Plastic lumber

Last updated
PVC window boxes 2010 windowboxes MarlboroughMA 4878255212.jpg
PVC window boxes

Plastic lumber is a plastic form of lumber made of virgin or recycled plastic. It is mostly made of plastic and binders such as fiberglass or rebar; not to be confused with wood-plastic composite lumber. Widely employed in outdoor decking, it is also used for molding and trim and garden furniture such as park benches. Resistant to cracking and splitting when appropriately installed, plastic lumber can be molded with or without simulated wood grain details. Even with a wood grain design, plastic lumber is still easy to distinguish visually from natural timber: the grains are the same uniform color as the rest of the material.

Contents

Manufacturers claim plastic lumber is more environmentally-friendly and requires less maintenance than wood/plastic composites or rot-resistant wood. [1] Commercially available polyvinyl chloride fiberglass composite lumber sold for decking meets stringent fire code standards. [2] Because plastic lumber can displace wood timber (as harvested by forestry), it can be a carbon negative and a carbon capture and utilization technology. [3]

Production

Plastic lumber is composed of virgin or waste plastics including HDPE, PVC, PP, ABS, PS and PLA. The powder or pellets are mixed to a dough-like consistency at roughly 400 °F (204 °C) and then extruded or molded to the desired shape. Additives such as colorants, coupling agents, stabilizers, blowing agents, reinforcing agents, foaming agents, and lubricants help tailor the end product to the target application. The material is formed into both solid and hollow profiles or into injection molded parts and products.

Resin, regrind, and most of the additives are combined and processed in a pelletizing extruder. The new material pellets are formed in a mold and cooled.

Properties

Plastic lumber can be molded to meet almost any desired spatial condition, a major advantage over wood. It can also be bent and fixed to form strong arching curves. Plastic lumber works like wood - it can be shaped, drilled, and cut using conventional woodworking tools. At the same time, it is waterproof and resists all types of rot and mold, although it is not as rigid as wood and may slightly deform in extremely hot weather. Plastic lumber is not sensitive to staining from a variety of agents. A major selling point of this material is it doesn't need to be painted and is overall low-maintenance. It is manufactured in a variety of colors, and is widely available in grays and earth tones.

While the compressive properties of plastic lumber are equal or greater than those of wood, the modulus of elasticity is very low. Moreover, plastic lumber is subject to far more creep than wood. [4] Use in load-bearing structures requires different considerations from wood. [4]

Some plastic lumber, such as commercially available polyvinyl chloride plastic decking fiberglass composite lumber, outperformed composite wood plyetheline composite lumbers in fire safety performance. [2] Plastic lumber also deforms easily at high temperature; planning for the event of fire needs to take this into account. [4]

Standards

ASTM has standardized test methods to measure the properties of plastic lumber: [5]

Applications

Plastic lumber is used in such applications as:

Most plastic lumber in decks is used as flooring. -111wiki.jpg
Most plastic lumber in decks is used as flooring.

See also

Related Research Articles

Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.

<span class="mw-page-title-main">Thermosetting polymer</span> Polymer obtained by irreversibly hardening (curing) a resin

In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure, or mixing with a catalyst. Heat is not necessarily applied externally, but is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.

<span class="mw-page-title-main">Lamination</span> Technique of fusing layers of material

Lamination is the technique/process of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance, or other properties from the use of the differing materials, such as plastic. A laminate is a permanently assembled object created using heat, pressure, welding, or adhesives. Various coating machines, machine presses and calendering equipment are used.

<span class="mw-page-title-main">Structural insulated panel</span>

A structural insulated panel, or structural insulating panel, (SIP), is a form of sandwich panel used in the construction industry.

<span class="mw-page-title-main">Plastic welding</span> Welding of semi-finished plastic materials

Plastic welding is welding for semi-finished plastic materials, and is described in ISO 472 as a process of uniting softened surfaces of materials, generally with the aid of heat. Welding of thermoplastics is accomplished in three sequential stages, namely surface preparation, application of heat and pressure, and cooling. Numerous welding methods have been developed for the joining of semi-finished plastic materials. Based on the mechanism of heat generation at the welding interface, welding methods for thermoplastics can be classified as external and internal heating methods, as shown in Fig 1.

Fibre-reinforced plastic is a composite material made of a polymer matrix reinforced with fibres. The fibres are usually glass, carbon, aramid, or basalt. Rarely, other fibres such as paper, wood, boron, or asbestos have been used. The polymer is usually an epoxy, vinyl ester, or polyester thermosetting plastic, though phenol formaldehyde resins are still in use.

<span class="mw-page-title-main">Wood-plastic composite</span> Composite materials made of wood fiber and thermoplastics

Wood-plastic composites (WPCs) are composite materials made of wood fiber/wood flour and thermoplastic(s) such as polythene (PE), polypropylene (PP), polyvinyl chloride (PVC), or polylactic acid (PLA).

<span class="mw-page-title-main">Compression molding</span> Method of molding

Compression molding is a method of molding in which the molding material, generally preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured; this process is known as compression molding method and in case of rubber it is also known as 'Vulcanisation'. The process employs thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms.

<span class="mw-page-title-main">Fiberglass molding</span> Process in which fiberglass reinforced resin plastics are formed into useful shapes

Fiberglass molding is a process in which fiberglass reinforced resin plastics are formed into useful shapes.

<span class="mw-page-title-main">Plastic extrusion</span> Melted plastic manufacturing process

Plastics extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weatherstripping, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings, and wire insulation.

<span class="mw-page-title-main">Kydex</span> Thermoplastic material

Kydex is a line of thermoplastic acrylic-polyvinyl chloride materials manufactured by Sekisui SPI. It has a wide variety of applications, including for aircraft bulkheads, firearm holsters, and sheaths.

Fiber-reinforced concrete or fibre-reinforced concrete (FRC) is concrete containing fibrous material which increases its structural integrity. It contains short discrete fibers that are uniformly distributed and randomly oriented. Fibers include steel fibers, glass fibers, synthetic fibers and natural fibers – each of which lend varying properties to the concrete. In addition, the character of fiber-reinforced concrete changes with varying concretes, fiber materials, geometries, distribution, orientation, and densities.

Composite construction is a generic term to describe any building construction involving multiple dissimilar materials. Composite construction is often used in building aircraft, watercraft, and building construction. There are several reasons to use composite materials including increased strength, aesthetics, and environmental sustainability.

<span class="mw-page-title-main">Flexural modulus</span>

In mechanics, the flexural modulus or bending modulus is an intensive property that is computed as the ratio of stress to strain in flexural deformation, or the tendency for a material to resist bending. It is determined from the slope of a stress-strain curve produced by a flexural test, and uses units of force per area. The flexural modulus defined using the 2-point (cantilever) and 3-point bend tests assumes a linear stress strain response.

Carbon fiber-reinforced polymers, carbon-fibre-reinforced polymers, carbon-fiber-reinforced plastics, carbon-fiber reinforced-thermoplastic, also known as carbon fiber, carbon composite, or just carbon, are extremely strong and light fiber-reinforced plastics that contain carbon fibers. CFRPs can be expensive to produce, but are commonly used wherever high strength-to-weight ratio and stiffness (rigidity) are required, such as aerospace, superstructures of ships, automotive, civil engineering, sports equipment, and an increasing number of consumer and technical applications.

<span class="mw-page-title-main">Granulation</span> Forming grains or granules from a powdery or solid substance

Granulation is the process of forming grains or granules from a powdery or solid substance, producing a granular material. It is applied in several technological processes in the chemical and pharmaceutical industries. Typically, granulation involves agglomeration of fine particles into larger granules, typically of size range between 0.2 and 4.0 mm depending on their subsequent use. Less commonly, it involves shredding or grinding solid material into finer granules or pellets.

<span class="mw-page-title-main">Plastic film</span> Thin continuous polymeric material

Plastic film is a thin continuous polymeric material. Thicker plastic material is often called a "sheet". These thin plastic membranes are used to separate areas or volumes, to hold items, to act as barriers, or as printable surfaces.

Composite lumber is a material that is a mixture of wood fiber, plastic, and some type of binding agent. These ingredients are put together to form a material that is denser, stronger, and heavier than wood alone, a wood-plastic composite.

Plastic is the generic name for a family of synthetic materials derived from petrochemicals. It is often product of two or more components.

References

  1. Dias, Bernardo Zandomenico; Alvarez, Cristina Engel de (June 2017). "Mechanical properties: wood lumber versus plastic lumber and thermoplastic composites". Ambiente Construído. 17 (2): 201–219. doi:10.1590/s1678-86212017000200153 . Retrieved 17 February 2023.
  2. 1 2 See Table 2 on page 7 of Malvar, L. Javier; Tichy, Robert; Pendleton, David E. (May 2001). Fire Issues In Engineered Wood Composites For Naval Waterfront Facilities. 46th International SAMPE Symposium and Exhibition. Long Beach, California. CiteSeerX   10.1.1.472.8781 .
  3. Sturla, Brandon (2020-03-01). "Analyzing More Sustainable Alternatives Than Using Ordinary Portland Cement in Commercial Construction". Construction Management.
  4. 1 2 3 Development and Testing of Plastic Lumber Materials for Construction Applications. DIANE Publishing. ISBN   978-1-4289-1323-3.
  5. Krishnaswamy, Prabhat; Lampo, Richard (2001). "Recycled-Plastic Lumber Standards: From Waste Plastics to Markets for Plastic-Lumber Bridges". CiteSeerX   10.1.1.551.129 .{{cite journal}}: Cite journal requires |journal= (help)