UNIVERSITY OF SANTO TOMAS    
SENIOR HIGH SCHOOL  
 
PRACTICAL RESEARCH 2 
1st Term, AY 2018-2019 

Construction and Evaluation of Composite Boards made from High Density

Polyethylene and Corn (​Zea mays​) Silk Fibers

Presented to the Senior High School

University of Santo Tomas

Manila, Philippines

In Partial Fulfillment of the Requirements

for the Subject of

Practical Research 2

By:

Arceo, Julliene Alex J. [6]

Asiddao, Jacob Dominic [7]

Baculod, Kristine Erica L. [8]

Bairan, Lalaine Ashley [9]

Baldomero, Kobe Y. [10]

12 STEM 18

April 30, 2018

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Abstract

Sustainability, as one of the main problems in the Philippines today, are

continuously being studied and mitigated through a novel way of manufacturing natural

composites made from agricultural waste and recycled plastic. In this study, corn silk

fibers were utilized as fillers for the construction of a High Density Polyethylene (HDPE)

composite board. HDPE plastics were recycled and collected by the researchers and

were hot pressed together with the fibers in molds at a constant temperature of 180C.

Two treatments, Pure HDPE (control) and 30:70 Concentration Ratio, with five

replicates each were created and evaluated through four physical tests: Drop Test,

Abrasion Test, Thickness Swelling and Water Absorption. Drop testing results to

comparable performance of pure HDPE that reached 1.5 m drop and the 30:70 ratio

with 1.8 m drop. The 30:70 Ratio resulted to 0.003% mass loss for abrasion testing as

compared to pure HDPE with 0.019 %. In terms of thickness swelling and water

absorption, the 30:70 Ratio garnered 6.59% and 0.25% thickness change and weight

change respectively. High percentages are rooted to the natural ability of the fibers to

retain moisture. All results gathered passed the ASTM C1186-08 Standards for

composite boards and proved to pose its potential as an alternative construction

material alongside Pure HDPE. The study proposed a practical and cost-efficient

manufacturing method which made use of discarded materials, thereby aiding in

sustainable development while providing materials that possess comparable physical

and mechanical properties with existing composite boards.

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Chapter 1

Introduction

I. Background of the Study

Sustainability still holds the spot as one of the main problems being faced in

the Philippines today. Nowadays, the raw materials, which are inorganic, used for

construction are accountable for ecological imbalance. A research studied by

Morelli (2011) defined the concept of ecological sustainability as an idea that

links human needs and ecosystem services. It also portrays as the biological

conservation or the regeneration of the environment to meet the needs of the

human society. Over the years, the spectrum of health, environment, and

development hazards have seriously changed. These matters are in need of

holistic approaches and imply that it is the time to unite or to implement

harmonized global strategies for sustainability (Schirnding, n.d.) and in turn be

able to raise funds to implement approaches for a sustainable country.

With that being said, the rise of the use of organic fibers and organic

plastic composites contributed greatly in pursuing the sustainable goals of the

society. The use of natural fibers greatly influenced the interest of the

researchers mainly because of the advantages it can provide. Corn silk, or corn

hair, is a thread-like fiber that grows out of the base of the corn but is usually

discarded and considered only a by-product of the plant itself and reasoning from

this fact, Garadimani (2015) conducted a research wherein as the fiber content

increases, tensile strength also increases. Studies have been conducted that
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made use of corn silk as an aggregate for cement and as a packaging film and

wrapper. Results of the study conducted by Tran, Satomi and Takahashi (2017)

showed that corn silk performed well in reinforcing cement sludge. Similarly, corn

silk as an additive in packaging films demonstrated enhanced effects on the

physical properties of the product (Jamaluddin, 2009).

As an effect, corn stalk fibers manifested adhesion in the production of

board composites (Liu & He, 2012). Organic composites, specifically High

Density Polyethylene, are considered to be eco-friendly since it is made up of

post-consumer products and are recyclable as well (Arete Industries, n.d.).

According to an article in Plastics Make it Possible, its properties continue to

contribute to its growing popularity, making it today’s most widely used type of

plastic. It’s made by stringing together ethylene molecules, which were

predominantly extracted from natural gas resources in the United States. It’s

lightweight yet durable, which is why HDPE is presently used in many fields—for

convenience and increased efficiency.

Composites made with polyethylene and natural fibres or fillers have been

studied by other authors and some interesting results were obtained. Notable

studies made use of Polyethylene modified with different fillers like maleic

anhydride and then processed with wood flour, cornstarch and rice straw.

(Araujo, Waldman, & De Paoli, 2008). It was found out that cornstarch based

products yielded higher flexural strength and recommended that the results

obtained from the study be applied for creating panels or boards (Liu, Jia & He,

2012). Thus, it serves as a basis for further improvement that would be applied to
 4

the study regarding corn silk fibers. Moreover, the potential of waste corn silk

fibers as an efficient material that could modify composites brings out many

benefits as it does not only help advance knowledge on engineering and

construction, but also greatly impacts the environmental, social and ecological

balance in our society (Tran, Satomi & Takahashi, 2017).

Due to aforementioned circumstances, the researchers aim to respond to

the ever-growing need of our society in terms of responsible consumption and

construction from raw materials that are made available to us. Thus, the

researchers aim to correlate the emerging benefits of utilizing natural yet

discarded products like corn silk fibers to the production of environmentally

sound composite HDPE boards. With numerous past studies that have

discovered the effectivity of organic composites, it is widely recommended to

pursue a study that would construct eco-friendly materials made from corn silk

fibers to improve sustainability in the country.

II. Statement of the Problem

Many manufacturers use non-renewable and inorganic resources in

creating composite boards and this study aims to minimize this use through

constructing a High Density Polyethylene Board from Corn Silk Fibers and

evaluating its characteristics based from certain parameters. This study seeks

answers to determine the physical characteristics of the HDPE board in terms of

color, shape, texture and size (length, width, thickness) and to determine which
 5

composite board (pure HDPE and 30:70 Ratio) would give best results for the

following tests: drop test, abrasion test, thickness swelling and water absorption.

III. Objectives of the Study

The main objective of the research is to construct an HDPE Board from

Corn Silk Fibers and evaluate its characteristics based on certain parameters.

The specific objectives of this research are:

a.) to Collect and authenticate Corn Silk and HDPE.

b.) to construct the composite boards through compression molding,

c.) to determine the physical characteristics of the HDPE board in terms of

color, shape, texture and size (length, width, thickness) and

d.) to determine which of the two composite boards (pure HDPE and

30:70 concentration ratio) would yield the best results in terms of drop

test, abrasion test, thickness swelling and water absorption.

IV. Significance of the Study

The main objective of the research is to construct an HDPE Board from

Corn Silk Fibers and evaluate its characteristics based on certain parameters.

The results of this study will be of benefit to both the environment and the people.

Specifically the study will be able to satisfy the characteristics and capabilities of

a composite board without the expense of non-renewable sources. This would

enable innovative ideas using renewable resources as discarded corn silk and

recycled HDPE plastics are used to create products that can potentially be sold

in the market. In connection to this, the study is very eco-friendly due to the
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materials that is used, which is mainly from recycled and organic materials

hence, the product of this research is recyclable. The study gives importance to

use of alternative materials that are much safer and will help lessen the

environmental concerns the planet is currently facing. Lastly, the study can serve

as a foundation or background for other researches that would be conducted in

the future regarding the field of construction of organic boards. The research may

give new ideas that can add to the existing body of knowledge. It may also

provide background information about plants with similar construction capability

and characteristics which the Corn (Zea mays) Silk Fibers have.

V. Scope and Limitations

The study focuses on the construction and evaluation of an HDPE Board

made from Corn Silk Fibers. It will be conducted during the school year 2018-

2019 in the University of Santo Tomas. The research will make use of only Corn

Silk Fibers as the material to be incorporated as a filler to the board. High Density

Polyethylene will then be used as the binder of the constructed boards. The

study would make use of varied concentration ratios of corn silk fibers and HDPE

namely pure HDPE and 30%-70% ratio. The mixtures would then be hot pressed

in a steel mold with dimensions of 8 in x 8 in x 0.5cm. The HDPE Boards will then

be evaluated through a series of tests, namely drop test, abrasion test, thickness

swelling and water absorption. The study would also determine the physical

characteristics of the board in terms of color, shape, texture and size (length,

width, thickness). All experimentation procedures would be done in the University

 7

of Santo Tomas and all tests would be conducted by the researchers. The study

is also set locally in the Philippines.

The study is limited in the use of Corn (Zea mays) Silk Fibers and High

Density Polyethylene; other plants and binding materials are beyond the scope.

Other parameters of evaluation on the HDPE board and concentrations ratios are

outside the research study as well. Further application of findings in the locale is

yet to be done since the study is only defined as a construction and evaluation of

HDPE Composite Board form Corn Silk Fibers. It only seeks to contribute to the

existing body of knowledge.

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Chapter 2

Review of Related Literature

I. Composites

A. Characterization of Composites

Composites are widely used in building construction, siding, ceilings, floors, roofs

and tile backer boards. It is also used for replacement of wood siding because it’s

less expensive, more durable, and have lower maintenance costs (Akhavan,

Catchmark & Rajabipour, 2017). Precast of concrete made from fibre-reinforced

composite offers a variety of advantages, such as efficiency of construction

processes, improved quality, better budget control, consumption of less materials

and less waste on site. It also provides the builder with quicker erection times

reduced need for plant on site, easier management of construction sites and the

realization from simple to complex structures (Ardanuy, Claramunt & Toledo,

2015). Composites are also characterized by high aspect ratio, high ultimate

tensile strength, relatively high modulus of elasticity, good chemical compatibility

with Portland cement, good affinity with water and no health risks (Noushini et al.,

2013).

B. High Density Polyethylene

Mass-produced in the United Kingdom in the 1930’s, according to an

article in Plastics Make it Possible, its properties continued to contribute to its

growing popularity, making it today’s most widely used type of plastic. It’s made

by stringing together ethylene molecules, which were predominantly extracted

from natural gas resources in the United States. It’s lightweight yet durable,
 9

which is why HDPE presently is used in many fields—for convenience and

increased efficiency.

The following are a few among several properties which make it an

essential building block. First, it is impact resistant, so even when dropped or

thrown, the material would remain intact (and even bounce). It also resists mold,

mildew, rotting, and insects, meaning it could last under environmental elements

that could deteriorate other materials. In addition, it is malleable. Like any other

plastic, HDPE can be molded into any shape, therefore granting it the benefit of

versatility, covering a wide range of possible products.

Based on the study by Faruk and Matuana (2008), incorporating nanoclay

to HDPE can enhance their mechanical properties by reinforcing it. The first

method was melt-blending process. It involved the reinforcement of HDPE matrix

with the nanoclay. The second method was the direct addition of the nanoclay

into the HDPE composites by conventional dry compounding/direct dry blending

process.

On the other hand, there are methods on reinforcing HDPE composites

such as surface treatment methods or simply chemical bonding and oxidation.

This was used to strengthen the interfacial bonding properties of the natural fiber

reinforced polymeric composites. The IFSS or interfacial shear strength of the

fibers was obtained by the use of statistical parameters (Li, Hu & Yu, 2008).

In testing the composites, an industrial-scale process is highly

recommended to test the form of composite, specifically the tensile strength. In

relation to the process, the mechanical performances will improve depending on

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the size distribution of the particles that will be added (Chaudemanche, Perrot,

Pimbert, Lecompte, & Faure, 2018).

In addition , the study conducted by Charoenvai (2014) found that with a

compressed temperature of 180C and 10% fiber content is needed to produce

the composite with the use of recycled HDPE. The HDPE and content fiber

(durian) was prepared through successive twin screw extrusion blending. It was

highly recommended that when improving the elasticity behavior of the HDPE,

durian peel fibers can be an added with other fibers as well. On the other hand,

a study that made use of cornstarch and rice straw to construct composites

found out that cornstarch based products yielded higher flexural strength and

recommended that the study be applied for creating panels or boards (Liu, Jia &

He, 2012). Thus, it serves as a basis for further improvement that would be

applied to the study regarding corn silk fibers.

C. Importance of Varying Concentration Ratios

Consequently, concentration ratios are responsible for the properties of

constructed HDPE Boards. Studies show that fibers have a certain percentage

where they would exhibit best effects. In Gesoglu, Güneyisi, Muhyaddin and

Asaad’s study, they stated that with micro steel fiber, the best compressive

strength of 180 MPa, highest tensile strength and modulus of elasticity was given

by the 2% concentration and that the results also showed that the beneficial

influence of using micro glass fiber began to decrease after the 1.5% fiber

volume ratio.

Similarly, the study of Hannawi, Bian, Prince-Abgbodjan and Raghavan

 11

concluded that concentration of fibers slightly influence compressive strength and

modulus of elasticity for concrete aggregates. The fibers also restrain cracking

when the concrete was placed in mechanical loading. Lastly, a similar study

stated that the ratios of the particles that will be added may influence the physical

and mechanical properties of the composite product. Through sieve column and

image analysis, the particle size and form were carried out which reveals the

limits of particles with a high aspect ratio. The mechanical and physical

properties is solely based on the ratios of the size distribution of the particles

(Chaudemanche et al., 2018).

II. Natural Fibers

A. Definition and Classification of Natural Fibers

Thus, natural fibers are now of great interest in the field of material

science. Natural Fibers are classified into two namely plant-based or vegetable

fibers and animal-based fibers. Plant fibers are mostly gathered from basts,

leaves, fruits, grass, straws and wood pulp. Different fibers constitute for varying

mechanical properties and tensile strength. When it comes to tensile strength,

numerous fibers are comparable with that of glass and synthetic fibers (Zini &

Scandola, 2011).

B. Importance of the use of organic materials/natural fibers

Natural fibers are now becoming a growing interest for the field of

research. The materials are not costly and also possess fairly adequate physical

properties, strength and are of course, eco-friendly. Studies show that the tensile

strength of polymer composites increases with its fiber content (Ku et al., 2011).
 12

Studies conducted by Pickering, Efendy and Le (2015) and Zini and

Scandola (2011) both agree on the advantages of using organic materials and

natural fibers to reinforce synthetic composites. Some advantages include low

density, high specific strength, renewable resource, involves carbon dioxide

absorption, low hazard manufacturing process, and low emission of toxic fumes.

Additionally, advantages include their non-toxicity and efficient insulation

properties.

Most agricultural waste are natural fibers that may be used as

reinforcements and fillers in the production of polymer composites instead of

being readily discarded in the environment (Abba, Zahari, Sapuan & Leman,

2017). Composites made with polyethylene and natural fibres or fillers have been

studied by other authors and some interesting results were obtained. One study

made use of Polyethylene modified with maleic anhydride and processed with

wood flour. (Araujo, Waldman, & De Paoli, 2008).

In connection to fiber content, composites making use of wood fiber

conclude that fiber length and distribution has an effect on the performance of the

composites. It was added and discussed that short fibers would be the easiest to

mix with HDPE as compared to longer ones; yet long fibers still produce good

quality composites (Migneault et al., 2008) This information then suggests the

appropriate length of fiber that must be utilized in order to create quality boards.
 13

III. Entities to be studied

A. Corn Silk Fibers

1. Overview of Corn Plant

Doebly (2004), stated that Maize is a cereal grain which was first grown in

ancient Central America. It is now the third most important cereal crop in the

world. Most parts of the corn is used to make corn ethanol, animal feed and other

maize products, such as cornstarch and corn syrup. Since only a part of the

whole is consumed, the researchers decided to use another uncommonly used,

discarded part of the plant that could enhance the durability of the polyethylene

board.

2. Characterization of Corn Silk

Having learned that natural fibers are becoming of interest, corn came into

the picture. In an experimental study on corn silk or corn husk fibers by Wardana,

Sari, Irawan & Siswanto (n.d.), it was considered a natural and renewable

material and also a waste material of corn that is not harmful to humans or

animals. Its natural fibers along with porous cell structure and low density is

becoming popular. Corn silk fibers have best tensile performance whether raw or

treated. It can also provide different porous microstructures and acoustic

properties.

Yet a study conducted by Garadimani, Raju and Kodancha (2015), disagrees

and states that some natural fibers are hydrophilic thus are incompatible with

hydrophobic polymers and has a capability to form aggregates. These hydrophilic

 14

fibers are not good in resisting moisture, which lead to high water absorption,

consequently resulting in inadequate tensile properties of the natural fiber

reinforced composites.

In disagreement with the previous research, a study discovered the presence

of Zein, a prolamine rich protein found in corn that is hydrophobic, thus it is

widely used for making films in coatings (Jamaluddin, 2009).

3. Common uses of Corn Silk Fibers

So in order prove these properties, corn silk has been used for different

applications. Since it is readily discarded most of the time, a study saw the

potential of waste corn silk fibers as an efficient material that could modify

composites. It was stated that this may bring out many benefits as it does not

only help advance knowledge on engineering and construction, but also greatly

impacts the environmental, social and ecological balance in our society (Tran,

Satomi & Takahashi, 2017). In 2009, Jamaluddin conducted a research that

utilized corn silk and starch to enhance the chemical gas well as the physical

properties of a composite biodegradable film. Results show that corn silk

increased the physical properties of the said film due to its protein, as mentioned

earlier, Zein.

Furthermore, numerous studies agree that tensile strength analysis

results show that as fiber content increases, tensile strength also increases. This

is inferred to be caused by the reinforcing effect of the fibers on the composite.

On the contrary, too much fiber content i.e. greater than 7.5% based on the
 15

study, resulted to a decrease on tensile strength properties (Garadimani, Raju &

Kodancha, 2015).

IV. Standard Testing Methods

Through abrasion testing the resistance of a material could be determined.

Many civil engineering structures experience premature deterioration of common

materials due to abrasion, which is a critical problem for them (Zhao, Van Dam,

Lange & Sun, 2017). According to Yetgin & Çavdar (2011), there a number of

factors that influences the abrasion resistance, such as surfacing finish,

aggregate properties, compressive strength, types of hardeners, and curing. On

the other hand, Malhotra (2018), stated that the drop test method was meant for

evaluating the capability of a container to resist damage from the shock of a free

fall. This may also be used to compare the durability of different composite

designs. Finally, this may also allow the observation of the chronic failure (or

deterioration over time) of a material.

Kwayie, Zoya & Adinkrah-Appiah (2016), implied that drop test may be

destructive but it evaluates up to what extent a certain material can withstand

failure if dropped from a particular distance. Moreover, this tests the ability of the

fibers to grasp the broken pieces of the boards which may give the performance

of the boards on how much impact it got. Some of the experts in this industry

consider abrasion to be a feasible mechanism and a lack of knowledge regarding

the various interactions that affects the severity of abrasion may result in an

empirical design process for structures and fastening systems (Shurpali,

Edwards, Kernes, Lange & Barkan, 2014).

 16

Chapter 3

Methodology

I. Methods and Materials

Figure 3.1. Schematic Diagram

 17

A. Collection of Corn Silk Fibers and High Density Polyethylene

Corn silk fibers were gathered from Balintawak Market and an

approximate of 200g of Corn Silk Fibers was gathered for the

experimentation. The collected corn silk fibers were authenticated in the

Department of Agriculture’s Bureau of Plant Industry (BPI) to determine

whether the corn fibers are from the species Zea mays. The certificate

given by the bureau signaled that the plant used was of correct species

and that further experimentations may now be carried out. High Density

Polyethylene was purchased from local junk shops in Trece Martirez,

Cavite and was gathered from the researcher’s homes. A seal number of

2 authenticates that the plastic products are indeed made from High

Density Polyethylene. Since HDPE to be utilized will be recycled, scraps

will be gathered and collected to a weight of at least 500 grams. Since five

replicates would be made for each trial, HDPE collected must suffice for

the given concentration ratios i.e. at most 100 grams for each trial

depending on the percentage of ratios.

B. Preparation of Corn Silk Fibers and High Density Polyethylene

Before mixing the corn silk fibers with the High Density

Polyethylene (HDPE), the corn silk fibers were cleansed with distilled

water. Distilled water undergoes a process called distillation to purify

unwanted chemicals and minerals, thus the corn fiber was washed several

times to enhance its purity and was then allowed to dry naturally.
 18

The gathered HDPE were then cut and shredded to increase

surface area and in turn be easier to melt. The shredder utilized operates

at nearly 60 rotations per minute (rpm) and has dimensions of 552 by 600

by 280 millimeters.

Figure 3.2. Gathering of Corn Silk Fibers and HDPE

C. Concentration Mixtures

1. Stainless Steel Molding Preparation

A stainless steel mold with dimensions 8 in x 8 in x .5 cm was

readily available in the composite fabrication machine in Trece Martirez,

Cavite. The mold served as the container for the HDPE and Corn Silk

Fiber Mixture while it was compressed into panels.

2. Compression Molding

The HDPE collected were in different forms such as bottle caps and

containers, thus it was melted using the pre-heated steel molds that were

readily available in the composite fabrication site. An alternation of pouring

 19

occurs between the HDPE and Corn Silk Fibers. For the pure HDPE

boards, approximately 100g of HDPE was added to the molds to be

compressed for 30 minutes. The heat press was constructed out of

stainless steel with an interior measurement of eight by eight inches (8 in x

8 in). The heat press runs on 220 volts, requiring 44 kilowatts while

heating from room temperature and 15-20 kilowatts when pre-heated. For

the 30:70 (30 grams of corn silk) Ratio, a layer of corn silk fibers was

placed and manually oriented to suffice the mold before adding another

round of HDPE. The mixture was also compressed for 30 minutes. The

process was carried out at 180 C. The mold was kept at room temperature
0

before the composites were taken out (Enriquez, Santiago, Ong &

Chakraborty, 2009).

Figure 3.3. Compression Molding of Concentration (Pure HDPE: top, 30:70

Ratio:bottom)
Note: 5 replicates for each concentration ratio
 20

D. Analysis of Physical Characteristics of the Corn Fiber

Reinforced HDPE Composite Board.

The determination of the effectiveness of the mixture of each

concentration ratios of the corn silk fibers and HDPE was based on the

analysis of its physical characteristics. Figure 4 shows the enumeration of

tests to be done on the boards. Five replicates were produced and each

replicate was assigned for the specific tests. Size, shape, color and

texture were observed a few days after the product was produced. The

drop test, abrasion test, thickness swelling and water absorption was done

by the researchers. All data gathered were recorded and analyzed.

The size of the HDPE board (length, width, thickness) was measured with

a measuring tape, and was recorded. The shape, color, and texture was

then determined simply through observation.

This drop test is a destructive test wherein the extent to which a

material will break or crack after it has been dropped from a known

distance is determined. The first two boards from each category was

selected for this test and were then dropped from four reference points of

1 m,1.3 m ,1.5 m, and 1.8 m. The extent of failure was then assessed after

the tests. Results obtained were tabulated and analyzed.

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Figure 3.4. Drop Test of HDPE Board at 6ft

For abrasion test, the boards were initially weighed using a gram balance;

afterwards, the boards were scratched 120 times using a wire brush. The final

weight of the boards was measured again to determine weight loss. The weight

loss percentage was determined by the formula:

W2 − W1
𝑊𝐿 = ( ) 𝑥100
W2

Figure 3.5. Visible Scratch Marks after Abrasion

To test for thickness swelling, the boards were soaked in water for at least

24 hours and the swelling of the boards was measured by a caliper afterwards.

Results obtained were tabulated and analyzed.

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Figure 3.6. Measuring of Thickness by Caliper

For water absorption test, the initial weight of the boards was measured

using a gram balance. After a 24 hour water immersion, the boards were

removed from the water and wiped with a dry cloth, and weighed (Wt). (Feng,

Shi, Chen & Huang, 2014). Water Absorption or WA was then computed using

the following equation:

W2−W1
𝑊𝐴 = ( ) 𝑥100
W2

Figure 3.7. Weighing of Boards on Gram Balance and

Submerging into water
 23

E. Statistical Analysis

The chi-squared test was used in determination of significant

differences between the expected outcomes and the observed outcomes.

The purpose of this test was to determine whether the observations would

closely equal to the expected results.

Results of tests conducted on the HDPE boards were afterwards

compared with ASTM C1186-08 standards to determine if the produced

boards would serve as effective substitutes for commercially available

alternatives.
 24

Chapter 4

Results and Discussion

I. HDPE Characterization

The physical characteristics of the composite boards were evaluated. The

color, shape, texture and size were recorded and tabulated below.

Table 4.1: Characteristics of Composite Boards in terms of Color, Shape,

Texture and Size
REPLICATES COLOR SHAPE TEXTURE SIZE
PURE HDPE
1 Mixed Dark Blue and White Square Dominantly Smooth 6.75 in x 6.75 in
x 0.5 cm
2 Mixed Dark Blue, Yellow, Red, Square Dominantly Smooth 6.75 in x 6.75 in
and Green x 0.6 cm
3 Mixed Dark Blue, Yellow, Red, Square Dominantly Smooth 6.75 in x 6.75 in
and Green x 0.5 cm
4 Light Blue Square Dominantly Smooth 6.75 in x 6.75 in
x 0.5 cm
5 Light Blue Square Dominantly Smooth 6.75 in x 6.75 in
x 0.6 cm
30:70 Ratio

1 Light Blue with Brown Square Smooth with 6.75 in x 6.75 in

Highlights grainy parts x 0.8 cm
2 Light Blue with Brown Square Dominantly Smooth 6.75 in x 6.75 in
Highlights x 0.6 cm
3 Light Blue with Brown Square Dominantly Smooth 6.75 in x 6.75 in
Highlights x 0.6 cm
4 Light Blue with Brown Square Dominantly Smooth 6.75 in x 6.75 in
Highlights x 0.5 cm
5 Light Blue with Brown Square Dominantly Smooth 6.75 in x 6.75 in
Highlights x 0.6 cm
 25

Figure 4.1. Pure HDPE Concentration (left) has a mixture of colors given the
various recycled HDPE plastics gathered by the researchers. The boards have a
smoother finish as compared to 30:70 Ratio (right). The composite boards with
corn silk fibers have noticeable streaks of brown fibers and has a more raw
finish.

The two composite boards have noticeable differences in color as streaks

of the corn silk fibers were evident on the 30:70 Ratio Board. One of the boards’

texture resulted to a grainy texture given the addition of fibers to its matrix. A

similar study conducted by Cao,Guo and Li (2016), stated that the ‘raw’ surface

or quality of surface of constructed boards was one of the observations, yet

secondary surface treatments may be able to enhance the aesthetic of the

composite boards and this was not a factor that affects its performance.

Moreover, the thickness of the boards varies by small points due to minimal

discrepancies that arise from the production by compression molding. Another

factor that contributed to the varying thickness are the corn silk fibers oriented on

the boards. Due to the reinforcement, the boards became a bit thicker to fill in the

fibers. Nonetheless, the physical characteristics of the 30:70 Ratio boards are

comparable to the control (pure HDPE).

 26

II. Drop Test

The table below shows results gathered through the drop test which was

done at different heights. It shows the difference between the performance of

Pure HDPE and 30:70 Ratio.

2.5
(p>0.05)
2

1.5
Rating

0.5

0
1m 1.3m 1.5m 1.8m

Height of Drop
Pure HDPE 30:70 Ratio

Legend: 2 - Sturdy 1 - Partially Broken 0 – Broken

Figure 4.2. Given the ratings, Pure HDPE Concentration partially chip off at the
height of 1.8 m. The boards have no fibers to hold cracks together as compared
to 30:70 Ratio. Error bars overlap at certain points thus showing insignificance.
Moreover, P value was greater than 0.05 for drop testing thus, no significant
difference was obtained.

The drop test was done to determine the rate of failure of the boards when

subjected to impact. As observed, cracks advanced from the ends of the pure

HDPE and chip off as it was dropped at a height of 1.8 m. On the contrary, the

30:70 Ratio remained sturdy due to the fibers that held the cracks together in

place. This result is consistent with the study conducted by Kwayie, Zoya and

Adinkrah-Appiah (2015) that obtained results showing how the coconut fibers
 27

held the cracks of the board together after impact. In addition, a study supports

that the breakage is caused by small voids present between the matrix thereby

resulting to a weaker adhesion of the fibers to the HDPE plastic. (Mazharuddin,

Reddy & Rao, 2015). The result is not significant at p < .05. Therefore, it follows

that there is no significant difference between pure HDPE and 30:70 Ratio.

III. Abrasion Test.

The abrasion test was done through scratching the boards 120 times with

a wire brush to determine the quality and weight change of the boards. Moreover,

this test was done to be able to know if the boards are resistant to abrasion. The

table below shows results gathered through the abrasion test. It also shows the

difference between the performance of Pure HDPE and 70:30 Ratio in terms of

nominal and ratio values.

2.5
(p>0.05)
2
Rating

1.5

0.5

0
Board 1 Board 2

Composite Boards
Pure HDPE 30:70 Ratio

Legend: 2 - Noticeable Abrasion 1 - Heavy Abrasion

Figure 4.3. Given the ratings, Pure HDPE Concentration obtained noticeable
abrasion as compared to 30:70 Ratio. Error bars do not overlap thus conclusive
of a significant value but P value was greater than 0.05 for abrasion testing thus,
there was still no significant difference was obtained.
 28

Table 4.2: Abrasion Test Weight Change Table

Concentration Ratio Initial Weight Final Weight Percentage
PURE HDPE
2 181.54 g 181.50 g 0.022%
3 126.55 g 126.53 g 0.016%
30:70 Ratio
2 160.10 g 160.09 g 0.006%
3 148.90 g 148.90 g 0%

After scratching each one of the boards, the percentage weight loss of the

boards were determined to be able to know which is more vulnerable to abrasion.

These varies from 0% to 0.022% however, the lower percentage corresponds to

the 30:70 Concentration Ratio. A similar study that used coconut fibers had a

similar result which stated that boards containing coconut fibers are denser

compared to those without fibers. These fibers make the boards more resistant to

abrasion (Kwayie, Zoya, and Adinkrah-Appiah, 2015). Through obeservation, it

could be deduced that the Pure HDPE boards is more susceptible to abrasion

compared to 30:70 Concentration Ratio yet the result is not significant at p < .05;

therefore, it follows that there is no significant difference between pure HDPE

and 30:70 Ratio despite the observed factors.

 29

IV. Thickness Swelling

The table below shows results gathered through the thickness swelling

test. This test determines the percentage of the change in thickness of the

boards measured by a caliper. It also shows the difference between the

performance of Pure HDPE and 30:70 Ratio in terms quantitative data.

Table 4.3: Results on Thickness Swelling

Concentration Ratio Initial Thickness Final Thickness Percentage
PURE HDPE
3 0.5 cm 0.5 cm 0%
4 0.5 cm 0.5 cm 0%
5 0.6 cm 0.6 cm 0%
30:70 Ratio
3 0.6 cm 0.7 cm 14.29%
4 0.5 cm 0.52 cm 3.85%
5 0.6 cm 0.61 cm 1.64%
(p>0.05)

Thickness swelling test was done by submerging the boards overnight.

The swelling of the manufactured boards varies from 0% to 14.29%, the lowest

values corresponding to the ratio with a high (100%) HDPE plastic content. A

study that made use of sugarcane bagasse as fillers gathered similar results as

well. It was stated that the higher the bagasse content, thickness swelling tends

to increase as well due to insufficient bonding created by the reinforcement.

(Talavera, Guzman, Richter, Dueñas, and Quirarte, 2007). It could be inferred

that the greater the fiber content that are insufficiently bonded,the greater it

allows moisture intrusion. This shows how the pure HDPE, with sufficient

bonding and little to no space for intrusion garnered 0% thickness increase.

Another factor was the natural ability of the corn silk fibers to retain moisture.

Thus, the 30:70 Ratio demonstrates that it is susceptible to moisture intrusion

 30

unlike the pure HDPE concentration. The result is not significant at p < .05.

Therefore, it follows that there is no significant difference between pure HDPE

and 30:70 Ratio.

V. Water Absorption

The table below shows results gathered through the water absorption test.

It was done by calculating the percentage of the change in weight of the boards

measured by a gram balance. It also shows the difference between the

performance of Pure HDPE and 30:70 Ratio in terms of quantitative data.

Table 4.4: Results on Water Absorption

Concentration Ratio Initial Weight Final Weight Percentage
PURE HDPE
3 126.55 g 126.55 g 0%
4 122.41 g 122.42 g 0.008%
5 123.18 g 123.18 g 0%
30:70 Ratio
3 148.11 g 148.90 g 0.53%
4 160.10 g 160.35 g 0.16%
5 142.09 g 142.16 g 0.05%
(p>0.05)

Similar to thickness swelling, water absorption percentages also varied

from 0% to 0.53%, the lowest also corresponding to the boards with higher

HDPE plastic content. This result was proven by the study conducted by

Garadimani, Raju and Kodancha (2015), which stated that some natural fibers

are hydrophilic and are thus incompatible with hydrophobic polymers. These

hydrophilic fibers were not good in resisting moisture, which led to high water

absorption. Thus, results indicating the increase of weight percentage are rooted

to the fiber’s ability to retain moisture and the insufficient bonding made by the
 31

matrices. The result is also not significant at p < .05. Therefore, it also follows

that there is no significant difference between pure HDPE and 30:70 Ratio.

VI. Comparison of Results to Composite Board Standards

The table below shows the summarized results gathered through all tests.

It also shows the comparison of the experimental values obtained to the ASTM

C1186-08 Standards of Composite Boards.

Table 4.5: Comparison of Results to ASTM C1186-08 Composite Standards

Test Performed Pure HDPE 30:70 Ratio ASTM C1186-08
STANDARDS
Drop Test 1.5 m 1.8 m ≤ 0.61 m will
collapse
Abrasion Test 0.019% 0.003% Loss mass ≤ 0.3
%
Thickness Swelling 0% 6.59% ≤ 37.72 %

Water Absorption 0.003% 0.25% ≤ 37.72 %

Based from the collected data from the tests done on the composite

boards, it could be inferred that the 30:70 Ratio meets the standards of a

composite board alongside Pure HDPE (control). In fact, the 30:70 Ratio

obtained the expected outcomes for Drop and Abrasion Testing as presented on

the Chi-Square Continuity Table. On the contrary, the 30:70 Ratio obtained

negative results for Thickness Swelling and Water Absorption as it garnered

 32

higher percentages of change in both weight and thickness. This result could be

traced from to the natural capacity of the corn silk fibers to retain moisture.

Nonetheless, the T-test critical values proved that there was no significant

difference between the two composite boards. This implies the potential of the

fiber-reinforced composite to be an alternative to pure HDPE plastic.

 33

Chapter 5

Conclusion and Recommendation

Conclusion

As highlighted on the discussions, the researchers conclude that corn silk

fibers are an effective reinforcement to HDPE boards. Based on the experimental

results, the 30:70 ratio, along with the pure HDPE concentration, garnered

outstanding test outcomes for drop and abrasion tests as it could both withstand

a drop of 1.8 m with minimal cracks. In addition, the 30:70 Ratio obtained

negative results for Thickness Swelling and Water Absorption as it garnered

higher percentages of change in both weight and thickness due to the natural

capacity of the corn silk fibers to retain moisture and the insufficient bonding

made by the HDPE to the fiber matrix. Nonetheless, the physical and

dimensional characteristics of the natural composite are comparatively superior

despite the absence of secondary treatment and finishing. The utilization of corn

silk fibers readily discarded as agricultural wastes and recycled HDPE will, at a

greater extent, aid and preserve sustainability of resources and reduce

production cost as well.

Recommendation

Based on the findings of the study, there are several areas that must be

addressed for improvement and modification. It is recommended to consider the

natural capacity of the fibers to retain moisture. Thus, union with higher

performance synthetic fibers can improve the materials with greater chance of
 34

structural application. It is also recommended to utilize other plant fibers like

rami, jute, sisal and curauá as reinforcements which are also comparable to corn

silk. Moreover, secondary surface treatments such as coatings may also be done

to enhance durability. Discarded fibers can be used as laminated composites to

decrease moisture absorption as well, thus preventing loss of mechanical

properties. In addition, other binders such as Low Density Polyethylene or

Polyurethane Glue can be used in the place of HDPE plastic. Furthermore,

application of a different compression molding approach such as Cold Pressing

or the use of the Two-Roll Mill Machine is also highly encouraged to maintain a

uniform size and shape of board at constant temperature and pressure.

 35

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 ​43
Appendix A

Plant Authentication Certificate

 44
Appendix B
Documentation of Results
Figure 11. I​ nitial and Final Weights of Boards on Gram Balance
Figure 12. ​Drop Test and Abrasion Test Documentation showing the testing process
and the results (evident cracks and scratches)
 47
Appendix C
Statistical Raw Data

Figure 13. ​Thickness Swelling T-Test

 48

Figure 14. ​Water Absorption T-Test

 49
Appendix D

Instrumentation

Hot Press It is used to apply heat to the surface of the HDPE

composites for a preset period of time.
Machine

(Hydraulic Press)

Steel Molds Serve as molders while in compression to ensure

proportional quadrilateral sizes of the HDPE
composites.

Caliper A measuring tool to determine thickness swelling

of materials.

Measuring Tape A measuring tool to measure the dimensions of

the boards (length, width, thickness).

Wire Brush A brush with steel wire bristles used for abrasion
tests.