Building Materials and construction-V

AR 8621, UNIT II –Plastics, 15 periods

Plastic as a building material. Brief history of their use through examples. Manufacture. Properties, types, uses and application
of plastics in building industry. Different types of adhesives and sealants. Plastic joints. Specific materials such as polycarbonate
sheet and Teflon. Introduction to plastic based products in building construction such as such as doors, windows, ventilators,
partitions, floors, walls, roofs, handrails. Current innovations.

Understanding of product literature/ shop drawings. Site visits with documentation in the form of sketches/ photos.

The word "plastic" or "plastics" comes from the Greek word "plastikos," meaning “to grow" or "to form." The word was
used first as an adjective meaning "formative” (capable of being deformed without rupture), then it began to be used
as a noun.

PANELS,EXTERIOR COVERING,
FACADES ROOFING,WINDOWS,
ROLLING SHUTTERS

PLASTICS IN
ARCHITECTURE

INTERIORS
WALL LINING, FLOOR COVERING
CEILING,SANITARY EQUIPMENT,
INSULATION
 MANUFACTURE OF PLASTICS
The production of plastics begins with the distillation of crude oil in an oil refinery. Naphtha is the crucial compound
for the production of plastics. Two main processes are used to produce plastics - polymerisation and
polycondensation.

Adhesives  - are bonding agents used to join materials by glueing. Two types of adhesives are used in construction:
Non structural adhesives and Structural adhesives i.e. those which give at least 5 to 8 MPa in tensile shear strength

The most common types of adhesive are as follows:

▪ PVA (polyvinyl acetate): general purpose woodwork glue, with some water resistant properties.

▪ Synthetic resin: strong water-resistant woodwork glue.
▪ Epoxy resin: Used for metals and plastics.
▪ Acrylic cement: Used for acrylic and some types of plastic. The adhesive ‘melts’ the surface of the plastic and fuses it
together.
▪ Casein: Made from sour milk. A cold setting adhesive in the form of a powder which is mixed with water.
▪ Urea formaldehyde: A cold setting resin glue. Although moisture resistant, it is usually restricted to timber members
used in dry, unexposed conditions as it loses strength after prolonged exposure to water or heat.
▪ Resorcinol formaldehyde: A cold setting glue that is suitable for timber members used in external situations. Will set
at temperatures down to 15°C and does not lose strength at high temperatures.
▪ Phenol formaldehyde: A warm setting adhesive that requires a temperature of above around 86°C to set.

Sealants - are used in construction to prevent fluids and other substances from passing through material surfaces,
joints, or openings. They can also prevent the passage of air, sound, dust, insects, and so on, as well as acting as a fire
stopping component.

Sealants are typically used to close openings between that are too small for other materials such
as concrete, timber or mortar to be used. 

The three basic functions of a sealant are as follows:

▪ Fill a gap between two or more substrates.

▪ Form a barrier through which other substances cannot pass.
▪ Maintain sealing properties for the anticipated lifetime.

Some of the most common types of sealants include:

▪ Acrylic resins
▪ Butyl rubber
▪ Epoxy thermosets
▪ Expanding foam
▪ Hot wax
▪ Latex sealants
▪ Metal sealants
▪ Paint sealants
▪ Polysulfide sealants - are designed for joints that need to withstand prolonged immersion in liquids. Typical
applications include swimming pools, fountains, cooling towers, fuel and chemical storage tanks, wastewater
treatment and petrochemical plants.
▪ Polyurethane sealants
▪ Rubber sealant
▪ Silicone sealant - used to attach glass, ceramic, metal, stone or composite panels to a building’s frame. This creates
a continuous flexible rubber anchor that absorbs stress and prevents air- and water-intrusion. Only silicone
sealants possess the unique combination of strength, flexibility and weather resistance.
▪ Urethane sealants
▪ Varnish

What is the difference between Adhesives & Sealants?

Sealants are designed to close gaps between surfaces and prevent things like dust, water or dirt from entering it.
Adhesives are generally made to make two surfaces stick together so that the surfaces can’t be separated.

Sealants have lower strength and high elongation/flexibility and are not used to bond materials together while
adhesives are meant to stick two things together by adhesion.

Sealants don’t always have the sticking power needed for long-term adhesion and adhesives don’t  dry properly when
used on an exterior surface

Sealants have a paste like consistency which allows filling of gaps between substrates and has low shrinkage after
application. Adhesives are in liquid form which become solid after application and then used to bind materials together.

Adhesive will offer a more rigid and durable feel and look as opposed to sealants which are lower in strength and far
more malleable.

ENGINEERING PROPERTIES OF PLASTICS

Chemical Resistance of Plastics: Plastics offer great resistance against chemicals and solvents. Chemical
composition of plastics during manufacturing will decide the degree of chemical resistance. Most of the plastics
available in the market offer great corrosion resistance. So, corrosive metals are replaced by plastic in the case of
water carrying pipes, etc.

Dimensional Stability: Thermo-plastic types of plastics can be easily reshaped and reused. But in the case of
thermo-setting type plastics, it is not possible to reshape or remold the material.
Ductility of Plastics: Ductile nature of plastic is very low. When tensile stress are acting on plastic member they may
fail without any prior indication.

Durability of Plastics: Plastics with sufficient surface hardness are having good durability. Sometimes, plastics may
affected by termites and rodents especially in the case of thermo-plastic types, however it is not a serious problem
because of no nutrition values in plastic.

Electric Insulation: Plastics are good electric insulators. So they are used as linings for electric cables and for
electronics tools.

Finishing: Any type of finishing treatment van be given to the plastics. Mass production of plastic particles with
uniformity of surface finish is done by having technical control during manufacturing.

Fire Resistance: The resistance to temperature or fire for varieties of plastics considerably varies depending upon
the structure. Plastics made of cellulose acetate are burnt slowly. PVC made plastics do not catch fire easily. Plastics
made of phenol formaldehyde and urea formaldehyde are fire proof materials.

Fixing: Fixing of plastic materials is so easy. We can bolt, drill or glued to fix plastic material position.

Humidity: The plastics made up of cellulosic materials are affected by the presence of moisture. The plastics made
of poly vinyl chloride (PVC pipes) offers great resistance against moisture.

Melting Point: Generally plastics have very low melting point. Some plastics may melt at just 50C. So, they cannot
be used in the positions of high temperature. Thermo setting type of plastics are having high melting point than
thermo plastic type plastics. However, thermo setting types are cannot used for recycling. To improve the heat
resistance of the plastics, glass fiber reinforcement is provided in its structure.

Optical Property: There are so many types of plastics. Some plastics are transparent which allows light in its original
direction and some are translucent nothing but semi-transparent which allows light but changes light rays direction.

Recycling of Plastics: Disposal of plastics in the environment causes severe pollution. But it is not a serious
problem because of its recycling property. We can use plastic waste disposal conveniently to produce drainage pipes,
fencing, hand rails, carpets, benches etc.

Sound Absorption: By the saturation of phenolic resins we can produce acoustic boards. These acoustic boards are
sound absorbents and provide sound insulation. Generally for theatres, seminar halls this type of acoustic ceilings are
used.

Strength: Practically we can say that plastic is strong material but ideal section of plastic which is useful for structural
component is not designed yet. Generally by reinforcing fibrous material into plastic improves its strength. If the
strength to weight ratio of plastic is same as metals, then also we cannot give preference to plastics because of
various reasons like, heavy cost, creep failure may occur, poor stiffness and sensitive against temperature.

Thermal Property: The thermal conductivity of plastics is very low and is similar to wood. So, foamed and expanded
plastics are used as thermal insulators.

Weight of Plastics: The Plastics have low specific gravity generally ranges from 1.3 to 1.4. So they are light in
weight and easily transportable to any place in a large quantity.

TYPES OF PLASTICS
There are many different types of plastics, and they can be grouped into two main polymer families:
● Thermoplastics (which soften on heating and then harden again on cooling).
● Thermosets (which never soften once they have been moulded).
Thermoplastics: Thermoplastics are defined as polymers that can be melted and recast almost indefinitely. They are
molten when heated and harden upon cooling. When frozen, however, a thermoplastic becomes glass-like and
subject to fracture. These characteristics, which lend the material its name, are reversible, so the material can be
reheated, reshaped, and frozen repeatedly. As a result, thermoplastics are mechanically recyclable.

Examples of Thermoplastics
Acrylonitrile butadiene styrene (ABS) – Used in keyboard, power-tool housing, the plastic face-guard on wall sockets
(oftentimes a PC/ABS blend), and LEGO toys.
Polycarbonate (PC) - Used in windows and skylights to wall panels and roof domes to exterior elements for LED
lighting.
Polyethylene (PE)- used in construction as vapor retarders, window films, flooring and counter top protection, and
even in roofing. Polyethylene sheet can be used to seal off rooms, cover building materials, and be used in lead
abatement projects.
Polyethylene terephthalate (PET)- Used for synthetic fibres, containers
Polytetrafluoroethylene (PTFE) – Used as Teflon, roofing applications
Polyvinyl chloride (PVC) - Used in drinking water and waste water pipes, window frames, flooring and roofing foils,
wall coverings, cables
Polymethyl methacrylate (PMMA)- Used as substitute for glass in products such as shatterproof windows, skylights,
illuminated signs, and aircraft canopies.
Polypropylene (PP) - Used in cups, cutlery, containers, house wares and car parts e.g batteries. 
Polystyrene (PS) - Used as Foam
Expanded Polystyrene (EPS) - Used in insulated panel systems for walls, roofs and floors as well as facades for both
domestic and commercial buildings

Polyvinyl chloride: Polyvinyl chloride (PVC) was one of the first plastics discovered, and is also one of the
most extensively used. It is derived from salt (57%) and oil or gas (43%). It is the world's third-most widely produced
synthetic plastic polymer, after polyethylene and polypropylene. PVC comes in two basic forms: rigid (sometimes
abbreviated as RPVC) and flexible.

Polyolefins : Polyolefins are a family of polyethylene and polypropylene thermoplastics. They are produced
mainly from oil and natural gas by a process of polymerisation of ethylene and propylene respectively. Their
versatility has made them one of the most popular plastics in use today.

Expanded polystyrene: Expanded polystyrene, or EPS, is one of the most widely used commodity
polymers. It has been a material of choice for more than 50 years because of its versatility, performance and cost
effectiveness. It is widely used in many everyday applications.
Thermoset plastics: components as implied by their name become set in their physical and chemical properties
after an initial heat treatment and therefore are no longer affected by additional heat exposure. The process is very
similar to hard boiling an egg. Once the egg is boiled, additional reheating does not cause disfiguration – similar to
the curing process associated with a thermoset part. After initial heat forming, thermoset material’s ability to exhibit
resistance to heat, corrosion, and mechanical creep make them perfectly suitable for use in components that require
tight tolerances and excellent strength-to-weight characteristics, while being exposed to elevated temperatures.    

Examples of Thermosets
Epoxide (EP) – Used in Adhesives
Phenol-formaldehyde (PF)- Billiard balls, printed circuit boards, glues for construction grade wood panels such as
plywood, handles, knobs,
Polyurethane (PUR)- coatings, elastomers and foams. Car bumpers
Unsaturated polyester resins (UP)- FRP, sanitary-ware, tanks, pipes, gratings, and high performance components for
the marine and transportation industry such as closure and body panels, fenders, boat hulls/ decks

Fluoropolymers: are renowned for their superior non-stick properties associated with its use as a coating
on cookware and as a soil and stain repellent for fabrics and textile products, contributing to significant advancement
in areas such as aerospace, communications, electronics, industrial processes and architecture and medical
applications. The most well-known member of Fluoropolymers is PTFE (polytetrafluoroethylene) discovered in 1938.
ePTFE discovered in 1968

Epoxy resins: Epoxy resins have been around for more than 50 years, and are one of the most successful
of the plastics families. Their physical state can be changed from a low viscosity liquid to a high melting point solid,
which means that a wide range of materials with unique properties can be made. In the home, you’ll find them in soft-
drinks cans and special packaging, where they are used as a lining to protect the contents and to keep the flavour in.
They are also used as a protective coating on everything from beds, garden chairs, office and hospital furniture, to
supermarket trolleys and bicycles. They are also used in special paints to protect the surfaces of ships, oil rigs and
wind turbines from bad weather.

Polyurethanes: Polyurethane (PUR) is a resilient, flexible and durable manufactured material. There are
various types of polyurethanes, which look and feel very different from each other. They are used in a very broad
range of products. In fact, we are surrounded by polyurethane-containing products in every aspect of our everyday
lives. While most people are not overly familiar with polyurethanes because they are generally 'hidden' behind covers
or surfaces made of other materials, it would be hard to imagine life without them.
Biodegradable plastics: Biodegradable plastics are plastics degraded by microorganisms into water, carbon dioxide
(or methane) and biomass under specified conditions. To guide consumers in their decision-making and give them
confidence in a plastic’s biodegradability, universal standards have been implemented, new materials have been
developed, and a compostable logo has been introduced.

Bio-based plastics: Bio-based plastics are made in whole or partially from renewable biological resources. For
example, sugar cane is processed to produce ethylene, which can then be used to manufacture for example
polyethylene. Starch can be processed to produce lactic acid and subsequently polylactic acid (PLA).
 APPLICATION OF PLASTICS IN BUILDING INDUSTRY

&

CURRENT INNOVATIONS

Expansion Joint Waterproofing 

GRP stands for ‘Glass Reinforced Plastic’ a material made from a polyester resin, which is reinforced by chopped
strand mat glass fibres to form a GRP laminate. It is a very popular composite material to use because not only is it
very strong but also surprisingly light.

Is GRP the same as fiberglass?

Yes, GRP or Glass Reinforced Plastic is just another name for fiberglass or glass fibre. It is made up of fiberglass
matt impregnated with a polyester resin to form a strong and very durable material. It has numerous uses including:
boats, cars, baths, hot tubs, water tanks, roofing, pipes, cladding and external door skins.

GEOTEXTILE
 SOURCES

https://www.bpf.co.uk/plastipedia/plastics_history/Default.aspx

https://www.plasticseurope.org/en/about-plastics/what-are-plastics/how-plastics-are-made

https://www.thomasnet.com/articles/plastics-rubber/thermoset-vs-thermoplastics/

https://visual.ly/community/infographic/other/history-plastic

https://www.thisisplastics.com/plastics-101/how-are-plastics-made/

https://drinkpathwater.com/blogs/news/what-is-the-best-material-for-bottled-water

https://www.slideshare.net/abhishekmewada54/building-materials-as-a-plastic

https://www.qualitylogoproducts.com/promo-university/different-types-of-adhesives.htm

https://www.explainthatstuff.com/adhesives.html
 ACTIVITY/DELIVERABLES
● Inviting Guest Lecture from Plastic manufacturing Company on further knowledge sharing.
● During design case study students to note the application of plastics used for the particular project,
checklist has been given to follow.
The output of this exercise is expected through sketches.
● Collection of product literature and shop drawings.
● Vocabulary and understanding of various plastics used in the building industry.

QUESTION PAPER
 PART-A
1. what property of plastic makes it a Building material.
2. what are the sources of plastic.
3. Give examples of plastic products in building industry.
4. what is an adhesive
5. what is a sealant
6. what in the difference between sealant and adhesive.
7. what are the poly carbonate products in building industry.
8. Is plastic a sustainable building material?
9. What are the two major classification of plastic.
10. Where is teflon used in building material.
11. Where is sealant used as a construction material.
12. What is latest invention in plastic.
13. Can plastic be recycled.
14. Is plastic fire resistant?

PART-B
1. What is the manufacturing process of plastic.
2. Sketch the detail of plastic window with all details.
3. What are the types of plastics available with their uses.