FDRE TECHNICAL & VOCATIONAL TRAINING INSTITUTE

FACULTY OF MECHANICAL TECHNOLOGY

DEPARTMENT OF MANUFACTURING TECHNOLOGY
MSc. Research Proposal

TITLE: AN EXPERIMENTAL INVESTIGATION OF GLASS

POWDER REINFORCED RHDPE POLYMER MATRIX
LIGHTWEIGHT CONCRETE FORMWORK FOR
CONSTRUCTION APPLICATION.

By: Melkamu Asfaw Dinkisa

Advisor: Birhanu Tolesa (PhD)

A Research Proposal Submitted to the Department of

Manufacturing Technology in Partial Fulfillment for the Degree
Master of Science in Manufacturing Technology

March 2025 G.C

Addis Ababa, Ethiopia
 FDRE TECHNICAL & VOCATIONAL TRAINING INSTITUTE
FACULTY OF MECHANICAL TECHNOLOGY
DEPARTMENT OF MANUFACTURING TECHNOLOGY
MSc. Research Proposal
APPROVAL SHEET FOR SUBMITTING RESEARCH PROPOSAL

Title: An experimental investigation of glass powder reinforced RHDPE polymer

matrix lightweight concrete formwork for construction application.

Submitted by:

Melkamu Asfaw Dinkisa Signature_________ Date__________

Approved by:

1. ___________________ ______________ ______________

Major Advisor Signature Date

2. ___________________ ______________ ______________

Co- Advisor Signature Date

3. ___________________ ______________ ______________

Chairman, DGC Signature Date

4. ___________________ ______________ ______________

Dean, SGS Signature Date

i|Page
Declaration

Hereby declare that the research work titled " An experimental investigation of glass powder
reinforced RHDPE polymer matrix lightweight concrete formwork for construction application."
is my own work, submitted in partial fulfillment of the Master’s Degree of in Manufacturing
Technology is a record of original work carried out by us under the supervision and conducted
under the guidance of Dr. Birhanu Tolesa at FDRE Technical & Vocational Training Institute.
The information and data presented in this Study are genuine and have not been submitted
elsewhere for any degree or qualification.
All sources of information and materials used in this research have been properly acknowledged,
and I have adhered to the ethical standards and guidelines set forth by FDRE Technical &
Vocational Training Institute throughout the development of this Study.
I understand that any violation of the academic integrity policies, including plagiarism, will
result in appropriate actions being taken by the institution. In keeping with the ethical practice in
reporting scientific information, due acknowledgements have been made wherever the findings
of others have been cited.

Name Signature
1. Melkamu Asfaw Dinkisa ___________________

Date of Submission

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Acknowledgement

This Study would not have been possible without the support of many people. We would like to
thank our supervisor Dr. Birhanu Tolesa for his guidance and support throughout this Study.
We also would like to thank our teachers for their strong support.
We would also like to give special thanks to our family as a whole for their continuous support
and understanding when undertaking our research and writing our Study. Your prayer for us was
what sustained us this far.
Finally, we would like to thank God, for letting us through all the difficulties. We have
experienced your guidance day by day. You are the one who let us finish our degree. We will
keep on trusting you for our future.

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Executive Summery
Plastic waste has become a major environmental concern worldwide, requiring urgent and
sustainable solution. One effective approach is recycling and repurposing plastic waste into
useful construction materials. Simultaneously, the construction industry, particularly in Ethiopia,
is experiencing rapid growth, leading to an increasing demand for cost-effective and durable
building materials. This study aims to explore the feasibility of utilizing High-Density
Polyethylene (HDPE) plastic waste and Glass powder as alternative materials for concrete
formwork in construction.
The research investigates different proportions of HDPE plastic waste and Glass powder
incorporated into concrete formwork to determine their mechanical properties, durability, and
cost-effectiveness compared to conventional formwork materials such as timber and steel.
Various experimental tests on strength, flexibility, water absorption, and load-bearing capacity
will be conducted to assess performance. Additionally, an economic and environmental impact
analysis will be carried out to evaluate the cost savings and sustainability benefits of the
proposed material.
Preliminary findings are expected to indicate that plastic waste and Glass powder formworks are
lightweight, durable, and cost-effective, while also reducing the environmental impact associated
with plastic pollution and excessive use of natural resources. By integrating these materials into
construction practices, this research contributes to sustainable building solutions and promotes a
circular economy in Ethiopia.

Keywords: Plastic Waste, High-Density Polyethylene (HDPE), Glass powder, Concrete

Formwork, Sustainable Construction, Circular Economy.

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 TABLE OF CONTENTS

Approval sheet for submitting research proposal

Declaration
Acknowledgement
Executive summery
Table of contents
List of figures and tables
List of figures
List of tables
Abbreviations
Chapter 1
1. Introduction
1.1 Backgrounds
1.2 Statement of the problem
1.3. Research questions
1.4. Objective of the study
1.4.1. General objective
1.4.2. Specific objective
1.5. Significance of the study
1.6. Scope and delimitation of the study
1.7. Limitation of the study……….
1.8. Delimitation of the study……….
1.9. Organization of the study……….
Chapter 2
2. Literature review
2.1. Introduction
2.2 Types of concrete form work
2.3. Importance of RHDPE and Glass powder Composite Formwork
2.4. Composite Materials in Construction formwork
2.5. Effects of RHDPE and Recycle Glass Composite Formwork
2.6. Summary of literature review
2.7. Research gap
Chapter 3
3. Materials and Methodology

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 3.1. Introduction
3.2. Material selection
3.3. Methodology
3.4. Design of experiments
3.5. Composite formulation
3.6. Composite Fabrication
3.7. Data Analysis and Optimization
Chapter 4
4. Time schedule and budget breakdown
4.1. Research timeline
4.2. Budget Breakdown
Reference

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 List of Figures and Tables

List of figures

Figure 1. Chart Types of Formwork in Construction......................................................................9

Figure 2. Flow chart for methodology 18

List of Tables

Table 1. Characterization Tests.....................................................................................................17

Table 2. Time schedule for research..............................................................................................19
Table 3. Budget for research..........................................................................................................20

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 ABREVIATIONS

ASTM : American Society for Testing and Materials

ACI : American Concrete Institute
ES : Ethiopian Standard
FRC : Fiber Reinforced Concrete
FRP : Fiber Reinforced Polymer
HDPE : High-Density Polyethylene
IS : Indian Standard
LCA : Life Cycle Assessment
LDPE : Low-Density Polyethylene
IMM : Injection Mold Machine
MMT : million metric tones
MDPE : Medium-Density Polyethylene
PFR : Polypropylene Fiber Reinforced
PVC : Polypropylene
SFRC : Steel Fiber Reinforced Concrete
SNFRC: Synthetic Fiber Reinforced Concrete
UTM : Universal Testing Machine

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 CHAPTER ONE
1. INTRODUCTION

1.1 Background of the study

In recent decades, the construction industry has undergone significant advancements, with a
growing emphasis on sustainable and eco-friendly building materials. One of the critical
components of any concrete structure is formwork, which provides a temporary mold for fresh
concrete until it gains sufficient strength. Traditionally, formworks are made from materials such
as timber, plywood, aluminum, and steel, each with its own advantages and limitations.
However, the rising demand for construction materials, combined with deforestation, high costs,
and material shortages, has created the need for alternative, cost-effective, and environmentally
friendly solutions[1].
Simultaneously, plastic waste has become a major environmental challenge worldwide,
particularly in developing countries like Ethiopia, where proper waste management infrastructure
is lacking. Among the different types of plastic waste, High-Density Polyethylene (HDPE) is one
of the most commonly used and discarded plastics, found in items such as bottles, containers,
pipes, and packaging materials[2]. Due to its non-biodegradable nature, HDPE waste
accumulates in landfills and the environment, causing severe ecological damage. Recycling and
repurposing plastic waste into valuable construction materials could be a viable solution to
mitigate environmental pollution while also addressing material shortages in the construction
sector[3].
At the same time, glass waste is another environmental concern. Millions of tons of glass are
discarded each year, with only a small percentage being recycled. Glass powder can be crushed
into fine particles and used as a replacement for various construction materials. When
incorporated into plastic-based formwork, Glass powder can enhance mechanical strength,
durability, and thermal resistance. An experimental approach using Injection mold machine and
universal testing machine (UTM) was employed to study the effect of low strain rate loading on
HDPE/saw dust composites. In fiber reinforced polymer composites, the increment of filler may
increase its tensile strength. In general, the filler is incapable to endure the stress transmission
efficiently and resulting low compression strength [4].
1.2 Statement of the problem
Ethiopia, like many developing nations, faces significant plastic pollution due to the excessive
use of single-use plastics and improper waste disposal. A considerable portion of this waste
consists of HDPE plastic, which is widely used in daily applications but rarely recycled
effectively. The accumulation of plastic waste leads to landfill overflow, environmental
degradation, and public health hazards.
On the other hand, the construction industry is expanding rapidly, increasing the demand for
materials such as wood, steel, and plywood for concrete formwork. The reliance on timber-based
formwork contributes to deforestation, while steel formwork is often expensive and energy-
intensive to produce. Additionally, traditional formwork materials have durability issues, such as
susceptibility to moisture, warping, and short lifespan, increasing construction costs over time.
Given these challenges, this study seeks to explore an innovative and sustainable alternative by
utilizing HDPE plastic waste and Glass powder to produce lightweight, reusable, and cost-
effective concrete formwork. This solution aims to address two major concerns:
1. Reducing environmental pollution by repurposing plastic and glass waste.
2. Providing an affordable and durable alternative to traditional formwork materials.
3. Environmental Impact: Timber formwork contributes to deforestation, while steel
formwork is energy-intensive to produce.
4. Economic Cost: Both timber and steel formwork are expensive and often single-use or
limited in reuse.

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1.3 Research Questions
1. What are the physical and mechanical properties of RHDPE plastic waste and Glass
powder when used in concrete formwork?
2. How do these materials compare to traditional formwork materials (timber, steel, and
plywood) in terms of strength, durability, and performance?
3. How does the proposed plastic-based formwork perform in terms of load-bearing
capacity, flexibility, and reusability?
4. What are the moisture resistance, thermal resistance of RHDPE plastic waste and Glass
powder formwork?

1.4 General Objective of the study

1.4.1 General objective of the study

The main objective of this research is to develop and evaluate a lightweight, reusable composite
concrete formwork system reinforced with glass powder and Recycled High-Density
Polyethylene (RHDPE). The goal is to provide a sustainable, cost-effective alternative to
traditional formwork materials, specifically custom-made to address the challenges posed by the
rapid urban expansion in Addis Ababa, including the supply-demand imbalance, escalating
construction costs, and environmental concerns.

1.4.2 Specific objectives of the study

1. To measure the mechanical properties (strength, load-bearing capacity, and durability) of
concrete formwork made from Recycle HDPE plastic waste and Glass powder.
2. To compare the performance of the proposed alternative formwork with conventional
materials like timber and steel, aluminum.
3. To evaluate the cost-effectiveness of using plastic waste and Glass powder in
construction formwork.
4. To analyze the environmental impact of repurposing Recycle HDPE plastic waste and
glass powder in construction applications.

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1.5 Significance of the Study

This study is significant in advancing sustainable construction by developing lightweight,

reusable composite materials for concrete formwork using Recycled High-Density Polyethylene
(RHDPE) and Glass powder. The research offers a cost-effective alternative to traditional
formwork materials like timber and steel, providing enhanced durability, wear resistance, and
moisture protection. By repurposing waste materials, it promotes recycling, reduces plastic
waste, and addresses material shortages in the construction industry. The findings of this study
contribute to environmental conservation and offer a practical solution for sustainable building
practices, influencing the future of construction materials and practices.
1.6 Scope of the Study

This study focuses on fabricating and analyzing RHDPE and Glass powder composites for
concrete formwork applications. The key areas of investigation are:
 Reinforcement Effects: Analyzing how different reinforcement materials affect the
mechanical properties of the composites.
 Wear Behavior: Evaluating the wear resistance of the composites under various loading
and sliding conditions.
 Optimization: Optimizing the reinforcement type, size, and volume fraction to enhance
the performance of the composite materials.

The research involves experimental fabrication and mechanical testing and characterization, with
data analysis based on standard testing methods for materials used in construction.

1.7 Limitation of the Study

 The study will focus on small-scale applications and may not cover large-scale industrial use.
 The research will be limited to specific ratios of RHDPE and Glass powder; other
combinations will not be explored.
 Long-term durability testing beyond a certain period may not be feasible within the study's
timeframe.
 The economic analysis will be based on regional cost data and may not be universally
applicable.

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1.8 Delimitation of the Study
This study is intentionally bounded to ensure focus, feasibility, and relevance within the
constraints of time, resources, and local context. The research is geographically confined to
Addis Ababa, Ethiopia, and while its findings may provide insights for other regions, they are
not directly applicable due to differences in climate, construction practices, and material
availability. The study specifically investigates the development and performance of a composite
material made from recycled high-density polyethylene (RHDPE) and Glass powder, selected for
their sustainability, cost-effectiveness, and local availability. Other materials or advanced
innovations in concrete formwork are excluded.
Time constraints limit the scope of field testing and the number of construction sites, restricting
the evaluation to short- to medium-term outcomes. Long-term durability, performance under
extreme conditions, or multi-year assessments is beyond the study's scope. The economic
analysis focuses specially on direct costs and savings, such as material production, labor, and
waste reduction, excluding broader factors like market fluctuations, regulatory impacts, or
secondary economic benefits. Additionally, the study operates within the technological and
resource limitations of Addis Ababa, avoiding high-tech equipment or experimental processes to
ensure practicality and local applicability. These delimitations ensure the study remains focused,
practical, and achievable, while providing valuable insights into the use of sustainable composite
materials in Addis Ababa's construction sector. The research aims to contribute to localized
solutions for sustainable construction, emphasizing cost-effectiveness, resource efficiency, and
environmental benefits.

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1.9 Organization of the study
This research is structured into six chapters, ensuring a logical and systematic presentation of the
study. Each chapter builds upon the previous one to provide a clear understanding of the
development, evaluation, and significance of the RHDPE and recycled glass composite
formwork system.
Chapter One: Introduction
This chapter provides an overview of the study, including:
Background of the Study: Highlights the challenges in conventional construction formwork and
the need for sustainable alternatives. Problem Statement: Identifies key issues related to
traditional formwork materials and plastic waste management. Research Objectives & Questions:
Defines the study’s purpose and key questions to be addressed. Significance of the Study:
Explains the study’s contribution to sustainability, construction cost reduction, and
environmental conservation. Scope, Limitations, and Delimitations: Establishes the study's focus,
constraints, and applicability.
Chapter Two: Literature Review
This chapter presents a review of relevant literature to establish the study’s foundation. It
includes:
2.1 Introduction – Overview of the literature review approach.
2.2 Types of Concrete Formwork – Discussion of conventional formwork materials (timber,
steel, plywood, aluminum) and their limitations.
2.3 Importance of Recycled HDPE and Recycled Glass Composite Formwork – Justification for
using these materials in formwork systems.
2.4 Composite Materials in Construction Formwork – Review of polymer-based composite
materials and their application in construction.
2.5 Effects of Recycled HDPE and Recycled Glass Composite Formwork – Analysis of its
impact on mechanical strength, durability, reusability, and cost-effectiveness.
2.6 Summary of Literature Review – Summary of previous experimental studies on similar
composite materials. Key takes away from existing studies.
2.7 Research Gap – Identification of gaps in knowledge that this study aims to address.

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Chapter Three: Methodology and Materials
This chapter outlines the research design, materials, fabrication process, and testing methods. It
covers:
3.1 Introduction – Overview of the research methodology.
3.2 Materials Selection and Preparation – Description of the raw materials (RHDPE, recycled
glass) and preparation techniques.
3.3 Methodology – Explanation of the research approach, including experimental and analytical
methods.
3.4 Composite Formulation – Process of blending RHDPE and recycled glass to form the
composite.
3.5 Design of Experiments – Experimental setup and factor levels (. RHDPE-to-glass ratio,
temperature, pressure).
3.6 Characterization – Mechanical, physical, and environmental testing standards.
3.7 Fabrication and Testing – Step-by-step description of the manufacturing and testing
procedures.
3.8 Data Analysis and Optimization – Methods used for statistical analysis, performance
evaluation, and result interpretation.
3.9 Summary – Recap of the methodology and expected outcomes.
Chapter Four: Time Schedule and Budget Breakdown
This chapter details the financial and timeline planning for the research. It includes:
4.1 Budget Breakdown – Estimated costs for materials, equipment, labor, and testing.
4.2 Research Timeline – Gantt chart or schedule outlining the key phases of the study.

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 CHAPTER TWO

2. LITRATURE REVIEW

2.1. Introduction
In our day to day life activities, the literature review serves to provide a comprehensive overview
of existing research, theories, and practices related to the development and use of composite
materials in construction, specifically in the context of concrete formwork[5]. This chapter
explores the background, key studies, and gaps in the current body of knowledge that the. Study
aims to address.
Concrete formwork plays a crucial role in the construction industry, providing temporary support
and shaping for freshly poured concrete until it gains sufficient strength[6]. Traditional
formwork materials such as timber, plywood, aluminum, and steel have been widely used due to
their availability and effectiveness. However, these materials come with significant
environmental and economic concerns, including deforestation, high costs, and limited
reusability[7], [8].

With the growing emphasis on sustainability and waste management, researchers and engineers
are exploring alternative materials for formwork production. One promising approach is the use
of recycled plastic waste and glass to develop lightweight, cost-effective, and durable formwork.
This chapter reviews existing literature on conventional and alternative formwork materials,
highlighting their advantages, limitations, and potential for sustainable construction[9], [10].

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2.2. Types of concrete form work
Concrete formwork is a critical component in construction, providing the molds in which
concrete is cast until it gains sufficient strength to support itself. Traditionally, formwork has
been made from materials such as timber, plywood, and steel, each with its own advantages and
disadvantages[5], [11]. This section reviews the evolution of formwork materials and
technologies, highlighting the need for innovation in this area.

Types of
Formwork in
construction

Timber &
Steel Aluminum Plastic
Plywood
Formwork Formwork Formwork
Formwork

Figure 1: Chart Types of Formwork in Construction

Timber & Plywood: Readily available and easy to use but prone to warping, degradation, and
limited reuse, leading to higher costs and environmental impact. Timber formwork is the most
common type of formwork among all others. Timber forms are extensively used in construction
since the ancient period. Timber formwork is the oldest type of form used in construction[12].
Plywood formwork: is one of re-molded timber resin-bonded plywood sheets are attached to
timber frames to make up panels of the required sizes. It is strong, flexible, and easy to handle.
Its life is too short compared to other materials[12].
Steel: Highly durable and reusable, ideal for large projects but heavy, costly, and labor-intensive,
with high environmental impact. Formwork is one become more popular due to its strength,
durability, and repetitive reuse for a long period. Steel formwork is costly for small work but can
be used for a large number of projects. Steel shuttering offers a smooth surface finish to concrete
compared to timber formwork[13]. It can be used for circular or curved structures such as tanks,
columns, chimneys, sewers, tunnels, and retaining walls.

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Aluminum: Lighter than steel with good reusability but high initial costs and recycling
challenges. Aluminum formwork is almost the same as formwork made from steel. Shuttering
down with aluminum form is proven economical if large numbers of repeating usage are made in
construction[14]. Its major drawback is that no alteration is possible once the formwork is
constructed.
Plastic: A lightweight, reusable, and moisture-resistant alternative with lower labor costs and
reduced waste, though it may have lower load capacity than metal options. Plastic formworks are
lightly weighted, interlocking systems and can be used more than 100 times. It can be used for
normal concrete construction[15]. This type of formwork is now becoming popular for similar
shapes and large housing schemes.

2.3. Importance of Recycled High-Density Polyethylene (RHDPE) and Glass powder

Composite Formwork.
Formwork is a cornerstone of modern construction, particularly for concrete structures, offering
a range of benefits that enhance efficiency, safety, quality, and cost-effectiveness[15]. Its
primary role is to shape and support fresh concrete until it gains sufficient strength, making it
irreplaceable in modern construction[16]. Formwork enables the rapid construction of concrete
structures, significantly reducing project timelines by lowering the floor-to-floor cycle time. This
efficiency allows construction teams to complete projects faster and take on more work within
the same timeframe, meeting budgetary demands.
One of the key advantages of formwork is its cost-effectiveness. By reducing construction time
and labor costs, it contributes to overall savings. Reusable formwork systems, such as those
made from steel or aluminum, further enhance cost efficiency by being used across multiple
projects, minimizing material wastage and promoting sustainability[15]. Additionally, formwork
provides safe working platforms and access to elevated areas, significantly improving worker
safety and reducing the risk of accidents. Properly designed formwork systems also ensure
structural stability during construction by handling overlay loads, such as the weight of wet
concrete and construction equipment[17].
Formwork plays a crucial role in achieving high-quality finishes and precise dimensions, which
are essential for both structural integrity and aesthetic appeal. Advanced systems allow for
intricate designs and complex geometries, enabling architects and engineers to realize creative
visions. Moreover, formwork facilitates efficient resource utilization by enabling precise

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shuttering and de-shuttering, ensuring materials and labor are used optimally[18]. This precision
also enhances project management by providing predictable timelines and resource requirements,
helping construction managers keep projects on schedule and within budget.
In recent years, innovative materials like Recycled High-Density Polyethylene (RHDPE) and
Glass powder Combination Composite Formwork have emerged, offering additional benefits.
These materials are not only reusable but also lightweight, making them easier to handle and
transport, which further reduces labor costs and construction time. The use of recycled materials
in formwork significantly reduces environmental pollution by minimizing waste and promoting
the reuse of resources[18]. This aligns with sustainable construction practices, contributing to a
reduction in the carbon footprint of construction projects.
2.4. Composite Materials in Construction Formwork
Composite materials, which combine two or more substances to enhance performance, have
gained traction in construction for their potential to improve sustainability and durability.
Recycled plastics, such as HDPE, are valued for their moisture resistance, chemical stability, and
flexibility, making them suitable for construction applications [9]. Similarly, Glass powder is
widely used as a reinforcing agent due to its high tensile strength and wear resistance. Hybrid
composites, which combine recycled plastics and glass, have shown promise in achieving
enhanced strength, durability, and environmental benefits [4]. However, their application in
formwork systems, particularly in resource-constrained and rapidly urbanizing settings, remains
underexplored.
2.5. Effects of Recycled High-Density Polyethylene (RHDPE) and Glass powder
Composite Formwork
The combination of Recycled High-Density Polyethylene (RHDPE) and Glass powder in
formwork presents both positive and potential challenges in construction applications. Below is
an analysis of its structural, environmental, economic, and construction-related effects:
Structural Effects: The combination of RHDPE and Glass powder in formwork results in a
material with improved durability compared to conventional plastic formwork. RHDPE provides
resistance to cracking, moisture, and chemical degradation, while Glass powder offers additional
rigidity and strength[13]. However, while the composite material exhibits good performance in
many aspects, it may not achieve the same high load-bearing capacity or toughness as steel or
timber, which could limit its use in heavy-duty applications or structures with high demands for

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formwork strength[19]. A key benefit of using this composite is its lightweight characteristic,
which makes it easier to handle, transport, and install compared to traditional formwork
materials. This reduction in weight also reduces labor costs and the risk of injury during manual
handling, making it safer and more efficient for workers.

Environmental Effects: The use of recycled materials is one of the composite’s primary
environmental benefits. Both RHDPE and Glass powder are often diverted from landfills,
promoting waste reduction and supporting a circular economy. Using these materials in
formwork contributes to lowering the environmental impact associated with the production and
disposal of virgin plastic and glass products. Producing RHDPE and Glass powder for formwork
generally has a lower carbon footprint than manufacturing new materials[18]. The recycling
process requires less energy than producing virgin plastics or glass, thus reducing overall
emissions. However, the long-term environmental impact, including the composite's recyclability
at the end of its life cycle, requires further study to determine whether the material can be
effectively repurposed or whether it will contribute to waste accumulation. Although durable
under typical construction conditions, the composite material may not perform as well in extreme
climates or environments with high levels of exposure to ultraviolet (UV) radiation, chemicals,
or high temperatures. This could limit its application in certain environments, requiring
additional protection or treatment for long-term outdoor use.
Economic Effects: Using recycled materials like RHDPE and glass can significantly lower the
material cost of formwork[18]. Additionally, the lightweight nature of the composite reduces
transportation and handling expenses, while its durability can result in lower maintenance costs
over time. These factors contribute to potential cost savings compared to traditional timber or
metal formwork systems. While the initial production cost of the composite material may be
higher due to the processing and development involved, the cost-benefit over time could prove
favorable, particularly in areas where material supply chains are less reliable or more expensive.
The composite’s long-term reusability and potential for fewer replacements could make it a more
cost-effective solution in the long run, although the full economic viability would require
detailed lifecycle cost analyses[11], [12]. The economic success of this composite material will
depend on its acceptance within the construction industry[11]. Contractors may be hesitant to
adopt a new material due to unfamiliarity or concerns over performance and cost comparisons

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with traditional materials. Widespread adoption may require education, pilot projects, and long-
term testing to prove its value and reliability.
Construction-Related Effects: The composite formwork is lightweight, making it easier for
construction workers to handle, position, and remove, which improves efficiency and reduces
labor costs. The reusability of the formwork system means it can be used multiple times; further
reducing waste and material costs over its lifecycle[20]. The flexibility of RHDPE also allows
for more versatile designs in formwork applications, offering a broader range of project
possibilities. One of the main challenges to widespread adoption is the need for construction
professionals to become familiar with the new composite material and its handling requirements.
Some resistance might come from contractors who are accustomed to traditional formwork
materials. Additionally, the material’s ability to perform in heavy-duty or high-stress
environments, like large-scale infrastructure projects, may need to be validated through further
research and real-world testing. The durability of RHDPE and Glass powder composite
formwork may lead to lower maintenance costs over time, as the material is resistant to the rot
and wear common with timber formwork[21], [22], [23]. However, the long-term durability of
the composite material must be carefully monitored, especially in areas subject to significant
stress or exposure to harsh environmental conditions. Periodic inspection and proper care are
required to ensure it performs optimally throughout its lifecycle[20].

2.6. Summary of Literature Review

The literature review highlights the growing need for sustainable, cost-effective, and reusable
formwork systems in the construction industry. Traditional formwork materials—such as timber,
steel, and conventional plastics—have been widely used but present various challenges. Timber,
though commonly used, is associated with deforestation, short lifespan, and high replacement
costs due to wear and tear. Steel formwork offers durability and reusability but is expensive,
heavy, and requires significant labor for handling. Conventional plastic formworks, while
reusable, often lack sufficient strength and stiffness for large-scale applications.
Recent studies have explored the use of recycled materials and composite technologies to
improve formwork performance and sustainability. Researchers have investigated various
recycled materials, including polymers, glass fibers, and waste aggregates, in concrete
construction. However, their direct application in formwork systems remains limited, with most
studies focusing on permanent structural components rather than temporary mold systems.

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The review further identifies key gaps in research related to the mechanical properties,
durability, and cost-effectiveness of composite formwork solutions. Although Recycled High-
Density Polyethylene (RHDPE) and Glass powder have been studied separately for various
construction applications, their combination in formwork has not been extensively examined.
Studies indicate that RHDPE offers good flexibility, durability, and chemical resistance, while
Glass powder can enhance stiffness and improve fire resistance. However, comprehensive
research on their combined structural performance, reusability, and economic feasibility in
formwork applications is lacking. This study seeks to address these gaps by developing, testing,
and evaluating a composite formwork system made from RHDPE and Glass powder. The
research aims to assess its mechanical properties, long-term durability, reusability, and potential
cost savings compared to conventional formwork materials.

2.7. Research Gap

In the face of extensive research on composite materials and sustainable construction, significant
gaps remain, particularly in the application of recycled high-density polyethylene (RHDPE) and
Glass powder composites. While individual studies on recycled plastics and glass are abundant,
there is limited exploration of their combined use in composite formwork materials. Key gaps
include the lack of research on the reusability, environmental impact, mechanical properties, and
economic feasibility of such hybrid systems. Additionally, there is a scarcity of studies
addressing the application of innovative formwork materials in rapidly urbanizing contexts like
Addis Ababa, Ethiopia, where sustainable and cost-effective solutions are urgently needed.
Furthermore, existing research often isolates environmental benefits from economic analysis,
leaving a need for a holistic cost-benefit evaluation that integrates both aspects.

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 CHAPTER THREE

3. MATERIALS AND METHODOLOGY

3.1 Introduction
This chapter outlines the materials used and the methodology adopted for evaluating the
feasibility of Recycled High-Density Polyethylene (RHDPE) and Recycled Glass Composite
Formwork. The research focuses on material selection, sample preparation, experimental
procedures, and data analysis to assess mechanical properties, durability, and cost-effectiveness
the systematic approach taken to develop lightweight reusable concrete formwork panels. It
includes the design methodology, selection of materials, fabrication processes, testing protocols,
and implementation strategies. The chapter aims to provide a comprehensive understanding of
how the Study evolved from concept to execution, ensuring that the final product meets the
functional, economic, and environmental objectives set forth. The test methods and analysis will
be adopted conformed to ASTM standard, British Standards, and other conventional standard
methods.

3.2 Materials Selection

This study focuses on developing a recycled high-density polyethylene (RHDPE) and Glass
powder composite for sustainable construction formwork. The materials are selected for their
availability, cost-effectiveness, and environmental benefits, aligning with the goal of creating
eco-friendly solutions for rapidly urbanizing cities like Addis Ababa.
The raw materials are sourced locally from waste management facilities, recycling centers, and
municipal waste streams within Addis Ababa. RHDPE proportion 60% is primarily obtained
from commonly discarded plastic products such as bottles, containers, and packaging, while
Glass powder proportion 40% is sourced from used glass bottles, windows, and other glassware.
Both materials undergo sorting, cleaning, and processing (such as shredding and crushing) to
ensure they meet the necessary quality standards for composite formulation. By utilizing locally
sourced waste materials, this approach not only supports waste reduction and recycling
initiatives but also offers a sustainable and cost-effective solution tailored to the specific needs of
the region's construction industry.

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3.3 Methodology

The methodology for this study is designed to systematically develop, test, and evaluate the
recycled high-density polyethylene (RHDPE) and Glass powder composite for construction
formwork applications. The approach integrates material preparation, experimental design,
fabrication, testing, and data analysis to ensure robust and reliable results.

3.4 Design of Experiments

The experimental approach is employed in which it is classified into four phases to achieve these
objectives the experimental design in phases, which is a great way to organize the research
process and Design of Experiments (DoE) is a structured, statistical approach used to plan,
conduct, analyze, and interpret controlled tests to evaluate the effect of multiple factors on a
process or product outcome. It is a powerful tool for optimizing processes, improving product
quality, and understanding interactions between variables. In this research, DoE will be
employed to systematically investigate the performance of recycled high-density polyethylene
(RHDPE) and Glass powder composites for construction formwork applications.

A factorial design will be used to explore the interactions between factors. For example, a full
factorial design with three factors at three levels each would require 27 experimental runs (3³ =
27), N=L F =33=2 7 ensuring robust statistical analysis. However, to reduce the number of trials,
a fractional factorial design or Taguchi method may be employed, depending on the complexity
and resources available. Design of Experiment (DoE) is a powerful tool for efficiently designing
and analyzing experiments in composite formwork development, enabling the creation of high-
performance materials with optimized properties like strength, durability, and water absorption.
Using designs like factorial, Taguchi, or RSM, it minimizes trials while maximizing efficiency.
The primary objective is to ensure that the composite material meets the required mechanical,
thermal, and durability properties for construction applications. The process involves material,
composite formulation, fabrication and optimization to achieve a sustainable and cost-effective
alternative to traditional formwork materials[23], [25], [26].

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3.5 Composite Formulation

The composite formulation process involves blending Recycled High-Density Polyethylene

(RHDPE) and Glass powder in specific proportions to create a material with enhanced
mechanical, thermal, and durability properties suitable for construction formwork. This section
outlines the steps, materials, and considerations involved in formulating the composite[24].
Proportions of RHDPE to Glass powder are varied to assess the best formulation for formwork
performance. The study will focus on the following factors and their respective levels:

 Factor 1: RHDPE-to-Glass Ratio (70:30, 60:40, 50:50)

 Factor 2: Processing Temperature and Curing Times (160°C - 200°C and 24 - 72hours)
 Factor 3: Compression Pressure (10 MPa, 15 MPa, 20 MPa)

These factors will be tested at multiple levels to understand their individual and combined effects
on the composite's properties, such as tensile strength, flexural strength, durability, and
reusability. Composite panels are fabricated by blending RHDPE and Glass powder in specified
ratios, followed by a controlled curing process[21], [23]. The response variables measured and
testing includes:
Table 1: Characterization Tests
Category Property Testing Standard
Mechanical Compressive Strength ASTM C39
Flexural Strength ASTM C78
Tensile Strength ASTM D638
Impact Resistance ASTM D256
Physical Density ASTM D792
Water Absorption ASTM D570
Thermal Stability TGA Analysis
Environmental Reusability(Cycles to Failure) Experimental Evaluation

Recyclability Material Composition Analysis

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3.6 Composite Fabrication
The fabrication of glass powder-reinforced RHDPE composite panels follows a precise and
controlled process using an Injection Molding Machine (IMM). This process ensures the
uniformity, durability, and high-performance characteristics of the composite panels, with
consistent mechanical properties that are reproducible across production batches. These qualities
make the composite panels an ideal choice for construction formwork applications, where
reliability and structural integrity are crucial. The optimized IMM process can be seamlessly
integrated into Ethiopian manufacturing facilities equipped with standard injection molding
capabilities. Such facilities, particularly those located in the industrial zones of Addis Ababa,
have easy access to injection molding machines, which allows for the efficient and scalable
production of these composite panels. This makes the process both practical and feasible for
local manufacturers, helping to meet the demand for innovative, cost-effective construction
materials.
3.7 Data Analysis and Optimization
Data will be collected through controlled laboratory experiments, including material testing and
performance evaluations. Statistical tools such as Analysis of Variance (ANOVA) and Minitab
software regression analysis will be used to analyze the data, identify significant factors, and
develop predictive models for the composite's performance. The approach integrates material
preparation, experimental design, fabrication, testing, and data analysis to ensure robust and
reliable results. Below is a detailed outline of the methodology: The research flow chart for
methodology is demonstrated in the following.
Composite
Materials
Literature Formulation
Selection and
review and Fabrication
Preparation

Experimental
Data Analysis Results
Testing and
and Interpretation
Characterazitio
Optimization and Discussion
n

Conclusion/End

Figure 2: Flow chart for methodology

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 CHAPTER FOUR
4 TIME SCHEDULE AND BUDGET BREAKDOWN
4.1 Research Timeline

Phase 3 4 5 6 7 8 9 10 11 12

Date Description Duration

Start End
4/1/25 5/30/25 Materials Selection 2 month

6/2/25 8/28/25 Fabrication of 3 month

Samples
9/29/2 10/1/25 Characterization 1 month
5 and Testing
10/2/2 11/28/25 Data Analysis and 1 month
5 Interpretation
8/5/25 9/25/25 Writing paper 2 month

11/1/2 11/25/25 Review and 1 month

5 Comments
10/2/2 11/28/25 Presentation 2 month
5
12/2/2 12/28/25 Final Submission 1 month
5
Table 2: Research Timeline

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 4.2 Budget Breakdown
Table 3: Budget requirement for the research
1 Consumables cost Unit Quantity Unit Price Total cost
Pencil Pcs 4 ETB 2.00 ETB 8.00
Pen Pcs 4 ETB 15.00 ETB 60.00
Eraser Pcs 2 ETB 0.50 ETB 1.00
Marker Pcs 4 ETB 12.00 ETB 48.00
Note - book Pcs 4 ETB 7.00 ETB 88.00
Sub total ETB 205.00
2 Characterization of HDPE Unit no of sample Unit Price Total cost
Physicochemical analysis of test 1 ETB3,000.00 ETB 3,000.00
RHDPE and Recycle Glass
Sub total ETB3,000.00
3 Material Sourcing Unit no of sample Unit Price Total cost
RHDPE recycled plastic kg 1 ETB 655.0 ETB 655.0
Glass powder crushed glass kg 0.5 ETB 945.0 ETB 945.0
Sub total ETB 1600.00
4 Composite Fabrication Unit no of sample Unit Price Total cost
Injection Molding Machine 220V 2 ETB 505.0 ETB 1010.00
Universal Testing Machine test 2 ETB 305.0 ETB 610.00
Sub total ETB 1620.00
5 Characterization of Tests Unit no of sample Unit Price Total cost
Tensile Strength Testing test 10 ETB 75.0 ETB 750.00
Compressive Strength Testing test 10 ETB 55.0 ETB 550.00
Flexibility and Durability Test test 10 ETB 65.0 ETB 650.00
Material Characterization test 4 ETB 75.0 ETB 300.00
Sub total ETB 2,450.00
6 Daily subsistence allowance travel Unit no of trip Birr/ day Total cost
Researcher Trip 10 ETB 206.00 ETB2,060.00
Sub total ETB2,060.00
7 Expert cost no of person Birr/ person Total cost
Lab. Assistant No 2 ETB 2,000.0 ETB 4,000.00
Sub total ETB 4,000.00
8 Report reproduction Unit Quantity Unit Price Total cost
Printing Page 1080 ETB 1.00 ETB 1,080.00
Binding Pcs 11 ETB 10.00 ETB 110.00
Sub total ETB1,190.00
Grand total ETB16,125.00

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