Garcia College of Technology

Kalibo, Aklan

“DEVELOPMENT OF COMPOSITE ROOF TILES UTILIZING

RECYCLED PLASTIC MATERIALS AND SAND”

A Research Study
Presented to:

ENGR. JOSEFINA R. DAGOHOY

Chair, Civil Engineering Department

In Partial Fulfilment
of the Requirements in Bachelor of Science in Civil Engineering

By:
MARICAR S. ALEJADO
ARIAN JADE O. ANDRADE
MARCO B. DELOS SANTOS
PAULINE S. ORQUIOLA
CASEY JOY PERUCHO
AMIEL RYLE A. REMBULAT
JANET TUMACA
BSCE-5

NOVEMBER 2019
 Garcia College of Technology
Kalibo, Aklan

Chapter 1
Introduction
Background of the Study
The roof is the main protective shell of a house and decisively affects its appearance.

During the planning phase, some important factor such as location or construction style of the

building, need to be taken into account. Roofing is also one of man’s most practical and

innovative creations. Throughout history, roofing materials and techniques have significantly

developed; as architecture has progressed, so has the design and production of roofs and the

architectural influences of each era can be clearly identified. Tile roofing has long been

considered a prevalent technique when installing a new roof to your home because of its

aesthetic appeal. Most importantly, a tile roof is great for insulation and protection against the

elements which include strong winds, inclement weather, fires, and earthquakes. The

fundamental function of roof tiling is to keep the building watertight, to give it a decent cap on

the off chance that you like. But tiling is about significantly more than that. They are highly

visual parts of a building, which add to the character of our townscapes in each viewpoint, from

domestic dwellings to buildings of high historical importance.

Traditionally roof tiles are usually made of concrete, slate, or clay. Recently there is a new

development on the use plastic roof tiles. They are tough, long lasting and relatively easy to

shape and produce. Plastics can be made to different shapes when they are heated. In closest

environment it exist in the different form such as cups, furniture’s, basin, plastic bags, food and

drinking containers, and they are become waste material. Accumulation of such waste can result

into hazardous effects to both human and plant life. Therefore, need for proper disposal, and, if

possible, use of these waste in their recycled forms occur. This can be done through process of
 Garcia College of Technology
Kalibo, Aklan

plastic management. Waste management in respect to plastic can be done recycling. If they are

not recycled then they will become big pollutant to the environment as they are not decompose

easily and also not allow the water to percolate in to the soil and they are recycled then they will

become big pollutant to the environment as they are not decomposed easily and also not allow

the water to percolate in to the soil and they are also poisonous. Utilization of these waste

materials is a partial solution to the environmental and ecological problems. Use of plastic helps

in getting them utilized in such types of material. It helps in reducing the cost of concrete

making. Aggregates are used in a variety of building applications, and can be said to be the

largest quantity of material used in any industry. Almost all aggregates are produced from

natural resources such as gravel, pits, river beds and rock quarries. In addition to depleting these

natural resources, mining for aggregates also poses serious environmental risks like disturbance

of natural habitats and creating open areas with no vegetation, therefore recycling of this material

has also indirect benefits such as reduction landfill cost, saving energy, and protecting the

environment from possible pollution effects. At a time when landfill space is becoming almost

impossible due to increasing land value, then recycling and reuse of wastes as beneficial

products should be strongly encouraged and examined. One potentially strong and viable market

is to developed recyclable waste into construction material, a common material used throughout

the construction industry. The reuse of waste materials in building construction is a great idea,

and the high demand for construction materials makes them a favourable medium in which to

reuse recyclable materials.

 Garcia College of Technology
Kalibo, Aklan

Abstract

The study investigates the most optimal mix ratio of the roof tile constituents to achieve the

desirable engineering properties of light weight, strength, and water tightness. Plastics are non-

biodegradable materials, so nature cannot absorb them as other waste. The purpose of this

research work was to provide an alternative to other traditional building technologies that

consume non-renewable resources, or produce negative environmental impact. It also paved the

way for the utilization of Expanded Polystyrene plastic as substitute for concrete in developing

roof tiles that will meet the ASTM requirements in order to help contribute to the industry in

saving the environment, to encourage the government to find solutions regarding the disposal to

landfills of solid waste materials, to provide new knowledge to the contractors and developers on

how to improve the construction industry methods and services by using recycled plastic

material, and to sustain good product performance and meet recycling goals.
 Garcia College of Technology
Kalibo, Aklan

Chapter 2

Literature Review

Roof tiles a manufactured piece of a hard wearing material such as ceramic, stone, metal,

or even glass, generally used for covering roofs, floors and walls. The word is derived from the

French word “tuile”. Roof tiles are designed primarily to keep out rain, and are traditionally

produced using locally available materials such as terracotta or slate. An extensive number of

shapes of roof tiles have developed. With modern technology, modern materials such as concrete

and plastic are also used and some clay tiles have a waterproof glaze.

Concrete roof tiles are made of mixture of sand, cement and water, which are moulded

under heat and high pressure. The exposed surface of a tile may be finished with paint like

material. Concrete tiles have additional water locks, or interlocking ribs on the edges that prevent

water infiltration. Concrete tiles can simulate the appearance of traditional clay tiles, wood

shake, slate and stone. Like clay, concrete tile surfaces can be textured or smooth, and tiles edges

can be ragged or uniform. They are resistant to hail wind, and fire, making them a very safe

roofing material when properly installed. It is clearly true that in just a few decades, plastic has

become a staple of most human societies.

The creation of plastic and its wide sweeping applications, has allowed for people to

acquire products much cheaper than they could in the past. In spite of plastic is continuously

increasing in recent years, which has a led to a big environmental problem. Increased demand for

plastic resulted to the increased volume of waste disposed in dumpsites, and remains visible in

waste streams and alleged, clogging and drainage canals. Plastic waste, like EPS, is non-

biodegradable but being a thermoplastic, it is a hundred percent recyclable. Therefore, in this

 Garcia College of Technology
Kalibo, Aklan

study, the researchers are pursuing for the solutions to develop a recycling technology for EPS

plastic waste; and to start converting this waste into functional and affordable products like

roofing tiles.

Recyclable materials were used in this research like waste Expanded Polystyrene (EPS)

plastic and used cooking oil. Sand, zinc oxide, and gas stove for liquefying were also used and

complement the materials needed to manufacture the roof tile.

 Garcia College of Technology
Kalibo, Aklan

Chapter 3
Methodology
Research Design
The method used in this study is the experimental method of research. This research
mainly focused on the development of an alternative construction material that will contribute to
the environmental decontamination and to reduce of using mechanical ventilation system which
is expensive. The goal is to determine the material, its properties and proportion to attain the
desired compressive strength of the roof tiles; and experiment to test some properties of the roof
tiles such as water absorption, compressive strength of the structure. Recyclable materials were
used in this research like waste Expanded Polystyrene (EPS) plastic and used cooking oil. Sand
and gas stove for liquefying were also used and complements the materials needed to
manufacture the roof tile.
Project Construction Procedure
1. The first process is the cutting of waste EPS into small pieces that is enough to fit inside
the metal container. This process is done by using a cutter and scissors.
2. After preheating oil in the metal container, the waste EPS pieces were poured and
allowed to liquefy.
3. And followed by a raw material, which is sand with an exact proportion.
4. Excess oil was removed from the metal container after EPS plastic was totally liquefied.
The sand was then poured and mixed until it all blended in.
5. The fifth process is the preparation and setting up of mould into a level surface. The
mould was initially brushed with oil so that product can be easily removed from the
mould.
6. Next, the mixture is poured into the mould gradually, to ensure that it is closely and
neatly packed together, some small forces have been applied on it using flat wood to
make it compacted.
7. EPS roof tile was left for 2 days. The last process is removal of solidified plastic roof tile
from the mould. And cut it to its desirable dimension.
 Garcia College of Technology
Kalibo, Aklan

System Model

Roof Tile Making Process: Compose the ratios of EPS plastic waste and sand

Collecting of Raw Materials: EPS, sand and used oil

Submerging EPS into pre-heated oil

Mixing of sand into melted EPS

Casting of mixture

Air Drying of Specimen (7 days)

Testing: Compressive Strength, Water Absorption and Density

Analysis of data obtained from mixture

Conclusion
 Garcia College of Technology
Kalibo, Aklan

Scope and Limitation

The study aims to determine the capability of recycled EPS plastic waste to act as a

binder for roof tile aggregates as a substitute for cement. Due to high cost of cement in the

market, the analysis of EPS plastic waste will reveal that this could be a substitute material to

help reduce the cost of the construction. Also, this research includes the determination and

computation of the cost of materials. The product of this study is limited only to the material

itself, to investigate the potential of EPS plastic waste for being used as a roof tile, and does not

concern the type, design and installation process of the roofing tiles. This study also includes

testing and identifying the water absorption, compressive strength, flexural strength and density

of the roof tile but not to guarantee to attain the minimum required strengths for roof tiles.
 Garcia College of Technology
Kalibo, Aklan

Statement of the Problem

Plastic pollution is a major problem in the Philippines which is frequently listed among

the world’s worst offenders. That’s why this study aims to demonstrate organization that by

using EPS to produce roof tile it can help to determine,

whether:

a) To analyze if by using of EPS or Expanded Polystyrene materials can save environmental

impact that may cause major problems for the future generations.

b) To determine the optimal mix ratio of the roof tile constituents to achieve the desirable

engineering properties of light weight, strength and water tightness.

c) EPS can be used as substitute for concrete to act as a binder for making of roof tiles.
 Garcia College of Technology
Kalibo, Aklan

Project Testing, Evaluation and Validation

Compressive Strength Test

ASTM 579 – 96 and ASTM 695 – 96 were used as a reference for the testing methods for the

determination of compressive strength of EPS roof tile. The researches provided cube samples

for the three different proportions since it was indicated that test specimen shall be cubes with

dimensions of 2-in. (50-mm).

Property Specification Requirements for Compressive Strength

Where:

M- High compressive-strength mortar, but not very workable

S- General all-purpose mortar with higher flexural bond strength

N- General all-purpose mortar with good bonding capabilities and workability

O- Low-strength mortar, used mostly for interior applications and restoration

Specification requirements for compressive strength of concrete roof tiles were carried out

according to ASTM C270 – 14. It indicates the values corresponding to the type of mixture used
 Garcia College of Technology
Kalibo, Aklan

for concrete roof tiles. Roof tiles were classified as type M which has high compressive-strength

mortar, but not very workable type of characteristics. The average compressive strength of

concrete roof tiles which is about 2500psi was used as a reference for the design strength of the

EPS roof tile.

Water Absorption Test

The water absorption was measured according to ASTM D570 - 98. The procedure used was the

Twenty-Four Hour Immersion where the conditioned specimens were placed in a container of

distilled water, rested on edge and were entirely immersed. At the end of 24h, the specimens

were removed from the water; all surfaces wiped off with a dry cloth and weighed to the nearest

0.001g immediately.

The water absorption is calculated as follows:

where:

M1 = conditioned weight

M2 = immersed weight

Standard Requirements for Water Absorption EPS roof tile.

 Garcia College of Technology
Kalibo, Aklan

In accordance with ASTM C1492 – 03, it shows the requirements for the water absorption that

tiles should be classified as normal, medium or lightweight with the corresponding standards for

the maximum absorption for roof tiles.

Density Test

The test was carried out according to ASTM D792 – 98. This test method was used to determine

the specific gravity and density. It was indicated that the test specimen shall be a single piece of

the material under test of any size and shape that can conveniently be prepared and tested.

Weight Classification

Weight Classification for Roof Tiles

It was carried out according to ASTM C1492 – 03.It indicates the weight variation for the roof

tiles to be classified as normal, medium or lightweight.

 Garcia College of Technology
Kalibo, Aklan

RESULTS AND DISCUSSION

The design requirement of this study is to use Expanded Polystyrene (EPS) plastic waste to act

as a binder for roof tiles as a substitute for cement; and to reduce the weight of roof tiles. EPS as

it proved an abundant waste in the Philippines, findings revealed that the use of it in construction

can be beneficial economically and environmentally. In this research, three mixes were studied.

The compositions of the plastic roof tile are characterized by their proportion by weight. The

compositions of the three proportions of roof tile are presented in the table 4.1

Compositions of the Mixtures

Components Proportion 1 Components Proportion 2

EPS (kg)
EPS (% of roof tile
composition)
AGGREGATES
(sand) kg
AGGREGATES (%
of roof tile
composition)
 Garcia College of Technology
Kalibo, Aklan

Result of Testing, Evaluation and Validation

Compressive Strength
The results of the compression tests from different samples for 7 days are tabulated below.
Proportion 1 (3:7) for Compression Test
Proportion 1
Average Compressive Strength (psi) =
Proportion 2 (6:4) for Compression Test
Proportion 2
Average Compressive Strength (psi) =
The following bar graphs show the compressive strength results that are presented in Psi
values for the different samples in each ratio.

Compressive Strength

3000
2900
2800
Stength (psi)

2700
2600
2500
2400
2300
2200
Proportion 1 (7:3) Proportion 2 (6:4)
 Garcia College of Technology
Kalibo, Aklan

Density Test

1.6
1.4
Unit Wieght (g/cc)

1.2
1
0.8
0.6
0.4
0.2
0
Poportion 1 proportion 2
 Garcia College of Technology
Kalibo, Aklan

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[2] Castillo, B. (2013). Status of Solid Waste Management in the Philippines. Retrieved from
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[3] Dubey, Prem. (2013). Concrete Roof Tile Manufacturing. Retrieved from
http://365days365businessideas.blogspot.com/2012/08/start-concrete-roof-tile-
manufacturing.html
[4] Loberiano, R., de Chavez, E., Redondo, M., Cerbito, R., Tolentino, M., and Bernardo, S.
(2009). Waste Foam Polystyrene Treatment and Recycling. Retrieved from
http://www2.gec.jp/gec/en/Activities/EST/2009/wasteplatics/TP2_TonyChiong.pdf
[5] Makai, A., Kiss, J., and Mucsi, G. (2015). The Possibilities of Polystyrene Waste Recycling.
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miskolc.hu/~microcad/publikaciok/2016/A_9_Makai_honlapra.pdf
[6] Paje, D. ( ). Retrieved from http://newsinfo.inquirer.net/42151/metro-manila-generates-25-of-
ph-daily-trash
[7] Sims, Bart. (2013). The Dangers of Polystyrene.Retrieved from
http://businessbarbados.com/trending/green-business/the-dangers-of-polystyrene/
[8] Taylor, Kevin. (2008). Roof Tiling and Slating: A Practical Guide. Crowood Press

Publisher. ISBN: 9781847970237.