research demonstrate

the necessity of modifying the flexural strength and stiffness values to take temperature and

creep into consideration. There are discussed the fundamental ideas for creating load duration

and temperature correction factors. The study makes it clear that plastic lumber's stiffness

attributes, notably its creep characteristics, need to be improved. If this product is to be used in

a wide range of structural applications, methods to increase the stiffness and creep qualities of

these members by inclusion of fillers such as fibreglass need to be vigorously studied. The

study's major goal was to demonstrate how using plastic in building may help minimise the

amount of trash plastic that accumulates across the world [18]. Along with that, how it may

shorten the amount of time and labour needed for building, assist in lowering the number of

fatalities during natural disasters like earthquakes, and help us comprehend the "total plastic"

construction phenomena and its benefits and drawbacks. It was determined that houses built of

recycled plastic had other advantages, such as providing speedy housing at a very low cost.

Anyone who needs a fast and affordable home can purchase one. It might become more

7
affordable than ever with more design optimisation. Houses may be completely put together in

a few days. Such homes should be built in earthquake-prone locations first since their low

material density means that if they fall, no one will be killed. Additionally, they are reassemble-

able if damaged. This will help save lives and the money needed for reconstruction. Maximum

stresses were recorded inside the structure as 2.32 MPa for load-bearing structures and 6.32

MPa, 3.48 MPa, and 3.32 MPa for framed structures, according to computer-based research.

Hence Recycled plastic lumber can withstand both tension (10.15 MPa) and compression

(25.88 MPa) loads. The homes underwent tests for forced, wind, and snow loading, and the

total displacement of the first-floor slab for load-bearing buildings was around 7.5 cm,

compared to 5.5 cm, 3.28 cm, and 2.56 cm for framed constructions. This demonstrates that

although the homes will be secure for habitation, considerable deformations were anticipated

because to a lower elasticity modulus. It suggests that these homes cannot be elevated above

the ground level without additional frame construction or without utilising a different slab

material.

2.2 RESEARCH GAP

Although research works have been carried out previously to determine the mechanical

properties of recycled plastic lumber but lots of investigations are still needed to understand its

behaviour more clearly. Lack of standard codal provisions limits its use on large scale. In this

project, efforts have been carried out to determine its mechanical properties related to strength

and stiffness in load-controlled and displacement-controlled setup first time in India probably.

8
 CHAPTER 3
PROBLEM STATEMENT AND OBJECTIVES

The main focus of this project is to carry out the investigations on the suitability of recycled

plastic lumber as an alternate structural construction material and then to perform a

comparative analysis of structural properties investigations between recycled plastic lumber

and HDPE (High density Polyethylene).

The objectives of this project are:

• To investigate the properties of recycled plastic lumber as an alternate structural

construction material

• To perform a comparative analysis between the investigations regarding structural

properties of RPL-MLP (Recycled Plastic Lumber-Multi Layered Plastic) and HDPE

(High Density Polythylene)

9
 CHAPTER 4
EXPERIMENTATION METHODOLOGY

The definition of plastic lumber is clearly defined in ASTM Codes. Plastic lumber, which often

has a rectangular cross-section and is used as a building material for similar uses to traditional

timber, is a manufactured good constructed mostly from plastic components (filled or unfilled).

It can be of 2 types viz virgin and recycled plastic lumber. In this project, all the studies have

been conducted on recycled plastic lumber considering environmental implications in the mind.

4.1 TENSION TESTS

4.1.1 Significance and Use

Tensile characteristics are known to change depending on specimen preparation, testing speed,

and testing environment. Therefore, these aspects need to be carefully controlled when exact

comparative findings are needed. It is understood that evaluating a material necessitates

examining the preparation process as well. Therefore, unless the test is to incorporate the

effects of sample preparation, we must take great care to guarantee that all samples are

produced in the same manner when comparative examinations of materials are needed.

Similarly, we should be careful to ensure the highest level of uniformity in preparation,

treatment, and handling details for referee reasons or comparisons within any particular set of

specimens.

4.1.2 Apparatus

A testing device of the continuous rate-of-crosshead-movement kind, primarily consisting of

the elements that follow:

• Fixed Member — A grip-carrying fixed member that is basically motionless.

10
 • Movable Member — A moveable part that carries a second grasp is known as a

movable member.

• Grips — Fixed or self-aligning grips may be used to hold the test specimen between

the testing machine's fixed and moveable members.

4.1.3 Procedure

• Each specimen's breadth and thickness are measured in millimetres.

• Set the specimen in the testing machine's grips, being careful to line up their long axes

with a hypothetical line connecting the spots where the grips attach to the machine.

• Starting the instrument after setting the testing speed to the appropriate rate.

• Captured the specimen's load-extension curve.

• Captured the load and elongation at the rupture as well as the load and development at

the yield point (if such existent).

4.2 COEFFICIENT OF LINEAR THERMAL EXPANSION AND SPECIFIC

GRAVITY

The following equation determines the coefficient of linear thermal expansion, 𝛼, between

temperatures 𝑇1 and 𝑇2 for a specimen whose length is 𝐿0 at the reference temperature.,

1 𝐿2 −𝐿1 1 𝛥𝐿
𝛼= . = . (4.1)
𝐿0 𝑇2 −𝑇1 𝐿0 𝛥𝑇

Where 𝐿1 and 𝐿2 will be denoting the specimen piece chosen lengths at different temperatures

𝑇1 and 𝑇2 , respectively. 𝛼 is, calculated by subtracting the linear expansion per unit length

from the temperature change.

11
4.3 COMPRESSION TESTS
4.3.1 Significance and Use

When used in situations that are like the settings in which the experiments are conducted,

compression testing can reveal information regarding the compressive characteristics of

plastics. For study and creation, assurance of quality, approval or disapproval under

regulations, and special objectives, compression measurements offer a standard means of

acquiring data. In applications with large differences from the load-time scale of the normal

test, the tests cannot be regarded as meaningful for engineering design. Additional testing are

needed for these applications, including fatigue, creep, and impact tests..

4.3.2 Apparatus

• Testing Machine — Any appropriate testing apparatus that can regulate a consistent

pace of crosshead movement.

• Compression Tool — Compression tools are used to apply pressure to test specimens.

4.3.3 Procedure

• At several locations along the specimen's length, the specimen's breadth and thickness

(or diameter) were measured. The cross-sectional area's minimum value was then

determined and noted. The specimen's length was also measured, and the result was

noted.

• • Carefully positioned the test sample across both sides that formed the compression

tool, making sure that both ends of the specimen were parallel to the outermost layer of

the compression tool and that the long axis' centre line was in line with the plunger's

centre line. The testing device's crosshead should be adjusted such that it barely touches

the leading edge of the compressive tool plunger.

• Starting the machine while adjusting the speed control to 0.5 mm/min.

12
 • Noted the greatest load that the test specimen could bear (often, this is the load near the

point of rupture).

4.4 FLEXURAL TESTS

4.4.1 Significance and Use

This test method's determination of flexural characteristics is particularly beneficial for

studying and developing, quality assurance, approval or denial of results within requirements

and special uses.

4.4.2 Apparatus

• Testing Machine — A fully calibrated testing device with a moveable head that can

move at a steady speed and accuracy of 61% of the maximum load anticipated to be

recorded. It must have a tool for measuring deflection. If the overall deformation due

to elastic forces of the system exceeds 1% of the overall deflection of the subject's

sample during testing, the stiffness of the testing apparatus must be adjusted

appropriately.

• Loading Noses and Supports —The surfaces of the loading noses and supports must

be cylindrical. For all specimens, the radius of the noses and supports must be at least

0.5 inches (12.7 mm) in order to prevent excessive indentation of the failure caused by

stress concentration right beneath the loading nostrils.

4.4.3 Procedure

• Flatwise or “Plank” Testing

Used an untested specimen for each measurement. Firstly, measured the width of the specimen

to a precision of 1 % of the measured dimensions at several points along the product’s length

and recorded the average value. Then, measured the depth of the specimen at several points

and recorded the average values.

13
The support span was set to within 1% of the calculated value after determining it to be

employed as indicated in the preceding section. The axes of the cylindrical surfaces were

parallel when the loading noses and supports were placed, and the load span was set to be a

third of the support span. A plate with parallel grooves allows for a parallelism check by

accommodating the loading noses and supports when they are correctly aligned. placing the

specimen in the middle of the supports, with its long axis parallel to the loading noses and

supports. The loading nose assembly must be of the non-rotating kind. taking load-deflection

measurements while simultaneously applying the load to the specimen at the chosen crosshead

rate. Figure 4.1 shows that (A) is equal to 12.7 mm and (B) is equal to 1.5 times the specimen

length for maximum radius.

Figure 4.1 Four-point loading Demo figure through the relevant ASTM Code

• Edgewise or ‘’Joist’’ Testing

Procedure will be same as Plank type position testing.

14
4.5 SHEAR TESTS

4.5.1 Significance and Use

One of the accepted ways for comparing materials, gathering information for engineering

design reasons, or both is to acquire shear strength using punch-type equipment. However, it

must be acknowledged that for end-use applications, there are probably going to be a lot of

variables that aren't taken into account by this test technique, such stress-concentrating

geometries and shear rates, which may have a significant impact on the observed shear strength.

Furthermore, the fact that the shear strength is computed by dividing the load by the sheared

edge's area (punch circumference X specimen thickness) does not imply that the shear strength

value derived in this manner is exclusively a material feature, independent of thickness.

4.5.2 Apparatus

• Testing Machine

• Shear Tool

• Micro-meters

4.5.3 Procedure

Measured the thickness of each test specimen at a minimum of three points from its centre.

Then, average the readings and recorded the same as specimen thickness. Further placing the

specimen over the 9.5-mm (3 ⁄ 8-in.) threaded pin of the punch and fastened it in place by

securing the washer and nut tightly. Centring the specimen and punch on the support fixture

and completed the assembly of the clamping fixture being sure to tighten the bolts securely.

Loaded the test specimen at a crosshead specimen at 0.5 mm/min. Pushed the punch far enough

through the specimen so that the sheared section clears the specimen proper. The specimen was

15
then adjacent to the necked-down portion of the punch, and it was then readily removed from

the tool.

4.5.4 Calculations

Shear strength was calculated in megapascals, or MPa, or pounds-force per square inch, or psi,

by dividing the load needed to shear the piece of material by the area of the sheared edge, which

was calculated as the product of the specimen's thickness and punch's circumference.

16
 CHAPTER 5
RESULTS AND ANALYSIS

5.1 TENSION TESTS ON RPL MEMBERS

Tension tests were carried out on dog-bone shaped samples cut out of RPL members in

accordance with ASTM D638-22 standards [20]. Corresponding to rigid and semi-rigid

plastics, type-3 specimens were prepared following relevant ASTM codes as shown in the

Figure 5.2. (The Type III specimen must be used for all materials with a thickness of greater

than 7 mm (0.28 in.).

Figure 5.1 Dimensions of the Type-3 Dog-Bone shaped specimen in accordance with relevant
ASTM Code

The specimen was fabricated in-house inside the laboratories of IIT BOMBAY following the

exact dimensions mentioned in the corresponding ASTM code with slight variations wherever

necessary mentioned in Figure 5.1.

17
 Figure 5.2 Dog-Bone shaped specimen prepared inhouse

Figure 5.3 Three Nos. of Dog-Bone shaped specimen with rectangular mild steel plates
attached with them to avoid crushing of the specimens during testing.

The specimen had a cross-section size of 19 mm × 19 mm and gauge length of 50 mm as shown

in the figure. shown in Figure 2. The tests were carried out using a displacement controlled

UTM at a rate of 5 mm/minute as shown in Figure 5.6.

18
 Figure 5.4 Side View of failed specimen after conducting tensile test

Figure 5.5 Failure pattern of Dog – Bone shaped specimen

There were challenges in carrying out the tension test on the UTM as the grips had to be

prestressed to an optimal value without crushing the specimen. Initially, the gripping pressure

in the hydraulic machine was coming to be about 20.684 N/𝑚𝑚2 and as a result, dog-bone

shaped specimens were getting crushed making it very difficult to determine its tensile strength.

Rectangular Mild steel plates were attached to all the four extended portions (front faces) of

the specimens as shown in Figure 5.3 to avoid the crushing of the specimen, but it was not that

much successful unfortunately. Then, appropriate rectifications were applied by technicians

inside the machine due to which pressure became controllable to about 6.894 N/𝑚𝑚2 . After a

few initial trials, the gripping pressure was controlled, and the test was carried out. Despite

these challenges, a very good curve was obtained in the stress-strain plot finally.

19
 Figure 5.6 Failed Specimen while conducting the Test.

The failure pattern of the dog-bone sample failed in tension is shown in Figure 5.4. The stress-

strain plot generated is shown in Figure 5.8. It can be seen that peak tensile stress is 3.0 MPa.

The initial tensile stiffness (modulus of elasticity, 𝐸𝑡𝑒𝑛 ) is about 210 MPa (207.998 MPa). The

tensile strength was found to be 2.98 MPa which is comparative to normal strength concrete.

The strain at peak tensile stress (𝜀𝑡𝑝𝑘 ) is about 0.025, while the tensile strain at ultimate (𝜀𝑡𝑢 )

is 0.05. This shows that the RPL member is highly deformable under tension.

20
 3.0

2.5

2.0
Load (kN)

1.5

1.0

0.5

0.0
0 1 2 3 4 5
Displacement (mm)

Figure 5.7 Load-Displacement (Tensile tests)

3.0

2.5

2.0
Stress (MPa)

1.5

1.0

0.5

0.0
0.00 0.02 0.04 0.06 0.08 0.10
Strain (mm/mm)

Figure 5.8 Stress Strain Curve (Tensile test)

21
5.2 SPECIFIC GRAVITY ON RPL MEMBERS

When two densities are measured by weighing in air, specific gravity is the ratio of one

substance's density to a standard reference material (such pure water). Here also, efforts have

been carried out to find the specific gravity and bulk density of RPL-MPL (Recycled Plastic

Lumber-Multi Layered Plastic) using water displacement method.

Table 5.1 Determination of Specific Gravity

Volume Specific Gravity

Weight of displacement (Weight of Bulk

S. No Specimen in = Weight of specimen in Density

air (g) Specimen in air/Weight of (Kg/𝒎𝟑 )

water (g) Specimen in water)

1 53 50 1.06 981

2 51.8 50 1.036 959

3 51.9 50 1.038 961

4 50.9 50 1.018 942

5 49.9 50 0.998 924

Efforts were also made to conduct the determination of specific gravity test using GP Thinner

(specimens were able to sink fully in that instead of water) using the methodology described in

ASTM D6111-19 standards [23] however, the results were not conclusive. Thus, results using

that method. were discarded. The specimens used here were squared prisms of dimensions 60

mm × 30 mm × 30 mm as shown in Figure 5.9.

22
 Figure 5.9 Squared Prism shaped specimens

A beaker was filled with water up to the mark of 700 ml. Then after sinking the RPL-MPL

specimens in each case, the water mark increased to 750 ml. Thus, volume displacement in this

case was found to be 50 ml for each specimen and accordingly, the weight of each specimen

in water would be 50 g. The average specific gravity was found to be as 1.03 and detailed

readings are tabulated as shown in Table 5.1.

5.3 THERMAL EXPANSION COEFFICIENT ON RPL MEMBERS

The test specimens were conditioned at –30, 73.4, and 140°F 63.6°F (–34.4, 23, and 60°C 6

2°C) for not less than 48 h at each temperature prior to testing, unless otherwise specified by

the customer or product specification. In cases of disagreement, the tolerance shall be 61.8°F

(61°C).

23
 Table 5.2 Determination of Linear coefficient of thermal expansion

Linear
Coefficient of
Initial
Changed Thermal
Specimen No. Length Temperature (°C)
Length (mm) Expansion
(mm) 1 𝐿2 −𝐿1
{ . }
𝐿0 𝑇2 −𝑇1
1 60.6 -34 60 9.104 x 10−4
2 62.7 24 63.2 4.124 x 10−4
3 62 -34 61.7 4.171 x 10−4
4 61.5 60 61.7 2.258 x 10−4
5 61.1 24 61.2 2.273 x 10−4
6 60.1 60 60.3 4.068 x 10−4

Test Conditions—I conducted the measurements in a laboratory atmosphere of 73.4 6 3.6°F

(23 6 2°C), within 1 min or less after removal from the conditioning environment unless

otherwise specified by the customer or product specification. In cases of disagreement, the

tolerance shall be 61.8°F (61°C) following the standards given in corresponding ASTM code

(ASTM D6341-21) [24]. but in my cases, there was no such issues. The results are tabulated

as shown in Table 5.2.

-
5.4 COMPRESSION TESTS ON RPL MEMBERS

Using the RPL samples available, cubes of size 31 mm × 31 mm × 31 mm were cut and milled

ensuring the specimen to be square and having straight edges, without any visible internal

defects (cavities) as shown in Figure 5.10. The samples were weighed, and their densities

evaluated. The compression tests were carried out in compliance with ASTM D695-15

standards [19] using a servo-controlled strain-based universal testing machine. The specimen

was subjected to a rate of loading corresponding to 0.5 mm/minute. The test was carried out

on three samples to verify the repeatability and consistency. The failure pattern of the cube

failed in compression due to crushing is shown in Figure 5.11.

24
 Figure 5.10 RPL cube for compression

Figure 5.11 Failure pattern of the RPL cube in compression

The stress-strain plots generated are shown in Figure 5.12. It can be seen that peak compressive

stress is in the range of 22.5 to 28 MPa, which can be attributed to the presence of micro-voids

in the sample.

25
 30

25

20
Stress (MPa)

15

10
Specimen 1
Specimen 2
5
Specimen 3

0
0.0 0.1 0.2 0.3 0.4 0.5
Strain (mm/mm)

Figure 5.12 Stress strain graph for compression of all 3 specimens

The strain at peak stress ((𝜀𝑝𝑘 ) is in the range of about 0.12 to 0.25, while the strain at ultimate

((𝜀𝑢 ) is 0.40 to 0.44. The initial stiffness (modulus of elasticity (𝐸𝑐𝑜𝑚𝑝 ) of the three samples

is ranged between 280 - 353 MPa.

The individual Load-Displacement graphs for all the 3 specimens are given below.

26
 30

25

20
Load (kN)

15

10

0
0 2 4 6 8 10 12 14
Displacement (mm)

Figure 5.13 Load-Displacement Graph for first specimen in compression

25

20

15
Load (kN)

10

0
0 2 4 6 8 10 12 14
Displacement (mm)

Figure 5.14 Load-Displacement Graph for second specimen in compression

27
 25

20
Load (kN)

15

10

0
0 2 4 6 8 10 12 14
Displacement (mm)

Figure 5.15 Load-Displacement Graph for third specimen in compression

Figure 5.16 Compression cube placed in UTM Machine

28
 Figure 5.17 Specimen failed in compression.

Even though having a disadvantage in terms of low compression modulus, it can still be used

in high deformable structures with the help of appropriate investigations. Such materials find

applications in high-seismic regions, where the drift demands can be significant. The addition

of fillers and additives can further improve the compression modulus and density of such

materials. The detailed results consisting of compression modulus and compressive strength

for all the three specimens are tabulated in the table given below.

Table 5.3 Compression Test Results

S. No. Compression Modulus Compressive Strength

(SPECIMENS) (MPa) (MPa)
1 280.99 25.35
2 337.13 23.10
3 353.85 29.13

5.5 FLEXURAL TESTS ON RPL MEMBERS

Flexure tests were carried out on RPL samples cut out of lumbers in accordance with ASTM

D6109-19 standards [21]. The specimens had a size of 600 mm ×120 mm × 30 mm as shown

in figure 5.18. The specimen were tested in both joist and plank positions with joist position

and plank position conduction of testing shown in Figure 13-(c ) and 13- (d) respectively.

29
 Figure 5.18 Specimens kept in joist and plank position respectively of dimensions 600 mm
×120 mm × 30 mm.

Efforts were done to conduct this test in displacement-controlled setup firstly with the test

speed as 110 micro m/sec but the graphs obtained were not coming good so no conclusive

results could have been formulated using them in future so further interpretations of results was

not done although for reference load-displacement graphs for all the 4 specimens (2 specimens

in joist position while the other 2 specimens in plank position) are shown below.

Load Vs Displacement Curve

4.5

3.5

3
Load (kN)

2.5

1.5

0.5

0
0 5 10 15 20 25
Displacment (mm)

Figure 5.19 Load-Displacement graph for the first specimen kept in plank position

30
 Load Vs Displacemnt Curve
3.5
3
2.5
2
Load (kN)

1.5
1
0.5
0
0 5 10 15 20 25 30 35
-0.5
-1
Displacemen (mm)

Figure 5.20 Load - Displacement graph for the second specimen kept in plank position.

Load Vs Displacement Curve

7

5
Load (kN)

0
0 1 2 3 4 5 6
Displacement (mm)

Figure 5.21 Load-Displacement graph for the third specimen kept in joist position.

31
 Load Vs Displacement Curve
6

4
Load (kN)

0
0 1 2 3 4 5 6 7
Displacement (mm)

Figure 5.22 Load-Displacement graph for the fourth specimen kept in joist position.

The reasons for these could be that the available machine inside the laboratory was

manufactured primarily for testing concrete structures etc.

Then efforts were done to conduct this test in load-controlled setup. The failure pattern of the

flexure beam (joist position) is shown in Figure 5.25 ( c) while for the plank position it is shown

in Figure 5.25 (d) . The tests were carried out in a load controlled bending test machine with a

rate of loading of 20 N/s. The load-deflection plot of the specimen in joist and plank positions

are shown in Figure 5.23 and 5.24 respectively.

32
 3.0

2.5

2.0
Load (kN)

1.5

1.0

0.5
Specimen3
Specimen4
0.0
0 5 10 15 20 25 30 35
Displacement (mm)

Figure 5.23 Load-Displacement graph for 2 nos. of specimens in plank position

12

10

8
Load (kN)

2 Specimen1
Specimen2
0
0 2 4 6 8 10 12 14 16
Displacement (mm)

Figure 5.24 Load-Displacement graph for 2 nos. of specimens in joist position

33
 Figure 5.25 Flexural Testing

The flexural modulus, 𝐸𝑓𝑙𝑒𝑥 for joist and plank positons range from 10.5 MPa - 12.9 MPa and

6.3 - 6.7 MPa respectively. The detailed results for all the 4 specimens for plank and joist

positions both are tabulated below:

Table 5.4 Flexural Test Results

S. No. Plank Joist Plank Joist Flexural Flexural

(Speci Position Position Position Position Modulus Strength
mens) (MPa) (MPa)
Peak Load Peak Load Max. Max.
(kN) (kN) Displacement Displacement
(mm) (mm)
1 - 12.02 - 15.377 12.93 55.64

2 - 7.565 - 8.765 10.50 35.13

3 2.069 - 19.83 - 6.71 9.63

4 2.718 - 30.989 - 6.33 12.54

5.6 SHEAR TESTS ON RPL MEMBERS

Shear tests were carried out on RPL samples cut out of lumbers in accordance with ASTM

D732-17 [22].

34
 Figure 5.26 Front view of Shear Punch tool box with dimensions mentioned in inches

Figure 5.27 Plunger to facilitate the failure of specimens.

The specimens prepared were 50 mm × 50 mm (square shaped) having a thickness of 10

mm with a central hole of 11 mm diameter, to facilitate the failure of specimens as shown

in the figure 19. The individual load-displacement graphs for all the 5 specimens are given

below.

35
 Load Vs Displacement Curve
8

5
Load (kN)

0
0.00E+00 5.00E-01 1.00E+00 1.50E+00 2.00E+00 2.50E+00 3.00E+00 3.50E+00 4.00E+00
-1
Displacement (mm)

Figure 5.28 Load-Displacement Graph for first specimen in shear

Load Vs Displacement Curve

8

6
Load (kN)

0
-0.5 0 0.5 1 1.5 2 2.5 3 3.5
-1
Displacement (mm)

Figure 5.29 Load-Displacement Graph for second specimen in shear

36
 Load Vs Displacement Curve
8

5
Load (kN)

0
0 0.5 1 1.5 2 2.5 3 3.5
Displacement (mm)

Figure 5.30 Load-Displacement Graph for third specimen in shear

Load Vs Displacement Curve

8

6
Load (kN)

0
-0.5 0 0.5 1 1.5 2 2.5 3 3.5 4
Displacement (mm)

Figure 5.31 Load-Displacement Graph for fourth specimen in shear

37
 Load Vs Displacement Curve
7

5
Load (kN)

0
0 0.5 1 1.5 2 2.5 3 3.5
Displacement (mm)

Figure 5.32 Load -Displacement Graph for fifth specimen in shear

The combined load-displacement and stress-strain graph for all the 5 specimens are also

provided here.

10

8
Stress (MPa)

4
Specimen 1
Specimen 2
2 Specimen 3
Specimen 4
Specimen 5
0
0.00 0.01 0.02 0.03 0.04 0.05
Strain (mm/mm)

Figure 5.33 Combined stress strain graph for shear of 5 specimens

38
 8

5
Load (kN)

3
Specimen 1
2 Specimen 2
Specimen 3
1 Specimen 4
Specimen 5
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Displacement (mm)

Figure 5.34 Combined Load-Displacement graph for shear of 5 specimens.

Figure 5.35 Dimensions of shear punch tool box

39
 Figure 5.36 Shear punch tool setup

Figure 5.37 Side view of Punch shear toolbox

40
Five samples were tested to check the repeatability of results by maintaining the rate of

loading as 0.5 mm/minute and corresponding stress-strain curve is shown above in graph

18.

Figure 5.38 Shear specimen prepared in accordance with relevant ASTM code.

Figure 5.39 Failure pattern of shear specimen

41
The punch shear toolbox was fabricated in-house for conducting this test following relevant

ASTM code as shown in figure 5.36 and 5.37 and the conduction of test shown in Figure

5.41.

Figure 5.40 Top view of shear punch tool setup

Figure 5.41 Shear test in progress

42
The failure pattern of the specimen is shown in Figure 5.39. The shear strength was found to

be ranging from 7.47 MPa to 9.31 MPa. The detailed results are tabulated as below.

Table 5.5 Shear Test Results

S. No. of Specimens Shear Strength (MPa)

1 7.471

2 9.214

3 8.982

4 8.455

5 9.309

5.7 COMPRESSION TESTS ON HDPE

Using the HDPE (High Density Polyethylene) samples available, cubes of size 21 mm × 21

mm × 21 mm were cut and milled ensuring the specimen to be square and having straight edges,

without any visible internal defects (cavities) as shown in Figure 5.42. The samples were

weighed, and their densities evaluated. The compression tests were carried out in compliance

with ASTM D695-15 standards [19] using a servo-controlled strain-based universal testing

machine. The specimen was subjected to a rate of loading corresponding to 0.5 mm/minute.

The test was carried out on two samples to verify the repeatability and consistency. The failure

pattern of the cube failed in compression due to crushing is shown in Figure 5.43.

43
 Figure 5.42 HDPE Cube for Compression

Figure 5.43 Failure Pattern of the HDPE Cube in Compression

The stress-strain plots generated are shown in Figure 5.44. It can be seen, that peak compressive

stress is in the range of 248-270 MPa.

44
 300

250

200
Stress (MPa)

150

100

50 SPECIMEN 1
SPECIMEN 2

0
0.0 0.2 0.4 0.6 0.8 1.0
Strain (mm/mm)

Figure 5.44 Stress-Strain Plot of HDPE

The strain at peak stress ((𝜀𝑝𝑘 ) is in the range of about 0.82 to 0.85, while the strain at ultimate

(𝜀𝑢 ) is 0.82 to 0.86. The initial stiffness and modulus of elasticity (𝐸𝑐𝑜𝑚𝑝) of the three samples

is ranged between 146.79 – 159.10 MPa.

The individual Load-Displacement graphs for all the 2 specimens are given below.

140

120

100
Load (kN)

80

60

40

20
Specimen 1

0
0 2 4 6 8 10 12 14 16 18 20
Displacement (mm)

Figure 5.45 Load-Displacement Graph for First Specimen in Compression

45
 140

120

100

80
Load (kN)

60

40

20
Specimen 2

0
0 5 10 15 20
Displacement (mm)

Figure 5.46 Load-Displacement Graph for Second Specimen in Compression

Figure 5.47 Compression Cube HDPE Placed in UTM Machine

46
 Figure 5.48 HDPE Specimen failed in Compression.

As observed it is having low compression modulus even compared to RPL and thus proving

the point that RPL can still be used in high deformable structures with the help of appropriate

investigations. The detailed results consisting of compression modulus and compressive

strength for all the two specimens are tabulated in the table given below.

Table 5.6 Compression Modulus and Compressive Strength

S. No. Compression Modulus Compressive Strength

(SPECIMENS) (MPa) (MPa)
1 146.79 12.49
2 159.10 11.33

It was observed that HDPE shows ductile behaviour in failure while RPL brittle one and the

results of lower compressive strengths for HDPE justifies the same.

47
5.8 TENSION TESTS ON HDPE
Tension tests were carried out on dog-bone shaped samples cut out of HDPE members in

accordance with ASTM D638-22 standards [20]. Corresponding to rigid and semi-rigid

plastics, type-3 specimens were prepared following relevant ASTM codes as shown in the

Figure 5.49. (The Type III specimen must be used for all materials with a thickness of greater

than 7 mm (0.28 in.).

Figure 5.49 Dimensions of the Type-3 Dog-Bone Shaped Specimen in Accordance with
relevant ASTM Code

Figure 5.50 Dog-Bone Shaped Specimen Prepared In-house

Figure 5.51 Dog-Bone Shaped Specimen with Rectangular Mild Steel Plates Attached with
them to Avoid Crushing of the Specimens During Testing.

48
The specimen was fabricated in-house inside the laboratories of IIT BOMBAY following the

exact dimensions mentioned in the corresponding ASTM code with slight variations wherever

necessary mentioned in Figure.

The specimen had a cross-section size of 19 mm × 19 mm and gauge length of 50 mm as shown

in the figure. The tests were carried out using a displacement controlled UTM at a rate of 5

mm/minute as shown in Figure 5.52.

Figure 5.52 HDPE Tensile Test Conduction

While conducting the test, since we had already experienced how the specimen gets crushed

due to high gripping pressure, thus we already reduced the gripping pressure to about 7

𝑁/𝑚𝑚2.

49
The failure pattern of the dog-bone sample failed in tension is shown in Figure 5.53. The stress-

strain plot generated is shown in Figure 5.53.

Figure 5.53 Failure pattern of Dog-Bone shaped specimen

2
Load (kN)

-2

-4

0 1 2 3 4
Displacement (mm)

Figure 5.54 Load-Displacement (Tensile tests) – HDPE

50
 6

2
Stress (MPa)

-2

-4

0.00 0.02 0.04 0.06 0.08

Strain (mm/mm)

Figure 5.55 Stress-Strain Curve for HDPE Tensile Test

It can be observed that the peak tensile stress is about 4.6 MPa while the peak tensile strain is

about 0.057. The initial tensile stiffness (modulus of elasticity, 𝐸𝑡𝑒𝑛 ) is about 171.24 MPa. The

tensile strength of HDPE was found to be as 4.56 MPa (the value of tensile strength being

higher than of RPL-2.98 MPa only) as its more ductile comparatively.

5.9 SPECIFIC GRAVITY TESTS ON HDPE

The specific gravity was again determined using water displacement method only. In the case

of HDPE also, 5 squared prisms of size 55 mm × 25 mm× 25 mm were fabricated in house.

Figure 5.56 Squared Prism Shaped Specimens

51
A beaker was taken and filled with water up to the mark of 700 ml. Then after sinking HDPE

specimens, the water mark increased to 735 ml. So, our volume displacement in our case= 35

ml for each specimen. Weight of specimen in water= 35 g.

Sample Calculation:

Weight of 1st specimen in air = 31.6 g

Specific gravity = (Weight of specimen in air / Weight of specimen in water) = (31.6/35) =

0.902

Bulk Density= 31.6/ (5.5×2.5×2.5) = 0.919 𝑔 ∕ 𝑐𝑚3 = 919 𝐾𝑔 ∕ 𝑚3

Table 5.7 Bulk Density Calculation for 5 specimens

Specific
Volume Gravity
Weight of displacement = (Weight of
Specimen in air Weight of specimen in Bulk Density
S. No.
(g) Specimen in air/Weight of (𝑲𝒈 ∕ 𝒎𝟑 )
water (g) Specimen in
water)

1 31.6 35 0.902 919

2 32.9 35 0.94 957

3 33.5 35 0.957 974

4 32.5 35 0.928 945

5 32.7 35 0.934 951

The specific gravity is calculated by averaging all the values for 5 specimens=

(0.902+0.94+0.957+0.928+0.934)/5= 0.932.

The bulk Density is calculated again as the average of 5 values= 949.2 𝐾𝑔 ∕ 𝑚3

52
5.10 COEFFICIENT OF LINEAR THERMAL EXPANSION DETERMINATION
ON HDPE
The test specimens were conditioned at –30, 73.4, and 140°F 63.6°F (–34.4, 23, and 60°C 6

2°C) for not less than 48 h at each temperature prior to testing, unless otherwise specified by

the customer or product specification. In cases of disagreement, the tolerance shall be 61.8°F

(61°C).

Table 5.8 Linear Coefficient of Thermal Expansion on HDPE

Linear
Initial Length Temperature Changed
Specimen No. Coefficient of
(mm) (°C) Length (mm)
Thermal
Expansion
1 55.0 -34 54.98 7.0175× 10−5

2 54.8 -34 54.79 6.212×10−5

3 55.0 60 55.11 6.189×10−5

4 55.04 60 55.07 6.383×10−5

5 55.19 23 55.20 6.993×10−5

Average Linear Coefficient of Thermal Expansion 6.558 x 10−5

5.11 FLEXURAL TESTS ON HDPE

Flexural tests were carried out on HDPE samples in accordance with ASTM D6109-19

standards. The specimens had size of 500 mm×60 mm×25 mm. The specimen was tested in

both joist and plank positions with joist position and plank position conduction of testing shown

in Figure and) respectively. The tests were carried out in a load controlled bending test machine

with a rate of loading of 20 N/s. the corresponding failure patterns are also shown here in both

positions. The load displacement graphs for joist and plank position are also provided here.

53
Figure 5.57 HDPE Specimen Kept in Plank Position

Figure 5.58 HDPE Specimen Kept in Joist Position

54
Figure 5.59 Failure Pattern of Specimen in Plank Position for HDPE

Figure 5.60 Failure Pattern of Specimen in Joist Position for HDPE

55
 2.0

1.5
Load (kN)

1.0

0.5

0.0
0 2 4 6 8 10 12 14 16
Displacement (mm)

Figure 5.61 Load Vs Displacement Curve for HDPE Specimen kept in Plank Position

3
Load (kN)

0
0 1 2 3 4 5 6 7 8
Displacement (mm)

Figure 5.62 Load Vs Displacement Curve for HDPE Specimen kept in Joist Position

56
 Table 5.9 HDPE – Flexural Strength and Displacement

Plank Joist Plank Joist

S. No. Position Position Flexural Flexural Position Position
(Specime (Peak (Max. Modulus Strength (Max. (Peak
ns) Load - Displaceme (MPa) (MPa) Displaceme Load -
kN) nt-mm) nt-mm) kN)
1 - 7.277 23.65 47.75 - 4.246

2 1.945 - 15.46 20.05 14.74 -

The flexural strength for the joist and plank position was found to be as 47.75 MPa and 20.05

MPa respectively. The flexural modulus for the joist and plank position was found to be as

23.65 MPa and 15.46 MPa respectively.

5.12 SHEAR TESTS ON HDPE

Shear tests were carried out on HDPE samples cut out of lumbers in accordance with ASTM.

D732-17 [22]. The specimens prepared were 50 mm × 50 mm (square shaped) having a

thickness of 10 mm with a central hole of 11 mm diameter, to facilitate the failure of specimens.

The same punch shear toolbox which was used for the shear testing of RPL specimens used

here following the same methodology. The individual load-displacement graphs for all the 5

specimens are given below.

Figure 5.63 Shear HDPE Specimen before Testing

57
 Figure 5.64 Shear Test Conduction

Figure 5.65 Failure Pattern of HDPE specimen in Shear

58
 12

10

8
Load (kN)

0
0 1 2 3 4 5 6 7
Displacement (mm)

Figure 5.66 Load Vs Displacement Graph for First HDPE Specimen

14

12

10
Load (kN)

0
0 1 2 3 4 5 6 7
Displacement (mm)

Figure 5.67 Load Vs Displacement Graph for Second HDPE Specimen

59
 14

12

10

8
Load (kN)

0
0 1 2 3 4 5 6 7
Displacement (mm)

Figure 5.68 Load Vs Displacement Graph for Third HDPE Specimen

14

12

10
Load (kN)

0
0 1 2 3 4 5 6 7
Displacement (mm)

Figure 5.69 Load Vs Displacement Graph for Fourth HDPE Specimen

60
 14

12

10
Load (kN)

0
0 1 2 3 4 5 6 7
Displacement (mm)

Figure 5.70 Load Vs Displacement Graph for Fifth HDPE Specimen

Five samples were tested to check the repeatability of results by maintaining the rate of loading

as 0.5 mm/minute and corresponding stress-strain curve is shown above in graph.

14

12

10
Load (kN)

6
SPECIMEN 1
4 SPECIMEN 2
SPECIMEN 3
2
SPECIMEN 4
SPECIMEN 5

0
0 1 2 3 4 5 6 7
Displacement (mm)

Figure 5.71 Combined Load Vs Displacement Graph for HDPE Shear Specimens

61
 18

16

14

12
Stress (MPa)

10

6
SPECIMEN 1
SPECIMEN 2
4 SPECIMEN 3
SPECIMEN 4
2 SPECIMEN 5

0
0.00 0.02 0.04 0.06 0.08 0.10
Strain (mm/mm)

Figure 5.72 Combined Stress-Strain Curve for HDPE Shear Specimens

The shear strength was found to be ranging from 14.025 MPa to 17.29 MPa. The detailed

results are tabulated as below.

Table 5.10 HDPE Shear Strength of Specimen

S. No. of Specimens Shear Strength (MPa)

1 14.025

2 16.78

3 16.26

4 17.29

5 16.51

If comparison with shear results of RPL with HDPE, then HDPE was found to be having more

shear strength in comparison with RPL based on the results obtained via tests.

62
 CHAPTER 6
COMPARISON AND CONCLUSION

Table 6.1 RPL Vs HDPE Comparison of Properties

S. No. Properties RPL HDPE

1 Compressive Strength (MPa) 25.86 11.91

2 Compressive Modulus of Elasticity (MPa) 325 152.945

3 Tensile Strength (MPa) 2.98 4.56

4 Tensile Modulus of Elasticity (MPa) 208 171.24

5 Shear Strength (MPa) 8.68 16.17

6 Linear Coefficient of Thermal Expansion (α) 4.33 × 10−4 6.558 × 10−5

7 Flexural Modulus for Joist Position (MPa) 11.71 23.65

8 Specific Gravity 1.03 0.932

9 Flexural Modulus for Plank Position (MPa) 6.53 15.46

10 Flexural Strength for Joist Position (MPa) 45.38 47.75

11 Flexural Strength for Plank Position 11.08 20.05

HDPE was found to be showing its ductile behaviour more compared to RPL (being a brittle

material) as evident from the tabular results also. The tensile strength of HDPE is more than

RPL while compressive strength is less. Even though HDPE shows more promise regarding its

higher shear strength, but RPL can found use in more applications in coming future.

63
The compressive strength of the RPL specimens used in this study was about 25 MPa, which

is comparative to normal strength concrete. Hence the material can be used to resist

compressive forces when acted upon it. However, the initial compression modulus was found

to be only about 325 MPa, which is significantly lesser than concrete having similar

compressive strength. This implies that the material would undergo larger deflections when

subjected to the same load.

The tensile strength of the RPL specimens used in this study was about 3 MPa, which is

comparative to normal strength concrete.

As far as RPL is concerned, material can be used in constructing low stress structural elements,

where deflections are not a concern. However, more tests are needed to confirm its fire

resistance and bonding with reinforcement. This material can be then used in constructing

structural members.

Bar Chart Showing Properties Comparision

350
300
250
200
150
100
50
0
Compressive Strength

Flexural Modulus for

Tensile Strength (MPa)

Tensile Modulus of

Flexural Strength for Joist

Compressive Modulus of

Shear Strength (MPa)

Flexural Modulus for Joist

Plank Position (MPa)

Plank Position (MPa)

Flexural Strength for
Elasticity (MPa)
Elasticity (MPa)

Position (MPa)
Position (MPa)
(Mpa)

1 2 3 4 5 6 7 8 9

RPL HDPE

Figure 6.1 Bar Chart Showing Properties Comparison

64
 Specific Gravity Comparison

1.04
1.02
1
0.98
0.96
0.94
0.92
0.9
0.88
RPL HDPE

Figure 6.2 Specific Gravity Comparison

65
 CHAPTER 7
SCOPE FOR FUTURE WORK

The scope for future work related to this project is that more tests are needed to confirm the

fire resistance and bonding with reinforcement of RPL material. This material can be then used

in constructing structural members.

66
 REFERENCES

[1] Kumar, S., Panda, A.K., Singh, R.K. (2011). A review on tertiary recycling of high-

density polyethylene to fuel. Resources, Conservation and Recycling. 55(11), 893–910.

[2] Baishya, P., Jain, A., Bora, M.P., Goswami, K. (2022). Reduction of groundwater

contamination by converting plastic waste to plastic lumber.

[3] Nosker, T.J., Renfree, R. (2000): Recycled plastic lumber: from park benches to bridges.

In: Approved for Proceedings of R’2000 5th World Congress, Toronto, Canada.

[4] Parkhill, L.D. (1992): Viability of the current market for geotextiles manufactured with

post-consumer recycled polyethylene terephthalate, the. 1990-1999 - Mines Theses &

Dissertations (1992)

[5] Shanker, R., Khan, D., Hossain, R., Islam, M.T., Locock, K., Ghose, A., Sahajwalla,

V., Schandl, H., Dhodapkar, R. (2022): Plastic waste recycling: existing indian scenario and

future opportunities. International Journal of Environmental Science and Technology.1–18.

[6] Jin, R., Chen, Q. (2013): An investigation of current status of “green” concrete in the

construction industry. In: 49th ASC Annual International Conference Proceedings. 1–8.

[7] Chen, C.-W., Salim, H., Bowders, J.J., Loehr, J.E., Owen, J. (2007): Creep behaviour

of recycled plastic lumber in slope stabilization applications. Journal of materials in Civil

Engineering. 19(2), 130–138.

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[8] Carroll, D.R., Stone, R.B., Sirignano, A.M., Saindon, R.M., Gose, S.C., Friedman,

M.A. (2001): Structural properties of recycled plastic/sawdust lumber decking planks.

Resources, conservation and recycling , 31(3), 241–251.

[9] Guades, E., Aravinthan, T., Islam, M., Manalo, A. (2012): A review on the driving

performance of frp composite piles. Composite Structures. 94(6), 1932–1942.

[10] Dos Santos, F.A., Canto, L.B., da Silva, A.L.N., Visconte, L.L.Y., Pacheco, E.B.V.

(2020). Processing and properties of plastic lumber. Thermosoftening Plastics.

[11] Klobbie, E.J. (1980). Method and apparatus for producing synthetic plastics products,

and product produced thereby. Google Patents. US Patent. 4,187,352.

[12] Lampo, R., Nosker, T.J. (1997). Development and testing of plastic lumber materials for

construction applications.

[13] Turku, I., Kärki, T., Puurtinen, A. (2018). Durability of wood plastic composites

manufactured from recycled plastic. Heliyon. 4(3), 00559.

[14] Dias, B.Z., Alvarez, C.E.d. (2017). Mechanical properties: wood lumber versus plastic

lumber and thermoplastic composites. Ambiente Construído. 17, 201–219.

[15] Carroll, D.R., Stone, R.B., Sirignano, A.M., Saindon, R.M., Gose, S.C., Friedman,

M.A. (2001) . Structural properties of recycled plastic/sawdust lumber decking planks.

Resources, conservation, and Recycling. 31(3), 241–251.

[16] Beshah, B., Mitiku, A., Chernet, M., Assefa, M., Addisu, M. (2014): Mechanical

property of plastic lumber produced from recycled high-density polyethylene (HDPE). Science,

Technology and Arts Research Journal. 3(1), 141–144.

68
[17] Krishnaswamy, P., Francini, R. (2000). Long-term durability of recycled plastic lumber

in structural applications.

[18] Gulhane, S.S., Gulhane, S.N. (2017): Analysis of housing structures made from recycled

plastic. Development. 45, 55.

[19] ASTM: Test method for compressive properties of rigid plastics. InternationalASTM.

doi 10 (2010)

[20] ASTM: Test method for tensile properties of plastics. InternationalASTM. doi (2014)

[21] ASTM: Standard test methods for flexural properties of unreinforced and reinforced

plastic lumber and related products. ASTM International. Doi (2013)

[22] ASTM: Standard test method for shear strength of plastics by punch tool.

InternationalASTM. doi (2017)

[23] ASTM: Standard test method for bulk density and specific gravity of plastic lumber and

shapes by displacement. InternationalASTM. Doi (2019)

[24] ASTM: Standard test method for determination of the linear coefficient of thermal

expansion of plastic lumber and plastic lumber shapes between –30 and 140°f (–34.4 and 60°c).

InternationalASTM. doi (2016)

69
 ANNEXURE 1

CONFERENCE CERTIFICATE

Attended and presented my research work in the International Conference at NIT Warangal.

The corresponding certificate is attached below.

INTERNATIONAL CONFERENCE ON “Cement and Building Koncrete for a sustainable

and Resilient infrastructure (CBKR 2023)” conducted between March 28-29, 2023 and was

organised by, Department of Civil Engineering, National Institute of Technology Warangal,

Warangal, Telangana State, India, 506004.

70
 ANNEXURE 2

POSTER PRESENTATION AT IIT BOMBAY

All Research Interns – 2022-23 and the Concerned PIs were instructed that as per the IIT

Bombay Research Internship guidelines, all Interns enrolled for IR-2022-23, were required to

make a Poster Presentation for IIT Bombay community / visitors on the project / research work

done during their respective Internship programme.

In this poster session, the interns were required to design an appropriate poster-paper about

their respective project work for display. Following is my Poster.

71
 ANNEXURE 3

CONFERENCE PAPER
A conference paper titled, “STUDIES ON EVALUATION OF STRUCTURAL PROPERTIES

OF MIXED MULTI-LAYERED RECYCLED PLASTIC LUMBER”, was presented in the

International Conference held at NIT Warangal and is in print. Copy of the paper is attached.

72
 Springer Nature 2021 LATEX template

STUDIES ON EVALUATION OF
STRUCTURAL PROPERTIES OF MIXED
MULTI-LAYERED RECYCLED PLASTIC
LUMBER
Upasana Surya Kiran Γ1,2*, M. N. Shariff Γ2 and U. M.
Sulthana Γ3
1* Department of Civil Engineering, Manipal Institute of
Technology, Manipal, 576104, Karnataka, India.
2 Department of Civil Engineering, Indian Institute of Technology

Bombay, Powai, Mumbai, 400076, Maharashtra, India.

3 Department of Civil Engineering, National Institute of

Technology Tiruchirappalli, Tiruchirappalli, 610101, Tamil Nadu,

India.

*Corresponding author(s). E-mail(s): upasana1.surya@gmail.com;

Contributing authors: shariff@iitb.ac.in; smash@nitt.edu;

Abstract
Severe burdening of landfills due to non-degradable plastic waste depo-
sition is a major environmental hazard. Although there have been
initiatives to use recycled plastic as a building material, it has been
successful only as a non-structural material or as a partial replace-
ment of aggregate in concrete. Further, the present design standards
do not discuss the use of recycled plastic as a construction material.
In this study, an experimental program is carried out to evaluate the
mechanical properties of recycled plastic lumbers (RPL) developed using
mixed multi-layered plastic (MLP). First, the specific density and coef-
ficient of thermal expansion of RPL-MLP are evaluated. Compression,
tension, flexure and shear tests are also carried out on the RPL-MLP
using displacement-controlled and load-controlled testing machine. All
tests are carried out using pertinent ASTM standards. Based on the
preliminary tests, it is found that the material exhibits a compres-
sive strength of about 25 MPa. The flexural modulus is determined to

1
 Springer Nature 2021 LATEX template

2 Article Title

be about 6 MPa and 12 MPa for the specimen kept in plank posi-
tion and joist position respectively. The initial compression modulus
was found to be only about 325 MPa. MLP exhibits excellent defor-
mation capability, although the ultimate failure is a brittle mode. The
paper also discusses the challenges involved in testing such a material
and ideas to improve its structural performance. It can be concluded
that RPL-MLP lumber can be used in low stress building applications.

Keywords: plastic, recycled, mechanical properties, plastic lumber

1 Introduction
Plastic is one of the most useful manufactured materials to date. However,
they are non-biodegradable and often lead to environmental pollution [1]. Up-
scaling of plastic and reuse is not very common, especially with domestic plastic
waste. To reduce the impact on landfills and use plastic waste in a useful man-
ner, some up-scaling of plastic in the form of recycled plastic lumber (RPL)
has been attempted in the past [2]. The use of RPL has been successfully
demonstrated in manufacturing outdoor furniture which are subject to low
stresses [3]. Recycled PET (Polyethylene Terephthalate) is used as geotextiles,
roof insulations and apparel [4]. Recycled plastic tiles have also been recently
used in the construction of pavements in Bengaluru, India [5]. Recycled plas-
tic aggregate has been extensively used in the manufacturing of sustainable
concretes [6]. However, the quantity of recycled plastic consumed in concrete
is only a fraction and hardly solves the problem at hand. One of the major
drawbacks of RPL has been to maintain consistency in the material properties.
Further, low compression and flexural modulus and low density seem to limit
their applications in load-resisting structural forms. RPL inherently exhibits
a visco-elastic behaviour leading to increasing deformations under sustained
loads [7]. It is known that the properties of RPL are dependent on the thermal
treatment they are subjected to. When RPL is subjected to higher temper-
atures, it has shown lesser strength in comparison to specimens subjected to
cooler or sub-zero temperatures [8]. RPL is also susceptible to fire, as it has
very low fire rating. Nevertheless, RPL has been used in marine pilings and
corrosive environments and has shown durable performance [9].
Despite the drawbacks, RPL can potentially become an alternate struc-
tural construction material on a large scale through engineered solutions. The
absence of standard codal provisions limits its use at a commercial scale. Recy-
cled plastic lumber manufactured using multi-layered plastics (RPL-MLP)
(collected through domestic waste) can be engineered as a sustainable mate-
rial for developing structural members. To test the efficacy of this material, it
is important to ascertain its mechanical properties.
 Springer Nature 2021 LATEX template

Article Title 3

In the present study, mixed multi-layered recycled plastic sourced from

domestic waste are studied. The lumber elements are manufactured by com-
mercial plastic manufacturers in Mumbai. The mechanical properties such as
compression strength, compression modulus, flexural strength, flexural mod-
ulus, tensile strength, tensile modulus, shear strength, coefficient of thermal
expansion, specific density and exposure to high temperatures are studied
through experiments.

2 Experimental Program
The primary objective of this testing program is to understand the mechanical
properties of RPL and ascertain its use in structural applications. The tests
were carried out at Indian Institute of Technology Bombay and the National
Institute of Technology Tiruchirappalli. All mechanical property tests were
carried out in ambient conditions of 27°C (± 3°C).

2.1 Compression Tests

Using the RPL samples available, cubes of size 31 mm × 31 mm × 31 mm
were cut and milled ensuring the specimen to be square and having straight
edges, without any visible internal defects (cavities) as shown in Figure 1.
The samples were weighed and their densities evaluated. The compression
tests were carried out in compliance with ASTM D695-15 standards [10] using
a servo-controlled strain-based universal testing machine. The specimen was
subjected to a rate of loading corresponding to 0.5 mm/minute. The test was
carried out on three samples to verify the repeatability and consistency.
The failure pattern of the cube failed in compression due to crushing is
shown in Figure 2.
The stress-strain plots generated are shown in Figure 3. It can be seen
that peak compressive stress is in the range of 22.5 to 28 MPa, which can
be attributed to the presence of micro-voids in the sample. The strain at

Fig. 2: Failure pattern of cube in

Fig. 1: Compression Cube
compression
 Springer Nature 2021 LATEX template

4 Article Title

peak stress (ϵpk ) is in the range of about 0.12 to 0.25, while the strain at
ultimate (ϵu ) is 0.40 to 0.44. The initial stiffness (modulus of elasticity Ecomp )
of the three samples is ranged between 280 - 353 MPa. Even though having
a disadvantage in terms of low compression modulus, it can still be used in
high deformable structures with the help of appropriate investigations. Such
materials find applications in high-seismic regions, where the drift demands
can be significant. The addition of fillers and additives can further improve
the compression modulus and density of such materials.

30

25

20
Stress (MPa)

15

10

Specimen 1

Specimen 2
5
Specimen 3

0.0 0.1 0.2 0.3 0.4 0.5

Strain (mm/mm)

Fig. 3: Stress-strain curve of RPL under compression

A parallel test was also carried out at NIT Trichy on a load-controlled

UTM under the conditions of being thermally treated at 105°C.
The stress-strain plots generated are shown in 4. It can be seen that peak
compressive stress is in the range of 26 to 34 MPa, which can be attributed
to the presence of micro-voids in the sample. The strain at peak stress (ϵpk ) is
in the range of about 0.17 to 0.22, while the strain at ultimate (ϵu ) is about
0.22 to 0.3. This shows that the RPL member is highly deformable under
compression.

2.2 Tension Tests

Tension tests were carried out on dog-bone shaped samples cut out of RPL
members in accordance with ASTM D638-22 standards [11]. The specimen
had a cross-section size of 19 mm × 19 mm and gauge length of 50 mm as
 Springer Nature 2021 LATEX template

Article Title 5

35

30

25
Stress (MPa)

20

15

10
Specimen 1

Specimen 2
5
Specimen 3

0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35

Strain (mm/mm)

Fig. 4: Stress-strain curve of RPL under compression

shown in 5. The tests were carried out using a displacement-controlled UTM

at a rate of 5 mm/minute as shown in 6.
There were challenges in carring out the tension test on the UTM as the
grips had to be prestressed to an optimal value without crushing the specimen.
Rectangular mild steel plates were attached to the bulk heads of the specimen
to avoid the crushing. After a few initial trials, the gripping pressure could be
controlled and the test was carried out.
The failure pattern of the dog-bone sample failed in tension is shown in 7.
The stress-strain plots generated are shown in 8. It can be seen that peak
tensile stress is 3.0 MPa. The initial tensile stiffness (modulus of elasticity
Eten ) is about 210 MPa. The strain at peak tensile stress (ϵtpk ) is about 0.025,
while the tensile strain at ultimate (ϵtu ) is 0.05. This shows that the RPL
member is highly deformable under tension.

2.3 Flexure Tests

Flexure tests were carried out on RPL samples cut out of lumbers in accordance
with ASTM D6109-19 standards [12]. The specimens had a size of 600 mm ×
120 mm × 30 mm as shown in 9a and 9b.
The specimen were tested in both joist and plank positions with joist posi-
tion and plank position conduction of testing shown in 9a and 9b respectively.
The failure pattern of the flexure beam (joist position) is shown in 9c while
for the plank position it is shown in 9d. The tests were carried out in a load
controlled bending test machine with a rate of loading of 20 N/s.
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6 Article Title

Fig. 5: Dog-Bone Shaped Fig. 6: Failure of dog-bone shaped

specimen for tensile test specimen while doing the test

Fig. 7: Failure pattern of

Dog-Bone shaped Specimen in
tensile test

The load-deflection plot of the specimen in joist and plank positions are
shown in Figures 11 and 12 respectively. The flexural strength of the material
was found to be about 11.08 MPa and 45.3 MPa for the specimen kept in plank
and joist position respectively. The flexural modulus Ef lex for joist and plank
positons range from 10.5 MPa - 12.9 MPa and 6.3 - 6.7 MPa respectively.

2.4 Shear Tests

Shear tests were carried out on RPL samples cut out of lumbers in accordance
with ASTM D732-17 [13]. The specimens prepared were 50 mm × 50 mm
(square shaped) having a thickness of 10 mm with a central hole of 11 mm
diameter, to facilitate the failure of specimens as shown in 13a. Five samples
were tested to check the repeatability of results by maintaining the rate of
loading as 0.5 mm/minute and corresponding stress-strain curve is shown in
10. The punch shear tool box was fabricated in-house for conducting this test
following relevant ASTM code shown in 13b and the conduction of test shown
 Springer Nature 2021 LATEX template

Article Title 7

3.0

2.5

2.0
Stress (MPa)

1.5

1.0

0.5

0.0

0.00 0.02 0.04 0.06 0.08 0.10

Strain (mm/mm)

Fig. 8: Stress-Strain Graph of Tension Test

(a) Specimen kept in joist position while(b) Specimen kept in plank position while
conducting the test conducting the test

(c) Failure pattern of specimen in joist(d) Failure pattern of specimen in plank

position position

Fig. 9: Flexural Tests

in 13c. The failure pattern of the specimen is shown in 13d. The shear strength
was found to be ranging from 7.47 MPa to 9.31 MPa.

2.5 Specific Gravity

Specific gravity is the ratio of the density of a substance to the density of some
substance (such as pure water) taken as standard when both densities are
obtained by weighing in air. Here also, efforts have been carried out to find the
 Springer Nature 2021 LATEX template

8 Article Title

10

8
Stress (MPa)

Specimen 1

Specimen 2

2 Specimen 3

Specimen 4

Specimen 5

0.00 0.01 0.02 0.03 0.04 0.05

Strain (mm/mm)

Fig. 10: Stress Strain Graph for shear tests of 5 specimens

specific gravity and bulk density of RPL-MPL (Recycled Plastic Lumber-Multi

Layered Plastic) using water displacement method.
Efforts were also made to conduct the determination of specific gravity
test using GP Thinner (specimens were able to sink fully in that instead
of water) using the methodology described in ASTM D6111-19 standards
[14]however, the results were not conclusive. Thus, results using that method
were discarded.
The specimens used here were squared prisms of dimensions 60 mm × 30
mm × 30 mm as shown in 14.

Table 1: Determination of specific gravity

Specific Gravity
Volume displacement (Weight of
S.No. Weight of Specimen =Weight of specimen in Bulk Density
(SPECIMENS) in air (g) Specimen in water air/Weight (kg/m3 )
(g) of Specimen
in water)

1 53.0 50 1.060 981

2 51.8 50 1.036 959

3 51.9 50 1.038 961

4 50.9 50 1.018 942

5 49.9 50 0.998 924

 Springer Nature 2021 LATEX template

Article Title 9

12

10

8
Load (kN)

Specimen 1
2
Specimen 2

0
0 2 4 6 8 10 12 14 16
Displacement (mm)

Fig. 11: Load-Displacement Graph in Joist position for 2 specimens

A beaker was filled with water up to the mark of 700 ml. Then after sinking
the RPL-MPL specimens in each case, the water mark increased to 750 ml.
Thus, volume displacement in this case was found to be 50 ml for each specimen
and accordingly, the weight of each specimen in water would be 50 g. The
average specific gravity was found to be as 1.03 and detailed readings are
tabulated as shown in 1.

2.6 Coefficient of Thermal Expansion

Linear coefficient of thermal expansion (α) was determined after keeping six
recycled plastic lumber specimens having dimensions of 60 mm × 30 mm
× 30 mm as shown in 14 at the temperatures prescribed in ASTM D6341-
21 standards [15] for not less than 48 hours. It was observed that α varied
significantly between the specimens as shown in 2.
The results of all tests carried on RPL are summarised in Table 3.

3 Conclusion
The following conclusions can be drawn for the experimental study.
• The compressive strength of the RPL specimens used in this study was
about 25 MPa, which is comparative to normal strength concrete. Hence
the material can be used to resist compressive forces when acted upon it.
However, the initial compression modulus was found to be only about 325
MPa, which is significantly lesser than concrete having similar compressive
 Springer Nature 2021 LATEX template

10 Article Title

3.0

2.5

2.0
Load (kN)

1.5

1.0

0.5
Specimen 1

Specimen 2

0.0

0 5 10 15 20 25 30 35

Displacement (mm)

Fig. 12: Load-Displacement Graph in Plank position for 2 specimens

Table 2: Determination of Linear coefficient of thermal expansion

Linear
Initial Changed Coefficient
Specimen Temperature of Thermal
Length Length
No. (◦ C)
(mm) (mm) h Expansion i
1 (L −L )
L
× (T2 −T 1)
0 2 1

1 60.6 -34 60 9.104 × 10−4

2 62.7 24 63.2 4.124 × 10−4

3 62 -34 61.7 4.171 × 10−4

4 61.5 60 61.7 2.258 × 10−4

5 61.1 24 61.2 2.273 × 10−4

6 60.1 60 60.3 4.068 × 10−4

strength. This implies that the material would undergo larger deflections
when subjected to the same load.
• The tensile strength of the RPL specimens used in this study was about 3
MPa, which is comparative to normal strength concrete.
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Article Title 11

(a) Shear specimen before testing (b) Shear punch-tool setup box

(c) Shear test in progress (d) Failed shear specimen

Fig. 13: Shear tests

PROPERTIES VALUE
Compressive Strength (MPa) 25.86
Compressive Modulus of Elasticity (MPa) 325.00
Tensile Strength (MPa) 2.98
Tensile Modulus of Elasticity (MPa) 208.00
Shear Strength (MPa) 8.68
Specific Gravity 1.03
Linear Coefficient of Thermal Expansion (α) 4.33 × 10-4
Flexural Modulus For Joist Position (MPa) 11.71
Flexural Modulus For Plank Position (MPa) 6.53
Flexural Strength For Joist Position (MPa) 45.38
Flexural Strength For Plank Position 11.08
Table 3: Combined Test Results

• The flexural and shear strength of the RPL specimens used in this study
was about (45 MPa for joist position and 11 MPa for plank position) and 9
MPa respectively.
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12 Article Title

Fig. 14: Squared Prism shaped recycled plastic lumber specimens

• The material can be used in constructing low stress structural elements,

where deflections are not a concern. However, more tests are needed to
confirm its fire resistance and bonding with reinforcement. This material
can be then used in constructing structural members.
Acknowledgments. The authors thank the lumber plastic material sup-
plied by Shakti Plastics, Mumbai.

Declarations
The authors declare no conflict of interest.

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