Construction and Evaluation of Composite Boards Made From High Density Polyethylene and Corn (
Construction and Evaluation of Composite Boards Made From High Density Polyethylene and Corn (
UNIVERSITY OF SANTO TOMAS
SENIOR HIGH SCHOOL
PRACTICAL RESEARCH 2
1st Term, AY 2018-2019
Manila, Philippines
Practical Research 2
By:
12 STEM 18
Abstract
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
material alongside Pure HDPE. The study proposed a practical and cost-efficient
Chapter 1
Introduction
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
links human needs and ecosystem services. It also portrays as the biological
human society. Over the years, the spectrum of health, environment, and
With that being said, the rise of the use of organic fibers and organic
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
3
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
board composites (Liu & He, 2012). Organic composites, specifically High
contribute to its growing popularity, making it today’s most widely used type of
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
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
construction, but also greatly impacts the environmental, social and ecological
construction from raw materials that are made available to us. Thus, the
sound composite HDPE boards. With numerous past studies that have
pursue a study that would construct eco-friendly materials made from corn silk
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
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.
Corn Silk Fibers and evaluate its characteristics based on certain parameters.
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
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
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
6
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
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
and characteristics which the Corn (Zea mays) Silk Fibers have.
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,
of Santo Tomas and all tests would be conducted by the researchers. The study
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
Chapter 2
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,
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
2015). Composites are also characterized by high aspect ratio, high ultimate
with Portland cement, good affinity with water and no health risks (Noushini et al.,
2013).
growing popularity, making it today’s most widely used type of plastic. It’s made
from natural gas resources in the United States. It’s lightweight yet durable,
9
increased efficiency.
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
to HDPE can enhance their mechanical properties by reinforcing it. The first
with the nanoclay. The second method was the direct addition of the nanoclay
process.
This was used to strengthen the interfacial bonding properties of the natural fiber
fibers was obtained by the use of statistical parameters (Li, Hu & Yu, 2008).
the size distribution of the particles that will be added (Chaudemanche, Perrot,
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
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.
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
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
numerous fibers are comparable with that of glass and synthetic fibers (Zini &
Scandola, 2011).
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
Scandola (2011) both agree on the advantages of using organic materials and
absorption, low hazard manufacturing process, and low emission of toxic fumes.
properties.
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
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
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
discarded part of the plant that could enhance the durability of the polyethylene
board.
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
properties.
and states that some natural fibers are hydrophilic thus are incompatible with
fibers are not good in resisting moisture, which lead to high water absorption,
reinforced composites.
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,
utilized corn silk and starch to enhance the chemical gas well as the physical
increased the physical properties of the said film due to its protein, as mentioned
earlier, Zein.
results show that as fiber content increases, tensile strength also increases. This
On the contrary, too much fiber content i.e. greater than 7.5% based on the
15
Kodancha, 2015).
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
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
Kwayie, Zoya & Adinkrah-Appiah (2016), implied that drop test may be
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
the various interactions that affects the severity of abrasion may result in an
Chapter 3
Methodology
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
Cavite and was gathered from the researcher’s homes. A seal number of
2 authenticates that the plastic products are indeed made from High
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
Before mixing the corn silk fibers with the High Density
Polyethylene (HDPE), the corn silk fibers were cleansed with distilled
unwanted chemicals and minerals, thus the corn fiber was washed several
times to enhance its purity and was then allowed to dry naturally.
18
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.
C. Concentration Mixtures
Cavite. The mold served as the container for the HDPE and Corn Silk
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
occurs between the HDPE and Corn Silk Fibers. For the pure HDPE
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).
concentration ratios of the corn silk fibers and HDPE was based on the
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
The size of the HDPE board (length, width, thickness) was measured with
a measuring tape, and was recorded. The shape, color, and texture was
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
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
W2 − W1
𝑊𝐿 = ( ) 𝑥100
W2
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.
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
W2−W1
𝑊𝐴 = ( ) 𝑥100
W2
E. Statistical Analysis
The purpose of this test was to determine whether the observations would
alternatives.
24
Chapter 4
I. HDPE Characterization
color, shape, texture and size were recorded and tabulated below.
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.
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
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
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
The table below shows results gathered through the drop test which was
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
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
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.
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
2.5
(p>0.05)
2
Rating
1.5
0.5
0
Board 1 Board 2
Composite Boards
Pure HDPE 30:70 Ratio
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
After scratching each one of the boards, the percentage weight loss of the
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
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;
The table below shows results gathered through the thickness swelling
test. This test determines the percentage of the change in thickness of the
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
that the greater the fiber content that are insufficiently bonded,the greater it
allows moisture intrusion. This shows how the pure HDPE, with sufficient
Another factor was the natural ability of the corn silk fibers to retain moisture.
unlike the pure HDPE concentration. The result is not significant at p < .05.
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
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.
The table below shows the summarized results gathered through all tests.
It also shows the comparison of the experimental values obtained to the ASTM
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
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
Chapter 5
Conclusion
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
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
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
Recommendation
Based on the findings of the study, there are several areas that must be
natural capacity of the fibers to retain moisture. Thus, union with higher
performance synthetic fibers can improve the materials with greater chance of
34
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
or the use of the Two-Roll Mill Machine is also highly encouraged to maintain a
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42
Instrumentation
(Hydraulic Press)
Wire Brush A brush with steel wire bristles used for abrasion
tests.