See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/345433709

Manufacturing of plastic sand bricks from polypropylene and polyethylene

waste plastic

Article in International Journal of Advanced Science and Technology · June 2020

CITATIONS READS

6 8,199

4 authors, including:

Ganesh Patil Santosh Walke

National University of Science and Technology, Oman National University of Science and Technology, Oman
20 PUBLICATIONS 69 CITATIONS 74 PUBLICATIONS 121 CITATIONS

SEE PROFILE SEE PROFILE

Nageswara Rao Lakkimsetty

National University of Science and Technology, Oman
211 PUBLICATIONS 489 CITATIONS

SEE PROFILE

All content following this page was uploaded by Nageswara Rao Lakkimsetty on 07 November 2020.

The user has requested enhancement of the downloaded file.

 International Journal of Advanced Science and Technology
Vol. 29, No. 08, (2020), pp. 2062- 2068

Manufacturing of plastic sand bricks from polypropylene and polyethylene

waste plastic
Ganesh N. Patil1, 2*Marwa al Yahmedi2, Santosh M. Walke2` L. N. Rao2
1. School of Chemical Engineering, VIT University, Vellore, Tamilnadu 632014, India.
2. Department of Mechanical & Industrial Engineering, College of Engineering, National University of Science and
Technology, Muscat, Oman
Address: College of Engineering, National University of Science and Technology, Al Seeb, Muscat, Oman
*Email: ganeshpatil.nsk@gmail.com, ganeshpatil@nu.edu.om
Mobile: 968 98513937
Abstract (or Summary)

Bricks are widely used in construction industries has been undergoing gradual structural changes to cope up with
increasing economic and environmental constraint on industries. Environmental pollution due to accumulation of
high percentage of plastic waste can be reduced by utilizing waste plastic in bricks industries. This benefit
construction industry by filling the gaps of demands of building materials, and disposal of plastic waste through
recycling instead of the process of landfilling, or burning, etc. This article presents the experimental setup for
manufacturing of plastic sand bricks from polyethylene & polypropylene, characterization of new bricks and
comparison of the same with sand bricks. Six plastic sand brick samples were prepared based on different plastic to
sand ratio. Testing was performed to determine compressive strength, efflorescence, water absorption, soundness,
and fire resistance test. Results showed that the plastic sand bricks have higher hardness, durability,low water
absorption rate and zero effloresce and is a effective source to reduce plastic waste.

Key words: plastic bricks, polyethylene, polypropylene, sand bricks, plastic waste.

1. Introduction

Concrete bricks are the most common material used in construction industry. Red clay bricks have certain
disadvantages like greenhouse emission due to combustion. Paihte P. L. et al did experimental study on Material-
filled waste plastic bottle by combining construction waste and plastic bottle waste. It is as best alternative for the
red bricks providing comparable compressive strength. Plastic bottles prepared from finer aggregates having size
less than 425 μm showed higher compressive strength [1-2]. Mondal M. K. studied the properties of plastics bricks
manufactured from polycarbonates, polystyrenes,and mixed plastics, fly ash, sand and ordinary cement [3]. The
bricks manufactured shows high thermal resistance and compressive strength more than 17 Mpa[3]. Cheeseman C.
et al studied the low density polyethylene (LDPE) sand blocks which shows compressive strength up to 27 Mpa. The
density and compressive strength were inversely proportional to sand particle size. LDPE bonded sand brick shows
30% load retention after failure [4]. Shiri N. d. et al compared compressive load on three types of bricks i. e.
polypropylene and rubber, LDPE and rubber, clay bricks. Among these three types’ polypropylene and rubber
composite plastic sand brick provides highest compressive load up to 17 tons [4-6,7].

ISSN: 2005-4238 IJAST 2062

Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 08, (2020), pp. 2062- 2068

Pakrashi et al performed compression test, sound insulation assessment, light transmission on the bricks
manufactured from waste Polyethylene Terephthalates (PET) bottles. It was identified that manufactured Eco bricks
have certain advantages like high sound reduction index, reduce the chances of injury due to lifting heavy materials,
non-brittle, light weight, and reduction in transportation cost [8]. Wahid et al studied the effect of waste plastic to
sand ratio for manufacturing of plastic sand bricks. Due to decrease in adhesive strength between cement and plastic,
compressive strength decreases with increase in plastic to sand ratio. This bricks are be suitable for low workability
applications like partition wall panels and canal linings [9-10].

Kognole et al studied the manufacturing of waste plastic bottles mixed with red soil, river sand and stone crush and
performed the compression and water absorption test. It was identified that plastic sand brick can provides highest
compressive load up to 97.5 N and 3% water absorption [5, 11].

Mathewet al manufactured plastic bricks from LDPE plastic pellets, gypsum sand and Prosopis Juliflora tree powder
and performed compression test, drop test and water absorption test [12].

Kumar et al studied the production of plastic bricks by addition of manufactured sand, waste plastic and thermocol
in different proportions and did the characterization tests for the plastic bricks [6, 13]. Kumar et al also studied the
plastic bricks manufactured from fly ash, sludge lime, gypsum, fine aggregate and high density polyethylene waste
plastic bottles in various proportions. Plastics quantity used in the samples was in the range of 5 to 20 % and it was
found that the compressive strength decreases with increase in the plastic percentage [6].

Nursyamsi et al did experimental study on waste plastic bricks by mixing the sand and plastic in different
proportions and performed compressive, water absorption, Efflorescence, Fire resistance and hardness test. It was
suggested that the cost can be reduced further by utilizing the fly ash or quarry dust instead of river sand [14].

Singhal et al compared the compressive strengths of pure concrete block and 4% waste plastics mixed in concrete
block and found that there was a slight deviation in the compressive strength. It was identified that there is
possibility of addition of 2% plastic in solid blocks and 4% plastic in paver blocks [10, 15]. Singhal et al also did
experimental investigation on plastic sand bricks by taking plastic to sand in the ratio of 3:7. IT was identified that
the plastic sand bricks shows zero percent water absorption, 5.6 N/mm2 compressive strength and compression load
taking ability up to 96 KN [15].

Taaffe et al manufactured 20% LDPE plastic sand bricks. Normal bricks and plastic bricks were compared for
absorbance, compressive strength, tensile strength and weight of and found that the normal bricks result in quality I
however 20% LDPE pellets brick results in quality III [16-17].

Walke et al did the experimentation on effective use of plastic waste for production of fuel. The plastic waste is
tested for conversion process using different catalysts and uses are also tested for other uses in sand filling operation
for construction of bricks [1, 18-20].

ISSN: 2005-4238 IJAST 2063

Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 08, (2020), pp. 2062- 2068

2. Experimental Section

2.1 Raw materials& apparatus

Plastic waste material i.e. polypropylene pipes and polyethylene bags, Soft refine sand (1.18 mm soft), Red oxide,
steel molds (205*205*100 mm sizes), Gas cooker, weighing balance, storage drums

Figure 1: Raw materials and apparatus

2.2 Methodology:

(1) Collection of scrap polypropylene pipes and waste polyethylene bags from the local industry in Oman. (2)
Identification of portioning of plastic sand into a defined ratio of (1:2, 2:1, 2:2, 2:3, 2:4, and 2:5) for producing 6
samples of plastic sand bricks. (3) Waste plastic was cleaned to remove all dust and other contaminants and cleaned
plastic were kept to dry for 1 day. (4) Polypropylene and polypropylene waste added into the heater in the ration of
1:1 and heated up to 180 C. Melting point of polypropylene is 160 C and high density polyethylene is 180 C. (6)
Mix 5 gms of red oxide along with the melted mixture to impart dark red color. (7)Sans is added based on the
desired ratios. (8) Mixture was mixed properly using steel rod and poured into the molds. Before pouring the
mixture into the molds, the sides of the molds were oiled for easily removal. (8) Sample were kept for 24 hours for
drying and removed from the molds. It was kept to cure for 14 days. (9) After the curing, Compression test, Water
absorption test, Efflorescence test were done for the sample bricks in laboratory.

ISSN: 2005-4238 IJAST 2064

Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 08, (2020), pp. 2062- 2068

Figure 2: Manufactured Plastic Bricks Samples

Results and Discussion

1. Weight of plastic sand bricks: Weight of each plastic sand brick samples was measured and given in the Table
1. As the sand ratio is increases the weight increases.

SI No Plastic sand ratio Size of dry PSB (mm) Weight of PSB (kg)
1 1:2 (125×195×100) 3
2 2:1 (140×195×100) 4.6
3 2:2 (155×195×100) 4.9
4 2:3 (200×195×100) 6.1
5 2:4 (200×195×100) 7.1
6 2:5 (200×195×100) 7.3
Table 1: Weight of six samples of Plastic sand bricks

2. Effloresces test: Since efflorescence is considered harmless but still it is not acceptable, and that is because in the
case of noticing and proportion of efflorescence on the bricks it may lead over time to a problem of increasing
moisture, thus deterioration such as breaking and peeling. In which it leads to the collapse of the building and needs
to be reform. Through this experience the results obtained from this experiment were not monitored any noticeable
deposit of the efflorescence.
3. Water absorption test:The results obtained of water absorption for plastic sand bricks ranges between 0- 2.82%,
the results are successful since the water absorption standard of the bricks should not absorb water more than 12%
by its weight. Although it is not preferred to have zero water absorption as we get in sample 1, 2, and 6; because in
construction field a small amount of water absorption must exist so that it will prevent any cracks or defect in future.
On the other hand, the obtained result is satisfied since the materials used are waste plastic rather the concrete. The
amount of water absorption measured by using the following formula
𝑊2− 𝑊1
Wa = ( ) ×100
𝑊1

ISSN: 2005-4238 IJAST 2065

Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 08, (2020), pp. 2062- 2068

Where, Wa = water absorption percentage, W1= weight of dry brick sample.

Sample No Plastic sand ratio W1 (kg) W2 (kg) Wa %

1 1:2 3 3 0
2 2:1 4.6 4.6 0
3 2:2 4.9 5 2.04
4 2:3 6.1 6.2 1.64
5 2:4 7.1 7.3 2.82
6 2:5 6.8 6.8 0
Table 2: water absorption test results

4. Compressive strength: From the obtained results it shows that the sample which having a ratio of 2:1 of plastic
sand respectively has the higher value of compressive strength that equals 12.43 N/mm2, in which it illustrate that
whenever the ratio of plastic increased it means it will result in high compressive strength, thus increase the quality
and demand of brick. Therefore, the relationship between plastic ratio and compressive strength is directly
proportional relationship. The third, fourth and fifth brick samples findings ranges between 3.76, 4.41, and 6.25,
which shows a slight increment, but it decreased to 3.84 in the sixth sample which can be due to some defects in the
brick.
The compressive strength of the brick sample can be calculated by using the formula of

𝐴𝑝𝑝𝑙𝑖𝑒𝑑 𝑀𝑎𝑥 𝑙𝑜𝑎𝑑 ×1000 (𝑁)

Compressive strength = 𝑐𝑟𝑜𝑠𝑠
𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑚 𝑚 2

Sample Plastic Dimensions of C/S area (mm2) Max load applied (KN) Compressive
No sand sample (mm) strength
ratio ( N/mm2)
1 1:2 (125×195×100) 120×195= 114.5 4.69
23400
2 2:1 (140×195×100) 150×195= 303.0 12.43
27300
3 2:2 (155×195×100) 155×195= 102.8 3.76
30225
4 2:3 (200×195×100) 200×195= 133.2 4.41
39000
5 2:4 (200×195×100) 200×195= 243.8 6.25
39000
6 2:5 (200×195×100) 200×195= 149.8 3.84
39000
Table 3: Compressive test results

ISSN: 2005-4238 IJAST 2066

Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 08, (2020), pp. 2062- 2068

Conclusion:

The new product of plastic sand bricks produced possess many characteristics and advantages that would take one
more step to the global development, including a reduction in the accumulation of plastic waste by recycling them,
which will lead to the minimization of the traditional disposal methods, thus saving the environment and the living
creatures. Moreover, creating plastic sand bricks which used in construction industries that made from easily
obtained material. The process followed in order to manufacture plastic sand bricks started by collecting raw
materials of waste plastic and soft refined sand, the mixing procedure is subjected on a fire till it turns into liquid
mixture. The whole mixture is then formed using a predesigned mold to get a fixed size plastic sand brick samples.

The results obtained shows that the plastic sand bricks possess new properties that would serve the construction
fields such as, high compressive strength up to 12.43 N/mm2 for plastic sand brick with a ratio of 2:1, as compared
to the normal concrete bricks, zero effloresce, a range of (zero-slight) water absorption, and a good fire resistance,
etc. To conclude, the new product of plastic sand bricks will effectively contribute in the removal of waste plastic,
reduction in the emission of greenhouse gasses, reduction in the use of clay and cement to manufacture bricks, as
well as cost efficiency.

References

[1] Abtihal l Zadjali, Walke, S. (2016). Plastic Recycling to Produce Fuel. International Journal of Emerging
Technologies and Engineering, 3(6), 44–47.

[2] Deepak Shiri, N., Varun Kajava, P., V, R. H., Lloyd Pais, N., & Naik, V. M. (2015). Processing of Waste
Plastics into Building Materials Using a Plastic Extruder and Compression Testing of Plastic Bricks. Journal
of Mechanical Engineering and Automation, 5(3B), 39–42. https://doi.org/10.5923/c.jmea.201502.08.

[3] Mondal, M. K., Bose, B. P., & Bansal, P. (2019). Recycling waste thermoplastic for energy efficient construction
materials: An experimental investigation. Journal of Environmental Management, 240(February), 119–125.
https://doi.org/10.1016/j.jenvman.2019.03.016.

[4] Karthikeyan, M., Balamurali, K., V, B. K., S, M. P., & Janarthanan, R. (2019). Utilization of Waste Plastic in
Concrete Utilization of Waste Plastic in Concrete, (April).

[5] Kognole, R. S., Shipkule, K., & Survase, K. S. | M. P. | L. P. | U. (2019). Utilization of Plastic waste for Making
Plastic Bricks. International Journal of Trend in Scientific Research and Development, Volume-3(Issue-4),
878–880. https://doi.org/10.31142/ijtsrd23938.

[6] Kumar, K. P., & Gomathi, M. (2017). Production of Construction Bricks by Partial Replacement of Waste
Plastics, 14(4), 9–12. https://doi.org/10.9790/1684-1404020912.

[7] Kumi-Larbi, A., Yunana, D., Kamsouloum, P., Webster, M., Wilson, D. C., & Cheeseman, C. (2018). Recycling
waste plastics in developing countries: Use of low-density polyethylene water sachets to form plastic bonded
sand blocks. Waste Management, 80, 112–118. https://doi.org/10.1016/j.wasman.2018.09.003.

[8] S. A Gaikar, R Bhore, S Ambre, Walke. (2015).Stored Potable Water-Evaporation Reduction by Thin Film
Surface Coating. Int. J. Inf. Futur. Res., vol. 2, no. 8, pp. 2929–2935.

[9] Lalzarliana Paihte, P., Lalngaihawma, A. C., & Saini, G. (2019). Recycled Aggregate filled waste plastic bottles
as a replacement of bricks. Materials Today: Proceedings, 15, 663–668.
https://doi.org/10.1016/j.matpr.2019.04.135.

ISSN: 2005-4238 IJAST 2067

Copyright ⓒ 2019 SERSC
 International Journal of Advanced Science and Technology
Vol. 29, No. 08, (2020), pp. 2062- 2068

[10] Lokeshwari, M., Ostwal, N., Nipun, K. H., Saxena, P., & Pranay, P. (2019). Utilization of Waste Plastic as
Partial Replacement of Fine and Coarse Aggregates in Concrete Blocks, 378–382.

[11]Manjarekar, P. A. S. (2017). Utilization of Plastic Waste in Foundry Sand Bricks. International Journal for
Research in Applied Science and Engineering Technology, V(IV), 977–982.
https://doi.org/10.22214/ijraset.2017.4178.

[12] Mathew, J., & Moolayil, J. T. (2018). Fabrication of Plastic Brick Manufacturing Machine and Brick Analysis,
(April 2016).

[13] S. K. Santosh Walke. (2015). Catalyst Deactivation and Regeneration. Int. J. Sci. Eng. Technol., vol. 4, no. 5,
pp. 281–285.

[14] Nursyamsi, N., Indrawan, I., & Ramadhan, P. (2019). The influence of the usage of ldpe plastic waste as fine
aggregate in light concrete bricks, 6, 0–6.

[15] Singhal, A. (2018). UTILIZATION OF PLASTIC WASTE IN MANUFACTURING OF PLASTIC SAND

UTILIZATION OF PLASTIC WASTE IN, (June), 1–5.

[16] Taaffe, J., O’Sullivan, S., Rahman, M. E., & Pakrashi, V. (2014). Experimental characterisation of
Polyethylene Terephthalate (PET) bottle Eco-bricks. Materials and Design, 60, 50–56.
https://doi.org/10.1016/j.matdes.2014.03.045.

[17] X, P. A., P, R. A. S., & M, S. A. J. (2019). Construction materials from the waste plastic, (April).

[18]Vikram P. (2014) ExperimentalCharacterization of Polyethylene Terephthalate 1(PET) Bottle Eco-ricks 60: 50-
56.

[19] Shibi Varghese , Praveen Mathew, Thomas paul, Eldho Varghese. (2013). Recycled Plastic as CoarseAggregate
for Structural Concrete. InternationalJournal of Innovative Research in Science,Engineering and Technology
vol. 2(3).

[20] Puttaraj Mallikarjun Hiremath, Shanmukha shettya(2014.) Utilization Of Waste Plastic In Manufacturing of
Plastic-Soil Bricks, Internationaljournal of technology enhancements and emergingengineering research 2(4):
2347-4289.

ISSN: 2005-4238 IJAST 2068

Copyright ⓒ 2019 SERSC

View publication stats