Section 3: Plastics

2013 ENGGDE4201: Materials (Civil)

1 Types of plastic
A. Thermoset or thermosetting plastics
Thermoset materials are usually liquid or malleable prior to curing and designed to be moulded into their final form, or used as adhesives. In the thermosetting process, a chemical reaction occurs during setting which is irreversible, therefore they cannot be recycled. Thermosets can melt and be moulded once, the cure/set may be induced by heat generally above 200 C; after they have solidified they stay solid. They are hard and durable but they will char and burn with further heating after the initial moulding. Thermosets are used for auto parts, aircraft parts and durable wheels and tires (roller coaster and escalator wheels), surface coatings and sealants and synthetic fibres. Examples include polyurethanes (rigid foam insulation panels, carpet underlay, shoe soles), epoxy resins (used in fibre reinforced plastics) and melamine (kitchen bench tops/Formica)

B. Thermoplastics
Thermoplastics are a polymer that becomes pliable or mouldable above a specific temperature, and returns to a solid state upon cooling. Less rigid than thermosets, thermoplastics do not undergo chemical change in their composition when heated and soften with heat and can be moulded into a new shapes again and again hence they can be recycled. They are easily molded and extruded into films, fibres and packaging. Examples include polyethylene (PE), polypropylene (PP), polystyrene and polyvinyl chloride (PVC).

Polyethylene (PE) (high HDPE & low density PE)

PE is the most commonly used engineering thermoplastic. Excellent chemical resistance properties. Good impact resistance, toughness and process ability. Used for electrical conduits, curing membrane, piping . (UHMWPE) ultra-high molecular weight polyethylene is tough and resistant to chemicals, used to manufacture moving machine parts, bearings, gears, artificial joints and some bulletproof vests. (HDPE) High-density polyethylene large strength to density ratio, commonly recycled, used as outdoor furniture, portable gasoline cans, corrosion-resistant piping and geomembranes. eg corrugated perforated subsoil drainage pipes (NovafloTM),and low pressure natural gas reticulation (yellow). (LDPE) Low-density polyethylene is softer and flexible and is used in the manufacture of squeeze bottles, retail store bags and plastic sheets often laminated with bitumen impregnated paper (or similar) for vapour barriers in walls and under concrete floors to stop water rising up through a concrete floor or through walls

Polypropylene (PP)
PP has a higher melting point than PE. PP is not as impact-resistant as the polyethylenes (HDPE, LDPE). Used both as a structural plastic and as a fibre. Does not soak up water, ideal for uses where it will be constantly subject to moisture (washing machine lids, WC cisterns, sink traps, car batteries) reusable plastic food containers and insulation for electrical cables.

2013 ENGGDE4201 Materials (Civil) Section 3: Plastics

Polyvinyl Chloride (PVC plasticised & uPVC unplasticised)

When made, it's brittle, so manufacturers add a plasticiser liquid to make it soft and moldable. PVC is commonly used for pipes and plumbing because it's durable, can't be corroded and is cheaper than metal pipes. Over long periods of time, however, the plasticiser may leach out of it, rendering it brittle and breakable. PVC (Plasticised) - Resembles polythene sheet but softer, more rubbery texture Curtaining, reservoir and tank linings, upholstery material (backed with fabric), protective clothing and rainwear, cable-covering, hoses. UPVC (Unplasticised) - Rigid, glossy, not quite glass-clear; tough - corrugated roof lighting sheets, lining of chemical tanks, rainwater goods ie spouting and guttering: water mains and irrigation pipe. Light weight and available in long lengths, ease of handling and jointing. UPVC has excellent chemical resistance with a broad band of operating pressures. Due to its lightweight, longterm strength characteristics, high stiffness and cost effectiveness, ease of use, handling and jointing, UPVC systems account for a large proportion of plastic piping.

Polystyrene (PS Extruded polystyrene and EPS Expanded polystyrene foam)

Polystyrene is in a solid (glassy) state at room temperature but flows if heated above about 100 C. It becomes rigid again when cooled. This temperature behavior is exploited for extrusion and also for moulding and vacuum forming, since it can be cast into moulds with fine detail. It is very slow to biodegrade. One of the most widely used plastics. Extruded uses include protective packaging, containers (such as clamshells), bottles and refrigerator containers. Expanded or foamed uses include building insulation and backfill in retaining walls and concrete floor slabs

Acrylic
Serves as a sturdy substitute for glass, examples include: aquariums, motorcycle helmet visors, aircraft windows, baths/sinks and signage.

Nylon
Serves as a substitute for silk in products like parachutes, flak vests and women's stockings. Nylon fibres are useful in making fabrics, rope, carpets and strings for musical instruments. In bulk form, nylon is used for mechanical parts, including machine screws, gear wheels and power tool casings.

Fibreglass
Also called Glass Reinforced Plastic (GRP) glass-fibre reinforced plastic, or (GFRP) The plastic matrix may be epoxy, a thermosetting plastic (often polyester) or thermoplastic. Complex shapes can be moulded and a smooth surface obtained provided care is taken in the laminating process to compact the fibre well and remove air. Only low technology fabrication is required. It is durable and has a high flexing tolerance. Has moderate/high strength/weight ratio. It is corrosion and impact resistant. Low cost and lightweight. Used for small engineering components/parts, car and boat bodies, mouldings, roofing, canopy, insulation.

2013 ENGGDE4201 Materials (Civil) Section 3: Plastics

2 Applications in Civil Engineering and Construction

Vapour Barriers/damp proofing
Polyethylene (plastic) sheet often laminated with bitumen impregnated (or similar) paper for vapour barriers in walls and under concrete floors to stop water rising up through a concrete floor or through walls. Extruded polystyrene or foil-faced foam board insulation Insulation Polystyrene sheet. Convenient to install in sheet form at time of construction. Easy to cut and handle. Foamed Polyurethane Pumped as a liquid (and swells into foam 31 times its original volume) into wall cavities of dwellings as post construction installation. Hardfill Polystyrene blocks are often used as a substitute for hard fill especially under concrete flooring slabs (because it is easier to handle, cut and faster to place than compacting sand or scoria as fill material) and blocks are inserted immediately behind retaining wall as it is porous and allows water to drain away to relieve the hydraulic pressure on the wall. Roofing Acrylics, uPVC, polycarbonates and glass fibre reinforced polyesters are all used for translucent roofing and cladding. Light weight, ease of cutting and handling, transparency are all reasons for their use. There are many different types of plastic roofing products currently available on the market must be aware that plastics produced/sourced from overseas markets may not withstand NZ UV levels. Plastics become brittle and crack with time when exposed to sun. Two main groups used for plastic pipe work High Density Polyethylene (HDPE) - for water mains (blue) and pressure sewers, sanitary (raising main - under pressure)/gravity (no pressure) and stormwater sewers, and corrugated perforated subsoil drainage pipes (NovafloTM), and low pressure natural gas reticulation (yellow). PVC and UPVC (UPVC unplasticised = rigid plastic used for pipes, PVC plasticised = can be flexible eg hoses, clothing, upholstery) - for water mains and pressure sewers, sanitary and stormwater sewers. - ducts for electrical (orange) and telecommunication (green) cables. - guttering and spouting.

2013 ENGGDE4201 Materials (Civil) Section 3: Plastics

3 Pipe jointing systems

Pipe jointing systems are very varied. Pipes can be made out of plastics, concrete or steel, there are a number of options depending on the type of pipe and purpose.

Spigot and socket joint

(spigot = straight inside end, socket = overlapping outside end)

This is where a smaller pipe fits into another pipe that has an enlarged end (concrete or plastic). The spigot and socket joint has a rubber ring in the shape of a circle and it compresses to an oval when it has been rolled on the pipe, the rubber ring squashes further when the two pipes come in contact and create the seal. Large pipes may require glue, were small diameter pipes may not. These pipes have markings to indicate when or if the rubber ring has been rolled on correctly. These joints are used on concrete pipes and generally smaller plastic joints.

Above left is a PVC water main with wedge-type rubber-ring, water pressure in pipe will inflate the ring into the socket joint and seal the connection. Above right is a PVC sewer pipe, similar to water pipe but with another profile of rubber-ring (only due to being a different manufacturer). Note: Pipe wall dimensions vary depending on their purpose, pipes under pressure will have a thicker wall but the bore size (inside pipe dimension) will remain the same, but overall diameter will be greater.

Rolling Ring Joints (RRJ)

Most commonly used on smaller concrete pipes and to a lesser extent ceramic pipes.

2013 ENGGDE4201 Materials (Civil) Section 3: Plastics

Skid-ring joint for larger diameter pipes (Alternative name = Z ring joints)
Different manufacturers produce different joint/pipe profiles. General method - Clean both the joint areas of the two pipes. Rubber rings to be clean and dry. Stretch the rubber ring while placing it evenly into the ring groove on the spigot making sure that no twist exists. Apply lubricant directly to the lead-in of the socket and along the entire socket internal surface. Do not apply lubricant under the ring or past the ring seating of the spigot, as this could cause the skid ring to slip off the spigot making joining impossible.

Flanged Joint

A flange is an external or internal ridge/rim (lip) used for strength or for attachment to another object/pipe. It is a disc of metal or plastic with a series of holes drilled in the disc which attaches pipe to pipe. The flange can be plastic and glued on the end of a pipe or it can be manufactured on the end of the pipes, ie the pipe can be bought with a flange already attached to it as below.

Above: Typical 4 bolt flange T joint (number of bolt holes varies). The steel pipes are welded with the flanges and then the complete unit is powder coated to resist corrosion, chemicals, heat, impact, abrasion and UV rays. This gets bolted with a rubber gasket to another flanged component, in this case to a fire hydrant on top.
2013 ENGGDE4201 Materials (Civil) Section 3: Plastics
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Welded joints
Mainly used in two different types of pipes: Steel and HDPE pipes

Left: Welded steel pipes

Above left: Couplings. Right: Electrofusion coupling section diagram

HDPE pipes (High-density polyethylene pipe) Electrofusion (is a method of joining MDPE, HDPE and other plastic pipes with special fittings (couplings) that have builtin electric heating elements which are used to weld the joint together.)

High Density Polyethyene (HDPE). The coupling has a series of wires running through it which connect onto two terminals. An electric current is attached to the terminals and wires, this welds or melts the pipe ends and coupling together. This melting can create a bead of melted plastic which depending on the pipe and purpose, might have to be shaved off to keep the pipe walls smooth and free of imperfections so sediment cannot build up. HDPE pipes are usually fusion-welded above ground in very long lengths (eg manhole to manhole up to 1km, individual pipe lengths approx. 6m long). The pipe gets pressure tested above ground to check for any leaks in the welds, and then the pipes are directional drilled into position. They can also be welded above ground in long lengths and lowered into an open trench and backfilled.

Point of difference - concrete vs plastic

Concrete skid ring or rolling ring jointed pipes are placed, by pipe length (2.5m) in trenches usually excavated in 6m lengths then backfilled before further excavation. HDPE pipe can be thrust in 1km lengths or use much longer trenches.
2013 ENGGDE4201 Materials (Civil) Section 3: Plastics
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Gibault Joint/coupling

This is the most common jointing system for pipes. Gibault joints are use on a wide range of materials and different sizes. The joint consists of a cylinder that sits across the pipe. There is a flange at each end and the joint tightens onto rubber rings at both ends. With this joint you can get away with small amount of deflection, if the pipes do not line-up exactly. This joint is a common joint for repairing pipes and can be used under wet conditions, where other jointing systems would be difficult to use. Larger diameter Gibaults are used for joining sections of cast iron or asbestos cement pipes.

In the diagram above it shows that the ring gets tightened from both ends by 3 bolts (or more), and end up with a pressure type joint. The problem with this joint is that you need to buy a different size for every pipe you are using. It is possible to join two different diameter pipes with a stepped gibault.

Straight Gibault for connecting pipes are the same diameter.

2013 ENGGDE4201 Materials (Civil) Section 3: Plastics

CLMS Pipe (Concrete lined mild steel pipe)

This is used in situations with corrosive materials and where you need a low maintenance pipe ie across busy roads and intersections (requiring to withstand more abrasion), and large diameter mains supply. 3 to 6mm mild steel plate is wound into a spiral and automatically welded together. A cement lining is centrifugally spun onto the pipe inside so to stop water corroding the inside of the steel pipe. A coating is also added to the exterior of the pipe to prevent the outside corroding (fabric impregnated with bitumen - a cold tar epoxy). Common uses for exterior coated steel pipes are for exposed sections of water and/or gravity mains as it is a better alternative to plastic, because UV light will corrode the plastic over time. This type of pipe is joined by steel flanges or gibault joints.

The above left pipe is made in three layers, steel pipe in the middle, concrete is spun onto the inside and material soaked cold-tar epoxy is wrapped onto the outside to stop the steel from corroding. Above middle and right: Section of used water pipe. 60-70 years old cast iron pipe with sediment, mainly corrosion (iron oxide) which eventually blocks the pipe and needs replacing, hence now steel pipes get coated inside and out.

Above: Asbestos cement pipe has not been manufactured for over 30 years due to the health hazard asbestos causes, but there are 100s of kms of pipe still in use all over Auckland and New Zealand. It is very dangerous to breathe the fibres which make-up the asbestos pipe, if you ever have to cut the pipe, it is safest cutting it wet so the fibres get saturated and dont get air-borne. This type of pipe fails in tension, it splits longitudinally and sections require replacing.
2013 ENGGDE4201 Materials (Civil) Section 3: Plastics
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