I.

EXECUTIVE SUMMARY

TITLE:

DEVELOPMENT OF DECORATIVE BLOCKS OUT OF

PLASTIC WASTES

INSTITUTION/COLLEGE: COLLEGE OF ENGINEERING

RESEARCHERS:
Project Leader:
MARY STA. MARIA
Assistant Proj. Leader:
MARLON DE GUZMAN
Members:
ARRELYN FAYE BAYUCAN
JOHN REY VERSULA
DEOVANIE SANGABOL
SECTOR:

ENVIRONMENT/CONSTRUCTION MATERIALS

STATUS:

COMPLETED

TYPE:

SCIENCE & TECHNOLOGY

DURATION:

JANUARY-MARCH 21,2016

ABSTRACT

The main aim of this work is to reduce the plastic waste that is rising in the present world
and to achieve this; an experimental research was conducted incorporating a plastic extruder
which plays a prominent part in recycling waste plastic into useful products. This work uses
waste plastics and converts them into building materials with the help of an extruder, thereby
reducing the plastic waste which is a key factor for environmental pollution. Presently waste
plastics are effectively converted into useful building materials like bricks, interlocks, roof
tiles, railway sleepers, paving slabs, retaining blocks etc., using either single origin plastic
waste material or a mixture of different plastic wastes along with waste rubber powder as
filler. After conducting several trials with the variety of plastic wastes processed into
composite brick, it was observed that the maximum compressive load sustained by the
Polypropylene/Rubber composite brick is 17.05 tons followed by LDPE/Rubber composite
brick with 16.55 tons which is much higher than the clay brick which sustained only 9.03
tons.
There are so many organizations helping the cause to reduce plastic production and
eradicate pollution as it rises rapidly. Plastics are not inherently bad, and they have many
redeeming ecological features; in fact, many of the techniques in the design of products
targeted use of plastic. Their durability and low maintenance reduce material replacement,
their light weight reduces shipping energy, their formulation into glue products allows for the
creation of engineered lumber and sheet products from recycled wood, and their into superior
insulation and sealant products improves the energy performance of our structures.
Keywords: Plastic waste, Plastic Extruder, Plastic/Rubber Composite Brick, Compression
Testing

II.

INTRODUCTION

Waste is now a global problem, and one that must be addressed in order to solve the
world's resource and energy challenges. Plastics are made from limited resources such as
petroleum, and huge advances are being made in the development of technologies to recycle
plastic waste among other resources. Plastics are non-biodegradable, synthetic polymers
derived primarily from petro-fossil feedstock and made-up of long chain hydrocarbons with
additives and can be molded into finished products. These polymers are broken in presence
of suitable catalyst, into monomers such as ethylene, propylene, vinyl, styrene and benzene.
These monomers are then chemically polymerized into different categories of plastics.
Plastics are generally categorized as Thermoplastics and Thermoset Plastics. Thermoplastics
can be heated up to form products and then if these end products are re-heated, the plastic
will soften and melt again. These include PET, HDPE, LDPE, PP, PVC, PS etc. Thermoset
plastics can be melted and formed, but once they take shape after they have solidified, they
stay solid and, unlike thermoplastics cannot be re-melted. The impacts of plastic production
in its many forms are heavy in every phase of its life cycle. While there is a common general
understanding that plastics have negative ecological associations, a closer understanding of
what types of plastics create what types of impacts will empower us to improve the toxic
footprint of our buildings.
Toxic chemical release during manufacture is another significant source of the negative
impact of plastics. Other research studied different ways to turn plastic waste into useful
materials like hollow blocks, plastic fuel, plastic asphalt, and decorative tiles.
Another way of turning plastic waste into useful materials that we, the researchers,
studied and experimented is the making of decorative blocks out of plastic wares.

III.

OBJECTIVE
GENERAL OBJECTIVE:
This project aimed to design and develop decorative blocks out of plastic wastes
to help reduce the environmental effects of it.
SPECIFIC OBJECTIVES:
To create decorative blocks that will be comparable to the commercialized
one.
To develop affordable decorative blocks out of plastic wastes.

IV.

REVIEW OF RELATED LITERATURE AND STUDIES

Polypropylene is a type of thermoplastic polymer resin. It is a part of both the average

household and is in commercial and industrial applications. The chemical designation is
C3H6. One of the benefits of using this type of plastic is that it can be useful in numerous
applications including as a structural plastic or as a fiber-type plastic.
One of the benefits it offers to manufacturers is the ability to add dye to it. It can be
colored in various ways without degrading the quality of the plastic. This is also one of the
reasons it is commonly used to make up the fibers in carpeting. It also adds strength and
durability to the carpeting. This type of carpeting can be found effective for use not only

indoors but also outdoors, where damage from the sun and elements doesn't affect it as
readily as other types of plastics. Other benefits include the following:
1. It does not absorb water like other plastics.
2. It does not mold or otherwise deteriorate in the presence of bacteria, mold or other
elements.
3. Newer versions contain an elastic element to them. This gives them a rubber-like
composition and opens the door for new uses.
4. It is unlikely to shatter and will take significant damage prior to breaking, though it is
not as sturdy as other plastics such as polyethylene.
5. It is lightweight and very flexible.

Plastic waste is increasingly becoming an eyesore and is polluting the environment,

especially in high mountain villages where no garbage collection system exists. This plastic
waste can be perfectly reused as source material for thermal insulation. Empty PET and
HDPE bottles are separated into clean and less-clean, and packed in PP fiber bags can be
utilized as thermal insulation material inside housing. Designs are provided for floors, over
ceilings and inside cavity walls. Used PVC shopping bags can be used to insulate water
piping of solar water heaters and warm water piping inside houses. Common nonbiodegradable waste products are re-used as high value thermal insulators, being extremely
needed in the high altitudes to conserve warmth and reduce firewood consumption. A basic
explanation on how thermal insulation works and a comparative table of insulation values are
included. ( Sjoerd Nienhuys.2004)
Recycled Plastic Aggregate (RPA) in concrete is acceptable there are for the making of
concrete used coarse aggregate having size 10mm, natural river sand used for making a
concrete and plastic aggregate used in concrete. Test carried out on these aggregate density,
and sieve analysis., water absorption, all these test conduct on Recycled plastic aggregate
sample conventional aggregate and compressive strength of concrete at 10%, 20%, 30
replacement of plastic aggregate in concrete.( Ganesh Tapkire.2009)
V.
PROJECT DESCRIPTION
The decorative block is a mixture of sand and plastic (Polypropylene) and dissolves
using used oil. The mixture is molded in a scrap tiles and pieces of wood that formed a
hexagonal shape. The product was presented in grayish color since white plastic wares were
used.
The product structural capability varies over its durability. It does not carry loads but
decorative block is useful for plastic wastes make the product non-breakable

VI.

METHODOLOGY

The purpose of this research is to develop a product that will reduce the disposal of
plastic wastes specifically plastic ware which was used to create decorative blocks. This
section includes the materials, procedure and treatment of data.

Research Design
Experimental research design was used in this study. Using trial and error method to
determine what portions of plastic wares and sand will produce a durable decorative blocks.

MATERIALS USED

Plastic wares (Polypropylene)

Sand
Stones
Used oil
Mold
Pan
Ladle

PROCEDURE
Collection of Materials. Wasted plastic chairs were collected as it is one kind of plastic
wares that can be used in the experiment. Then the researchers collected the sand to use it as
an aggregate.
Forming of Mold. Scrap tiles were used as the base of the mold. And by cutting pieces of
lumber, hexagonal shape molders were produced. Used oil was applied to the mold to
prevent the product by sticking into it.

Dissolving of Plastic Wastes. Little amount of used oil was poured into the pan. Pieces of
plastic wares were dipped until it was dissolve by heating. The consistency of the dissolve
plastic wastes was like a paste.
Mixing Sand into the Dissolve Plastic Wastes. When the plastic wastes turned into the
desired consistency, the sand was poured to mix with it. 250grams of sand was the initial
mixture then added another one until the desired one.
Treatment of the Mixtures. The sand was added to the dissolved plastic wastes then mixed
it thoroughly until the whole mixture turned the same. Table VI.1 below shows the proportion
of the components of the decorative blocks for every treatment.

Additives (plastic
Treatment

Sand

250grams

wares)
750grams

750grams

250grams

500grams

500grams

(Table VI.1- Treatment of Data)

After curing the mixture for 30 minutes, it was stripped out of the mold. It was
dried for another 30 minutes then tested its hardness by letting it fall from 3ft. to 6ft. The
hardness of the decorative blocks will be rated in the scale of 1-5; five being the hardest and
one being the least hard.

RESULT & DISCUSSION

This chapter shows the gathered data base on the durability test of the decorative
blocks.
Table VI.1 presents the data about the distribution of materials in every trial. The
researchers went up to three trials to determine what percent of the mixtures to use.

Trial
1
2
3

Durability
4
3
5

(Table VI.2- Test Result)

Table VI.2 shows the difference between three treatments. The findings about the product
are in terms of its physical characteristics and its strength and durability. Trial 1 shows that the
product is a little oily on its physical features; it is also lighter than a normal blocks. However,
when it comes to its strength, it does not easily break because it was pure plastic.
The product on trial 2 is a heavier and is rough in terms of its physical characteristics. But
it is heavier than a normal block. It breaks easily too. The product broke when it was fall to 6ft
high.
The product that was made on trial 3 which contains equal amount of sand and plastic, it
proved to have more durability compared to the previous trials when it was tested. It has a better
physical features also compared to other two.
STRENGTH AND VERSATILITY:
Plastic has high strength-to-weight ratio. Light products mean easier handling, often
eliminating mechanical handling aids and still complying with Health & Safety regulations.
Plastic is versatile with a wide range of construction products being made with recycled plastic.
You could get much of your requirements in the form of recycled plastic construction products.

VII.

CONCLUSION

Recycling plastic is difficult, energy intensive process, and yields a product that could be
inferior to the virgin material.
We have searched that the type of material we used (Polypropylene) has the possibility to
create a competitive product. From the result and discussion of the products being tested, it can
be concluded that:
1. With 50% of sand and 50% of plastic wastes the result will be good. The product that will
be produced could be marketable and comparable to the commercialized decorative
blocks.

2. The strength test showed that the decorative block was hard enough and very durable.
3. Plastic wastes could be a useful building material instead of being thrown up and create
environmental problems.

VIII. RECOMMENDATION
From the data gathered and the based from the result of the experiment, the researchers
came up with the following recommendations:
1. The researchers recommend that to create a useful product out of plastic wastes, they
must use their own creativity so that they could use it to reuse those plastic wastes.
2. A better quality of this product could be produced by finding other mixtures and materials
that will help to increase its durability and reliability.
3. The researchers also recommend trying different type of plastic wastes. And instead of
melting it, they could just granulate the plastic wastes.
IX. CONTRIBUTION TO ENVIRONMENT
By using recycled plastic products, you are telling the world that you care for the
environment. This can go a long way in generating goodwill that can benefit your business.
Recycled plastic products require little maintenance and up keep, are inert and do not
pollute water bodies or soil, and can be fully recycled at the end of their lives.
By using recycled plastic products, you are creating a demand for more recycled plastic
raw materials, removing them from polluting places.
IX.

TIME FRAME

Research Title: Plastic Wastes as additives in the Production of Decorative Blocks and
Concrete Non-bearing Wall Panels.
Activities

1. Surfing the net.

Collecting of data &
information

Jan2529,2016

Jan30-Feb.
5,2016

Feb. 612, 2016

Feb.1326, 2016

Feb.27March4,2
016

March 518,2016

2. Observation to different
manufacturers for
research purposes
3.Collection of facts &
data from different
references/encoding
4.Writing of draft
5.Development of
decorative blocks
6.Testing of the project
7.Submission of
Completion Report

X.

PROBLEM TREE
PROBLEM TREE
(College of Engineering)

Environmental Degradation

F
F
E

Excessive and Frequent

Flooding/Landslide

Health Hazard

C
T

Core Problem:

Improper Disposal of Plastic Wastes

S
Proximate Problem:

Increasing Volume of Plastic Wastes

C
A
U

Improper

Lack of

Unstoppable

Lack of

Govt

Permits

Disposal

Training

Increased

Dump

Policies

Red

Program

Plastic
Production

XI.

Sites &

Tapes

MRF

REFERENCES:
Books

Trey Farmer. September 21, 2009.Plastic Concrete: Building Bricks Made From Landfill
Waste.
Owen, Geiger. 2010.Recycled Plastic Block Houses
Peel, Nicola. 2012.How to Make Eco-Bricks Out of Garbage.
Claire Le Guem Lytie.2008.When the Mermaids Cry: The Great Plasticide.
Sjoerd Nienhuys .2004. Plastic Waste Insulation Re-Use of PET for High Altitude Houses

Web
Ahmed Cherif Megri, Gilbert Achard, Fariborz Hagnihat. 1998. Using plastic waste as thermal
insulation
for
the
slab-on-grade
floor
and
basement
of
a
building.
http://www.sciencedirect.com/science/article/pii/S0360132397000292
http://composite.about.com/od/Plastics/a/What-Is- Polypropylene.htm
http://www.motherearthliving.com/health-and-wellness/harmful-effects-of-plasticzeoz1205zsch.aspx
http://www.utne.com/environment/eco-bricks-zmoz12ndzlin.aspx
https://thinkgreen.wordpress.com/2007/01/23/hello-world/
Managing
Wastes
Through
Recycling
and
Categorized
Disposal.
https://thinkgreen.wordpress.com/2007/03/24/managing-wastes-through-recycling-andcategorized-disposal/

DOCUMENTATION
FABRICATION
Materials

Plastic (Polypropylene)

Tile

Sand

Pan

ladle

Mold

Measuring cups

Forming of Mold

Melting of plastic

Adding the sand to the melted plastic

Mi xture of melted plastic and sand

Decorative block in the mold

OTHER PRODUCTS FROM PLASTICWASTES

Polymer-Aggregate-Bitumen Mix
The polymer bitumen blend is a better binder compared to plain bitumen. The blend has
increased Softening Point and decreased Penetration Value with a suitable ductility. When used
for road construction it can withstand higher temperature. Hence it is suitable for tropical
regions. It has decreased Penetration Value. Hence its load carrying capacity is increased. The
blend with aggregate has no Stripping Value. So it can resist the effect of water.The Marshall
Stability Value is high. The bitumen required can be reduced depending upon the % of polymer
added. It is a good saving too. No toxic gas is produced. Disposal of waste plastic will no longer
be a problem. The binding properties of polymer also improve the strength of mastic flooring.
The use of waste plastics on the road has helps to provide better place for burying the plastic
waste without causing disposal problem. At the same time, a better road is also constructed. It
also helps to avoid the general disposal technique of waste plastics namely land-filling and the
incineration, which have certain burden on ecology.
Wall Cladding

Products such as plastic wall cladding have many advantages, such as hygiene, great
looks, ease of installation, freedom from maintenance and tailor-made properties. Plastic wall
claddings, soffits and fascias are also very popular and the construction industry is a major
consumer of plastic.
However, plastic has a reputation as a non-recyclable and environment unfriendly
material. It is in this context that the campaign to recycle plastic and produce construction
products from recycled plastic assumes great significance.
Wall claddings, soffits and fascias can be made from recycled plastic. Other construction
products being made from recycled plastic include damp proof membranes, water drainage, pipes
and ducting, kerbstones, roofing materials, piling and ground stabilization, scaffolding planks,
decking and flooring products and fencing.
INSULATION
Experimental and theoretical studies were performed to investigate the possibility of
substituting traditional insulation materials with a rigid manufactured polyethylene packing
waste. This procedure is of economic interest and contributes to the protection of the
environment, since the disposal of plastic waste consumes energy and results in emissions of
pollutants to air, water and soil.
The first part involved the measurement of the thermal characteristics of the plastic waste
using a non-isothermal procedure, based on the transient state of temperature. Two methods were
employed: the heat wire method and the ring sensor method. In the second part, a comparative
study was carried out for different building configurations using the traditional insulation or the
rigid manufactured polyethylene packing waste. The effect of the water table on a building with
a rectangular slab-on-grade foundation or with a basement was studied. An analytic method and
commercial software, which uses the finite difference method in two and three dimensions, were
used for the comparison. For all configurations, the quantitative values of the heat loss through
the ground from the building floor demonstrate the effective performance of the rigid
polyethylene packing waste insulation and substantiate the pertinence of its use.(Ahmed Cherif
Megri, Gilbert Achard, Fariborz Hagnihat.1998)