PLANNING MALAYSIA:

Journal of the Malaysian Institute of Planners

Volume XIII (2017), Page 1 - X

THE PERFORMANCE OF LIGHTWEIGHT CONCRETE WITH

RECYCLED POLYETHYLENE TEREPHTHALATE AND
POLYPROPYLENE AS DEMISING WALL

Chan Lek Heng1, Zalena Abdul Aziz2, Mohd Hafizal Bin Mohd Isa3

School of Housing, Building and Planning

UNIVERSITI SAINS MALAYSIA

Abstract

Concrete is an important construction material worldwide. The objective of this

study is to explore the potential of using lightweight concrete block mixed with
plastic waste and additional plastic material as a sustainable construction material
for constructing a demising wall in Malaysia’s construction industry. The
research has been conducted quantitatively through experiments to test the
density and strength of the materials. A series of experiments was conducted
based on two types of plastics, namely Polyethylene Terephthalate (PET) as a
replacement for coarse aggregate, and Polypropylene (PP) fibres, which
correspond to the percentage of cement mass added into the concrete mix. The
ratios were varied to observe the effects of variations throughout a series of tests.
The findings show that lightweight concrete mixed with 0.5% Polypropylene
(PP) fibres demonstrated outstanding results in terms of compressive strength
compared to the control specimen and PET specimen. It can be classified as high-
strength concrete and shows strong potential as a material for demising walls
while being lighter in weight than contemporary materials. The implication of the
study will contribute to a wider range of options for sustainable building materials
for project designers and architects.

Keyword: Recycled Plastic Waste, Compressive Strength, Building

Construction, Green Building Material

1
Student. Email: chanlekheng@student.usm.my
2
Lecturer at Universiti Sains Malaysia. Email: zalena@usm.my
3
Lecturer at Universiti Sains Malaysia. Email: hafizal@usm.my

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Chan Lek Heng, Zalena Abdul Aziz & Mohd Hafizal Bin Mohd Isa
The Performance of Lightweight Concrete with Recycled Polyethylene Terephthalate and Polypropylene as
Demising Wall
INTRODUCTION
The construction industry in Malaysia plays a vital role as a catalyst for the
economic growth and development of the country (Kamar & Hamid, 2012).
According to statistics by the Department of Statistics Malaysia, in 2015,
Malaysia’s construction sector represented 3-5% of the country’s GDP
(Department of Statistics Malaysia, 2016). On the other hand, the negative
impacts of the construction industry in terms of environmental issues have also
raised the concerns of the government and public. It is reported that Malaysian
construction activities have 67.5%, 21.0% and 11.5% effects on the ecosystem,
natural resources, and the public, respectively (Samaneh et al., 2021).
Sustainable ecological development is a trend nowadays, as people are
more aware of climate change and the destructive effects of the construction
industry on the environment (Sandanayake et al., 2020). Concerning the current
need to protect the environment, concrete plays an essential role mainly due to its
wide usage in the construction industry to be less harmful towards the nature and
maintain the pollution level as low as possible. One of the measures to achieve
this purpose is to replace the concrete cement, partially or totally, with other
cementitious materials that possess pozzolanic proprieties such as heating plants
ash, blast furnace slag, and metakaolin, among others (Bejan et al., 2020). For the
aggregates, materials such as industrial or agricultural waste can be introduced as
part of the concrete aggregate. With the different types of waste aggregate used
to create the concrete block, the block with specific properties can be applied for
different use and functions to achieve a more efficient and sustainable building
construction as well as performance.
Plastic waste has undeniably been a severe environmental problem for
decades. According to GA Circular (2019), at only 16%, Malaysia has the lowest
recycling rate of PET bottles among ASEAN countries (GA Circular, 2019). In
terms of its application as construction material, few studies have suggested that
plastic waste can be used as the replacement for partial aggregate in the concrete
mix, plastic waste such as polyethylene terephthalate (PET) (Iucolano et al.,
2013), (Saikia & De Brito, 2014), polyvinyl chloride (PVC) pipe (Binici &
Aksogan, 2016), high density polyethylene (HDPE) (Shanmugapriya & Helen
Santhi, 2017) and other polymer wastes. Plastic has considerably good properties
to be mixed with concrete as a new type of recycled aggregate lightweight
concrete. This is because it has a lower density, good performance in thermal
insulation, and is waterproof as well as offering noise reduction features (Li et
al., 2020). Malaysia has yet to fully utilise the advantages of recycled plastics in
construction and goods production (Kamaruddin et al., 2017).
Therefore, the objectives of this research are to study the suitability of
LWC mixed with plastic waste as sustainable building material for demising wall
and to identify the strength performance of the LWC mixed with plastic waste.
The significance of this study is to contribute a wider range of sustainable

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 PLANNING MALAYSIA
Journal of the Malaysia Institute of Planners (2017)

building materials choice especially constructing the demising wall for the
designer or architect. By utilising the plastic waste as the partial aggregate
replacement, it is estimated that approximately 30% reduction of the total waste
disposed from solid waste (Kamaruddin et al., 2017). Furthermore, the study also
aims to provide a solution by reducing the dead load and the size of structural
elements due to the replacement of partial aggregates into plastic waste, reducing
the weight of each concrete block.
In this research study, Polyethylene Terephthalate (PET) and
Polypropylene (PP) plastic wastes were chosen as the main subject to be studied
in this research. This is mainly because PET is the most commonly seen plastic
waste, as it mostly derived from used drinking bottles and PP obtained from food
packaging and carpet production. Different types of plastic waste have different
physical and mechanical properties. Various shapes and forms of plastic waste
will be produced based on the type of plastic used and their processing method.
The content, shape and size of the plastic waste are the important factors that
could affect the performance of the concrete, and therefore, different shapes and
sizes will require different amounts and ratios with concrete in order to achieve
optimum performance. These factors are studied by comparing previous research
works.

RESEARCH METHODOLOGY
An empirical study (physical experimental methods) is described in this
research which includes of a series of experimental lab tests. Based on the
literature review, two types of plastic waste, namely Polyethylene Terephthalate
(PET) and Polypropylene (PP) fibres, were selected, and different amounts were
added into a concrete mixture. The variables of the experiment are as follows:

Table 1: The Experiment’s Variables

Variables Description
Manipulated variable Percentage of plastic material in the concrete
Responding variable Density, Slump and Compressive Strength of specimens
Constant variable Dimension and thickness of the concrete blocks, cement
content, amount of fine aggregate, water-to-binder ratio,
amount of water

Materials
Cement
Ordinary Portland Cement (OPC) or ASTM type 1 of YTL Castle brand
was used as the primary binder material in the production of the concrete. The
specific gravity of the selected cement is 3.15 g/cm³.

3 © 2017 by MIP
Chan Lek Heng, Zalena Abdul Aziz & Mohd Hafizal Bin Mohd Isa
The Performance of Lightweight Concrete with Recycled Polyethylene Terephthalate and Polypropylene as
Demising Wall
Aggregates
Crushed granite from the quarry was selected as coarse aggregate for this
batch of concrete production. In this study, the coarse aggregate which was used
was at maximum nominal size of 10mm.The specific gravity of the selected
crushed granite was 2.650.
Fine aggregate is another important material in the production of concrete.
In this case, river sand has been used as fine aggregate for all the concrete
specimens. It contains a high proportion of particles passing through a sieve size
of 4.75mm. The specific gravity of selected river sand was 2.630.

Water
Water is the most crucial agent used to fulfil the functions of the concrete
mixing. It enables the hydration process that transforms the cement content to
form hardened concrete, and it increases the workability of the concrete mixture
to achieve the desired slump value. In the latter stage, water also plays a vital role
in the curing process.

Plastic
At first, the plastic waste will be collected and sorted out according to their
plastic classification. Polyethylene Terephthalate (PET) was used as partial
replacement for coarse aggregate. The amount of PET to be incorporated into the
concrete mixture was controlled at three different percentages – 5%, 10%, and
20% substituting the coarse aggregate.
Polypropylene (PP) fibres were used as additional material to be added into
the concrete mix during the production. The fibres had a length of 19mm with a
mesh fibrillated structure. The material was added as additional material during
the wet mix of the concrete at percentages of 0.5%, 1.0% and 2.0% to the cement
mass of the concrete.

Table 2: Type of Plastic Waste in Concrete and their properties

Variables Characteristics Size Percentage in
concrete
- Higher density -sieve size of - 5%, 10% and
- Lower melting 4.75mm 20%
point
- Higher durability
- Crack resistant

Polyethylene
Terephthalate
(PET) flakes

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 PLANNING MALAYSIA
Journal of the Malaysia Institute of Planners (2017)

- Lower density - 19mm in length - 0.5%, 1.0% and

- Higher melting 2.0%
point
- Heat resistant
- Good chemical
resistant
- Less flexible
Polypropylene
(PP) fibres

Preparation of Specimens
There were total 7 types of mixes in this study. One was an ordinary
concrete mix as a constant; three which had different percentage of aggregates
replacement in the concrete mixture; and another three with different percentages
of additional materials added into the mixture. In this experiment, there were total
21 concrete cube specimens, with 3 specimens for each type of design mix casted
for the compressive strength test in accordance with the standard BS 1881: Part
116: 1983 “Method for Determination of Compressive Strength of Concrete
Cube”.
Table 3: Details of Cube Specimen
Sample Type of Additional Replacement Volume / Number
Name Concrete Cube of Cubes
Mix
OPC100 OPC - - 1000 cm3 3
PET5 OPC - 5% of PET 1000 cm3 3
PET10 OPC - 10% of PET 1000 cm3 3
PET20 OPC - 20% of PET 1000 cm3 3
PF0.5 OPC 0.5% of PP - 1000 cm3 3
PF1.0 OPC 1.0% of PP - 1000 cm3 3
PF2.0 OPC 2.0% of PP - 1000 cm3 3
Note: OPC – Ordinary Portland Cement, PET – Polyethylene Terephthalate, PP – Polypropylene

All mixes were mixed by using the heavy-duty industrial mixer that was
able to mix 10 kg of mixing specimens at once. Once the concrete mixture was
ready, a slump test was carried out in accordance with standards of BS EN 12350-
2:2009 to determine the workability of the concrete. The mixture was poured into
the selected mould with a size of 100 x 100 x 100mm (cube). Specimens were
demoulded after 24±1 hours and placed in the water tank for 28 days of water
curing process. The curing process is crucial to maintain adequate moisture in
concrete at a proper range of temperature to aid cement hydration and develop its
strength and stability in the early ages. After the curing, the concrete specimens
were dried, and the density of the concrete specimens was measured and

5 © 2017 by MIP
Chan Lek Heng, Zalena Abdul Aziz & Mohd Hafizal Bin Mohd Isa
The Performance of Lightweight Concrete with Recycled Polyethylene Terephthalate and Polypropylene as
Demising Wall
recorded. The compressive strength test was then carried out on the specimens to
investigate their strength performance in high compression.

Figure 1: Standard Concrete Cube Specimen in accordance with BS EN 12350-2:200

(a) (b)

Figure 2: (a) LWC mixing with PET, (b) LWC mixing with PP fibres

RESULT
There were 7 types of mix specimens in this study, involving the control
specimen; three mixes with different ratios of Polyethylene Terephthalate (PET)
aggregates replacement in the concrete mixture; and another three with different
ratios of Polypropylene (PP) fibres as additional material added into the mixture.
The measurement and properties of the concrete blocks are recorded after 28 days
of curing, after which the specimens underwent compression tests to ensure the
strength quality of the concrete was up to the standards set by ACI and ASTM.

Density
The concrete density ranged from 2177.66 kg/m3 to 2186.29 kg/m3. The
typical density of normal weight concrete ranges between 2200 and 2400 kg/m3,
while lightweight concrete density is any below 2200 kg/m3 (Lee et al., 2019).

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 PLANNING MALAYSIA
Journal of the Malaysia Institute of Planners (2017)

Therefore, the concrete specimens produced in this experiment were all classified
as lightweight concrete. This result was recorded for a specimen age of 28 days.

Concrete Density
2500.00
2103.45 2068.97 2069.77
2000.00 1931.03 1965.52
2000.00
1724.14
Density, kg/m3

1500.00

1000.00

500.00

0.00
OPC100 PET5 PET10 PET20 PF0.5 PF1.0 PF2.0

OPC100 PET5 PET10 PET20 PF0.5 PF1.0 PF2.0

Figure 4: Average density for all specimens

Note: OPC – Ordinary Portland Cement, PET – Polyethylene Terephthalate, PP – Polypropylene

According to the tests, Figure 4.2 shows that the PET specimens showed a
noticeable deduction in density with an increase in PET. PET20 has the largest
amount of deduction in density at -18% compared to the density of control
specimen. The density decreases as the replacement ratio of PET increases mainly
because the coarse aggregate which initially contributed large amount of weight
and density was replaced by the lightweight PET. Furthermore, the PET
aggregate induced voids in the concrete mix, causing greater void volume within
the concrete matrix structure and therefore resulting the decrease in density
(Osubor et al., 2019). With such low density, it is suitable for use as lightweight
concrete for non-structural component in the construction. However, there was
no distinct pattern could be observed in the density of PF specimens even though
the PF was used as addition material into the concrete mixture, whereas a small
deduction in the concrete density occurred at only -7% on PF2.0 specimen as the
increase of PF amount in the mix as compared to the control specimen. The reason
is the reduction of the compaction degree of the mix, increasing the volume of air
voids in the concrete and resulting in an increase in water absorption and a
reduction of the density for the mature state of the concrete (Hasan et al., 2019).

Compressive Strength
Compressive strength is the most significant factor and usually indicates
the overall quality of the concrete. This is because the results of this test will

7 © 2017 by MIP
Chan Lek Heng, Zalena Abdul Aziz & Mohd Hafizal Bin Mohd Isa
The Performance of Lightweight Concrete with Recycled Polyethylene Terephthalate and Polypropylene as
Demising Wall
ascertain the quality of the concrete is up to the international standards, and
therefore to determine whether it is applicable to continue with other testing
experiments. In the trial mix design, the targeted strength for all the specimens
were chosen to be at 5000 psi, equivalent to 35 MPa. The purpose of this test was
to observe the comparison and contrast that occurs in a normal OPC concrete to
the concrete that uses a replacement material for the coarse aggregates or addition
material into the concrete mix.

Compressive Strength at 28 days of curing

45.00 41.52
39.50
40.00 37.99 37.63
35.38 35.76
Compressive Strength, MPa

35.00
30.00
25.00 21.14
20.00
15.00
10.00
5.00
0.00
OPC100 PET5 PET10 PET20 PF0.5 PF1.0 PF2.0

OPC100 PET5 PET10 PET20 PF0.5 PF1.0 PF2.0

Figure 5: Average compressive strength of the overall specimens at 28 days of curing

Note: OPC – Ordinary Portland Cement, PET – Polyethylene Terephthalate, PP – Polypropylene

All the concrete specimens were all tested at an age of 28 days. The reason
is that the concrete will achieve its true strength on that day. Based on the Table
4.1 and Figure 4.5, it shows that the control specimen – OPC100 had achieved
37.99 MPa, which it is considered as a better M35 grade of concrete. Comparing
the control specimen with other mix design specimens, PET5 and PF0.5
demonstrate better compression strength at 39.50 MPa and 41.52 MPa
respectively. It also shows that PF0.5 has the highest compressive strength,
making it acceptable for use in high-strength building materials. The graph shows
that the concrete specimen PET20 with the replacement of 20% of coarse
aggregate with PET aggregate had a drastic decrease in concrete strength of
almost 57% compared to the control specimen. These reductions are mainly due
to the weak bonds in concrete matrices caused by the replacement of granite
aggregate with excessive PET aggregate. Comparing the compressive strength
results among all the concrete mix design groups, the concrete specimen group
with additional Polypropylene (PP) fibres presented better compression strength

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 PLANNING MALAYSIA
Journal of the Malaysia Institute of Planners (2017)

than the group with Polyethylene Terephthalate (PET) aggregate as a replacement

for the coarse granite aggregate.

DISCUSSION
Through the results obtained from the experiments, density has a direct
relationship with the compressive strength of the concrete specimens. As the
percentage of PET and PP increased in the concrete mix, the density decreases
due to the reduction of using natural coarse aggregate. A graph of the results show
that the density of the concrete is directly proportional to the compressive strength
of the concrete.
The compressive strength tests performed on the concrete specimens show
that the inclusion of Polypropylene (PP) fibres will improve the compressive
strength of the concrete. This is mainly due to the PP fibres’ properties of high
modulus carbon microfiber in controlling the plastic shrinkage cracking of the
concrete with stronger bond between the fibres and concrete matrices. However,
there is a decreasing trend of compressive strength shown in the result, as the
fibre content was added to a certain value. This phenomenon can be explained by
some of the studies done by previous researchers that low workability resulted by
excessive fibres amount lead to the increase of void and air content within the
concrete, which eventually reduces concrete density and compressive strength
accordingly (Yap et al., 2014) (T. W. Ahmed et al., 2020).
However, it can be seen that Polyethylene Terephthalate (PET) as
replacement of coarse aggregate will affect and decrease the compressive strength
of the concrete, this is because of the PET aggregate’s glassy surface that reduced
the friction between the PET aggregate and the concrete mix and therefore
weaken the bond of concrete matrices. The PET20 specimen showed the weakest
compressive strength because of the presence of honeycomb in the concrete. The
honeycomb effect is due to the water-cement ratio, as the greater of water-cement
ratio, the less honeycomb appears.
Generally, it can be concluded that concrete mixed with 0.5%
Polypropylene (PP) fibres achieved the optimum performance in compressive
strength compared to the PET specimen group. The results showed that it could
be significant in contributing to the construction industry in terms of using higher
strength concrete to build higher floors and reducing the dead load of a building
at the same time.

9 © 2017 by MIP
Chan Lek Heng, Zalena Abdul Aziz & Mohd Hafizal Bin Mohd Isa
The Performance of Lightweight Concrete with Recycled Polyethylene Terephthalate and Polypropylene as
Demising Wall
Application in Construction Industry

Figure 6: Comparison of recycled plastic waste used in 1m3 of demising wall

construction

This study also provides the significant result of demonstrating how much
of plastic waste can be recycled through the concrete production. The calculations
in Table 2 show that incorporating 0.5% PP fibres into the 1m3 volume of
demising wall requires around 2kg of PP fibres, which is equivalent to 100 plastic
food containers. Mixing 5% PET into the same volume of wall requires
approximately 54kg of PET flakes, which is equivalent to around 6750 500 ml
plastic water bottles. In the context of recycling waste material, PET has a higher
recycling rate compared to PP fibres to make a 1m3 volume of demising wall as
a non-structural partition to divide the spaces in the building. In future projects
requiring Green Building Index (GBI) or Leadership in Energy and
Environmental Design (LEED) certification, utilising concrete mixed with PET
waste could help to achieve points in the criteria of using recycled content
materials as considerable amount of PET are recycled, especially as lightweight
concrete blocks for walls.

CONCLUSION
Based on this research, the conclusion made from the analysis on the concrete
mixing with plastic are as such:

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 PLANNING MALAYSIA
Journal of the Malaysia Institute of Planners (2017)

1. The results of present study showed that 5% PET replacement of coarse

aggregates gives better compressive strength than ordinary lightweight
concrete at 39.50MPa.
2. From the result, concrete mixed with additional 0.5% of PP fibres presented
the best compression strength with the curing age of 28 days while comparing
with other specimens. With an average compressive strength of 41.5 MPa, it
can be considered high-strength concrete.

The study shown that the lightweight concrete mixed with controlled amount of
plastic waste can be used as a new kind of sustainable building material in
Malaysia for construction due to its optimum performance in compressive
strength. In future, it is recommended that researchers further examine the
properties of both concrete types with different curing times.

ACKNOWLEDGEMENTS
The authors would like to thank Universiti Sains Malaysia for supporting
this study.

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Demising Wall
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