DESIGN AND DEVELOPMENT OF PLASTIC WASTES HOLLOW BLOCK MAKING

MACHINE

A Research Proposal
Presented to the Faculty of the Mechanical Engineering
College of Engineering, Architecture and Fine Arts
Batangas State University
Pablo Borbon Campus II
Alangilan, Batangas City

In Partial Fulfillment of the Requirement for

RM 416 – Methods of Research for ME

by
Valdez, Richard Joshua G.

April 23, 2019

 ACKNOWLEDGMENT

The proponent would like to extend their deepest gratitude to the following

persons who shared time, support and patience in the development of this study.

To Engr. MARY JOAN LEACILLE R. MANALO, for her encouragement and

patience as their instructor of Methods of Research for ME, knowledge and assistance

provided in the pursuit of this study.

To the researcher’s family, for serving us motivations and inspirations in life, and

for the patience, understanding and unconditional support provided.

To the researcher’s friends and classmates, especially ME-4208, for always

being there and ready to help in times of need.

And above all, all thanks to the Lord God Almighty for providing strength,

wisdom, guidance, inspiration and countless blessings that help them all throughout the

course.
 TABLE OF CONTENTS

Page

TITLE PAGE i

APPROVAL SHEET ii

ACKNOWLEDGEMENT iii

TABLE OF CONTENTS iv

CHAPTER

I THE PROBLEM AND ITS BACKGROUND

Introduction 1

Background of the Study 3

Objectives of the Study 4

Significance of the Study 5

Scope and Limitations of the Study 6

Conceptual Framework 7

Definition of Terms 10

II REVIEW OF LITERATURE

Conceptual Literature 12

Research Literature 16

Synthesis 28
III RESEARCH METHODS AND PROCEDURE

Research Design 29

Research Development 29

Development Stages 29

Design Stage 30

Fabrication Stage 30

Preliminary Testing Stage 30

Final Performance Testing Stage 31

Methods of Testing 31

BIBLIOGRAPHY /REFERENCES 34

APPENDIX 36
 CHAPTER I

THE PROBLEM AND ITS BACKGROUND

I. INTRODUCTION

Disposal of plastic waste in environment is considered to be a big problem due to its

very low biodegradability and presence in large quantities. In recent time significant

research is underway to study the possibility of disposal of these wastes in mass

concrete where strength of concrete may not be major criteria under consideration, such

as heavy mass of concreting in PCC in pavements. If plastic wastes can be mixed in the

concrete mass in some form, without significant effect on its other properties or slight

compromise in strength, we can consume large quantities of plastic waste by mixing it in

the concrete mass. Plastic is one component of municipal solid waste (MSW) which is

becoming a major research issue for its possible use in concrete especially in self-

compacting concrete and light weight concrete. Although some of these materials can

be beneficially incorporated in concrete, both as part of the cementitious binder phase

or as aggregates, it is important to realize that not all waste materials are suitable for

such use.

One of the main environmental problems today is the disposal of the waste plastics.

The use of plastics in various places as packing materials and the products such as

bottles, polythene sheets, containers, packing strips etc., are increasing day by day.

This results in production of plastic wastes from all sorts of livings from industrial

manufacturers to domestic users. To circumvent this pollution crisis, many products are

being produced from reusable waste plastics.

 The Philippine construction industry is facing problems due to insufficient and

unavailability of construction materials. So, we need to search for new construction

materials as well as a method to dispose the plastic waste. To find a solution to the

above problems, one of them can be used to solve the other.

Disposal of used plastics by land filling may be temporary solution and also affects

ground water recharging and soil microbe activities. Incineration of plastic material will

cause air pollution, global warming and monsoon failure. Investigations done so far

have shown that waste plastics can be utilized for making polymer aggregate blocks

with ceramics and granite, which can be used in laying footpaths. The blocks can take

350 tons of loads and prevents water penetration. They can also be used in lining of

canals. A bitumen blend can be used as a coat over reinforced cardboard for roofing.

Besides enhancing the strength and life of roofing, used by the poor, the blend will

provide better moisture resistant. A blend of waste plastics with mastic components and

flooring materials provides floors of more strength, especially in industrial units. Waste

polymers also infuse greater strength when mixed with cement as a reinforced concrete.

Concrete has proved to be an excellent disposal means for fly ash, silica fume,

ground granulated blast furnace slag (GGBS), marble powder, and so forth which not

only traps the hazardous material but also enhances the properties of concrete.

Concrete, as a material, has significantly been benefited from the usage of fly ash, silica

fumes, and GGBS. For a constant workability, the reduction in water demand of
concrete due to fly ash is usually between 5 and 15% when compared with Portland

cement only mix. The reduction is large at higher w/c ratio.

II. BACKGROUND OF THE STUDY

The Philippines concrete industry is today consuming about 400 million tons of

concrete every year and it is expected, that this may reach a billion tons in less than a

decade. All the materials required to produce such huge quantities of concrete, come

from the earth’s crust, thus depleting its resources every year creating ecological

strains. On the other hand, human activities on earth produce solid wastes in

considerable quantities i.e., over 2500 million tons per year, including industrial wastes,

agricultural wastes and other wastes from rural and urban societies. Disposal of such

solid wastes involves economic issues as well as ecological and environmental

considerations. The major ecological strain in disposal of solid waste may be due to the

presence of waste plastics in it.

The plastic is one of the recent engineering materials which have appeared in the

market all over the world. Some varieties of naturally occurring thermoplastics were

known to Egyptians and Romans who extracted and used these plastics for various

purposes. Plastics were used in bath and sink units, corrugated and plain sheets, floor

tiles, joint less flooring, paints and varnishes and wall tiles. Other than these,

domestically plastics were used in various forms as carry bags, bottles, cans and also
in various medical utilities. There has been a steep rise in the production of plastics

from a mere 30 million kN in 1955, it has touched 1000 million kN at present. It is

estimated that on an average 25% of the total plastic production in the world is used by

the building industry. The per capita consumption of plastics in the developed countries

ranges from 500 to 1000N while in our country, it is only about 2N. There is however

now increase in awareness regarding the utilization of plastic as a useful building

material in our country. These types of usages normally generate more amounts of

wastes which are to be disposed properly.

Environmentally sensitive aware people condemn the use of plastics for amount of

pollution caused by them in disposal. However this is not a serious problem in

comparison to the waste and pollution generated by a host of other industries. The

non-biodegradable plastic products used for soft drink bottles, milk and juice bottles,

bread bags, syrup bottles, coffee cups, plastics utensils etc., can be conveniently

recycled into carpets, detergent bottle, drainage pipes, fencing, handrails, grocery

bags, car battery cases, pencil holders, benches, picnic tables, road side posts etc,.

The developing construction field consumes a huge amount of concrete and it leads to

the depletion of natural products and causes environmental pollution.

Plastics are normally stable and not biodegradable. So, their disposal poses

problems. Research works are going on in making use of plastics wastes effectively as

additives in bitumen mixes for the road pavements. Reengineered plastics are used for

solving the solid waste management problems to great extent. This study attempts to

give a contribution to the effective use of waste plastics in concrete in order to prevent
the ecological and environmental strains caused by them, also to limit the high amount

of environmental degradation.

Four types of plastic materials were selected to mix along with the concrete: (1)

Polythene Sheet (2) Raw Plastics (3) Road Wastes (4) Plastic Straw to study their

behavior in conjunction with concrete. The properties of the materials used in the

present investigations were completely studied and the optimum mix of the above

plastic materials was found based on their compressive, split tensile, flexural strengths.

After finding the optimum mix percentages in compression, RC columns were cast and

tested for its compressive strength. From the investigation, the road waste mixed

concrete was found to take more loads in compression. Raw plastic mixed concrete as

well as plastic straw mixed concrete were also found to give better strength than the

reference RC column.

III.STATEMENT OF THE PROBLEM

1. How to solve the problems in waste about plastics in the Philippines?

2. What material can make out of waste plastics?

3. Can plastic be a raw material in making construction material?

 4. What can plastic bottles/PVC (ground) do to make a masonry material

more durable?

5. Is this material economical and more durable than an ordinary CHB

(Concrete Hollow Blocks)?

IV. OBJECTIVES OF THE STUDY

The main thrust of this study is to design and develop hollow blocks from plastic

waste.

Specifically, this study aims to:

1. To design and develop plastic wastes hollow block making machine

2. To determine the ways in solving about plastic waste problems in the

Philippines.

3. To determine if plastics are suitable in making construction material.

4. To make a construction material such as CHB (Concrete Hollow Blocks)

an economical and more durable material that are used in buildings.

V. SIGNIFICANCE OF THE STUDY

This study is significant in a way that it can make the construction supply help

Philippines in solving problems in waste plastics, and prevent floods in the regions,

cities and community that are highly producing of plastics waste.

This study can be a reflection to readers who have an insight of Mechanical

Engineering as a machine designing and maintaining mechanical systems, but also

being an investigators and inventors of material and also ecologist.

Lastly, this study can be a basis for students looking for responses regarding the

considerations of problems about their community, cities, regions and the whole

country.

VI. SCOPE AND LIMITATIONS OF THE STUDY

The focus of this study is to design and develop plastic wastes hollow block

making machine. This study will start with the investigation, design analysis and

mechanical part analysis of existing shredding, mixing and molding machines for the

efficiency of the making-process. Also the study deals with the evaluation of plastic

wastes used as hollow blocks.

VII. CONCEPTUAL FRAMEWORK

The study aims to develop a Plastic wastes hollow block making machine. This

includes the conceptualization and design of the machine. The different stages of the

study are taken into consideration such as conceive, design, implement and operate

stages.

Figure 1 shows the conceptual framework of the study.

The conceive stage for this study includes the knowledge requirements. Knowledge

requirements include basic knowledge regarding making a Hollow Blocks .Further

research and information pertaining to designing and fabricating such machine will

likewise be a tool in conceptualizing a working prototype.

The design stage of this study includes the software requirements. Software

requirements include 3D modeling and machine specification using the Solidworks

application. The 3D modeling includes part modeling, assembly and design

optimization. The machine specification includes the materials, dimensions and system

components.

The implement stage of this study includes the hardware requirements,

fabrication of the machine, preliminary testing, data gathering and final performance

testing. Hardware requirements include the materials to be used in making Hollow

Blocks, as well as the different tools that will be used to fabricate the machine.

The preliminary testing includes the operating time, production speed. This will

be followed by the data gathering. The performance testing, include tests for

determining machine production rate and efficiency and product quality.

 Finally, Plastic Wastes Hollow Block Making Machine, operation and

maintenance manual as well as the finished machine was considered in the operate

stage.

Figure 1: Research Paradigm of the Study

VIII. Definition of Terms

 Polythene - is a type of plastic made into thin sheets or bags and used

especially to keep food fresh or to keep things dry.

 Concrete Hollow Blocks (CHB): Concrete Hollow Blocks (CHB) - are

one of the most extensively used walling materials in the Philippines.

Some of the reasons for this are their relative low cost when compared to

other materials and speed of installation by semi-skilled laborers.

 Ground-granulated blast-furnace slag (GGBS or GGBFS) - is obtained

by quenching molten iron slag (a by-product of iron and steel-making)

from a blast furnace in water or steam, to produce a glassy, granular

product that is then dried and ground into a fine powder.

 Silica fume - is a byproduct of producing silicon metal or ferrosilicon

alloys. One of the most beneficial uses for silica fume is in concrete.

 Reinforced concrete column - is a structural member designed to carry

compressive loads, composed of concrete with an embedded steel frame

to provide reinforcement.

 Portland cement- cement that is manufactured from limestone and clay

and that hardens under water.

 CHAPTER II

REVIEW OF RELATED LITERATURE

This chapter presents the discussion on the related literature that was used as

basis for the development of the study.

In recent years there has been an increased use of mixing the Portland cement and

GGBS components directly in the concrete mixer. An advantage of this procedure is

that the proportion of Portland cement and GGBS can be varied at will. The granulated

slug can be ground to a fineness of any desired value, but usually, greater than 350

m3/kg. The presence of GGBS in the mix improves workability and makes the mix more

mobile but cohesive. However, the workability of concrete containing GGBS is more

sensitive to variations in the water content of the mix than is the case with Portland

cement only concrete. Mixes containing GGBS are found to exhibit an early loss of

slump. The presence of GGBS in the mix leads to retardation of 30 to 60 min at normal

temperatures. Silica fume has a very high reactivity with calcium hydroxide, and this

reactivity permits silica fume as a replacement for a small proportion of Portland

cement. Marble powder has higher density and it is assumed that this would improve

the segregation resistance of the self-compacting concrete. Corinaldesi et al. mentioned

that high fineness of marble powder is proved to be very effective in assuming very

good cohesiveness of mortar and concrete. They further showed that marble powder

had a very high Blaine’s fineness value of about 1.5 m2/g with 90% of particles passing

through 50 μm sieves and 50% under 7 μm. According to Gupta et al. the value of

segregation index increases with the increase in the amount of marble powder as a
replacement of fly ash. Binici et al. found that marble dust concrete had higher

compressive strength than that of the corresponding lime stone dust and control

concrete with equivalent w/c and mix proportion. Batayneh et al. found that glass

containing concrete composites was the most consistent composite than fiberglass

within the selected range of 5 and 20% aggregate substitutes. Rebeiz investigated the

strength properties of unreinforced and reinforced polymer concrete using an

unsaturated polyester resin based on recycle polyethylene terephthalate (PET) plastic

waste. The results showed that the resins based on recycled PET can be used to

produce a good quality of precast concrete. Sikalidis et al. investigated the utilization of

MSW for the production of mortar. Choi et al. investigated the effects of waste PET

bottles aggregate on p, properties of concrete. The waste plastic could reduce the

weight by 2–6% of normal weight concrete. However, the compressive strength was

reduced up to 33% compared to that of normal concrete. Similarly, the results of

Batayeneh et al. showed the deterioration of compressive strength with an increase in

the proportion plastic content. For the plastic proportion of 20% of sand, the

compressive strength was reduced up to 70% compared to that of normal concrete.

Recently, Marzouk et al. studied the use of consumed plastic bottle waste as sand-

substitution aggregate within composite materials for building applications and showed

the effects of PET waste on the density and compressive strength of concrete. It was

found that the density and compressive strength decreased when the PET aggregates

exceeded 50% by volume of sand. Jo et al. investigated the mechanical properties such

as compressive strength and flexural strength of polymer concrete using an unsaturated

polyester resin based on recycled PET, which contributes in reducing the cost of the
material and saving energy. Pezzi et al.used plastic material particles incorporated as

aggregate in concrete and evaluated the chemical, physical, and mechanical properties.

The results showed that the addition of polymeric material in fractions <10% in volume

inside of cement matrix does not imply a significant variation of the concrete mechanical

features.

Conceptual Literature

Plastic Shredding Machine

A plastic shredder is a machine used to cut plastic into smaller pieces for granulation.

Unlike plastic granulators, shredders are designed specifically for larger plastic waste,

like car bumpers, pipes, drums, and other items too big for granulators.

In the process, large plastic items are fed into the shredder. Moving at a slower speed

than a granulator, blades break the plastic down into smaller chunks. These pieces are

then collected and washed and treated in washing and recycling plants before being

granulated and sent to manufacturers.

 Hammer Mills

Used for shattering or pulverizing materials in a rotary drum that employs

swiveling hammers.
 Figure 1: (Hammer Mills)

 Granulators

Used for recycling plastic from production processes. Granulators also include

thermoforming units for producing scrap material that is easy to handle.

Figure 2: (Granulators)

 Chippers:
 Chippers feature high-speed rotary knives that efficiently reduce material to

flakes and chips.

Figure 3: ( Chippers)

 Grinders: Grinders use the combined power of abrasion and compression to

pulverize materials and produce granular products.

Figure 4: (Grinder)
 Shear Shredders: Available in different configurations, these shredders employ

rotary cutters and guillotine style knives for cutting materials according to

industrial needs.

Figure 5: (Shear Shredders)

 All-purpose Shredders: Widely used for recycling purposes and demolition

programs, all-purpose shredders are large, run at low-speed and have high

torque shafts.

Figure 6: (All Purpose Shredders)

Concrete Mixing Machine

A concrete mixer mixes cement, aggregates and water and produce concrete

mechanically. There are various types of concrete mixers available which makes

concrete production quick and economical.

1. Batch Concrete Mixers

Batch mixers are widely used machines for concrete mixing. Concrete mix

obtained by this mixer is collected batch by batch and time by time. So, it is

called as batch mixer.

After pouring all the materials into pan or drum, it mixes all of those for some time

and finally discharges. This process is repeated until required amount of concrete

mix is obtained.

Drum type mixers

In case Drum type mixers concrete ingredients are mixed in a drum which

is actually in double conical frustum shape.

Drum types mixers are classified into three types:

 Tilting Drum Mixers

Tilting drum mixer means the drum will discharge concrete by tilting

downwards. It is rapid discharge process and used for larger

projects. Rapid means it delivers concrete by gravity that is tilting

the drum downwards because of this the concrete mix obtained will

be not subjected to segregation

.Low workable concretes which contains large sized aggregates of

size greater than 7.5cm are also mixed efficiently with this tilting

type mixer. But the mixing efficiency depends on some of the

factors as follows:

a. Shape of the drum

b. Angle of the drum

c. Size of blades

d. Angle of blades

The only disadvantage of this mixer is sticking of concrete to

bottom of drum. To overcome this method called buttering of mixer

is applied in which some amount of cement mortar is mixed in the

mixer before mixing first batch of concrete.

 Figure 7: (Tilting Drum Mixer)

 Non-Tilting Drum Mixers

Non- tilting drum mixers are not allowed to tilt and the drum rotates

about its horizontal axis. For the discharge of concrete a chute is

arranged in inclined position which will receives the concrete mix

from drum and discharges out.

In this case, the drum is opened at two ends and consists blades

insides when materials are poured through one end and mix is

collected through another end.

Rapid discharge of concrete is not possible in this case. Due to this

delay, the concrete may be vulnerable to segregation.

 The larger size aggregate is not discharged easily with the mix. So,

size of aggregate mot more than 7.5cm is preferable for this type of

mixers. So, this type of mixers is generally used for small projects.

Figure 8: (Non-Tilting Drum Mixer)

 Reversing Drum Mixers

Reversing drum mixers are similar to non-tilting type mixers but in

this case reversal of rotation takes place for different action.

The drum has two openings, one end is for pouring materials and

other end is for discharge of mix. The drum rotates about its

horizontal axis. The rotation of drum takes place in one direction for

mixing and in opposite direction for discharging.

 Two different set of blades are arranged for mixing and discharging.

They are suitable for dry concrete mixes.

Figure 9: (Reversing Drum Mixer)

Pan Type Concrete Mixers

Pan type mixers consists a circular pan in which concrete is mixed. The

mixing is done by blades which are arranged in star shape inside the pan.

There are two types of pan mixers are available. In one case, the circular

pan is constant and only star blades rotate about vertical axis of pan. In

the other case, circular pan rotates while the blades are at static position.

But in both cases, the mixing is efficient and concrete mixture is collected

through central hole provided in the pan. The rotating star blades contains

special blades called scrapper blades which will make concrete not to

stick to the pan.

 The blades can also be adjusted in height so, there is no room for

concrete to store in the pan. We can say among the all types of batch

mixers pan type mixer are more efficient.

Figure 10: (Pan Type Concrete Mixers)

2. Continuous Concrete Mixers

Continuous mixer, the name itself telling its duty that the loading, mixing and

discharging of mix is continuously done until the work is complete or work break

occurs. The loading of materials is done continuously by screw feeders.

Continuous mixtures are used for very large projects such as dams, bridges,

construction of high rise buildings, etc.

 Figure 11: (Continuous Concrete Mixer)

Molding Machinery

Between different methods of molding, there are a few common features. One is the

presence of a material to be molded, typically in molten form. Another is the mold, which

contains the pattern the material will be shaped into. Finally, the needed force, or

pressure, that expands the material into the geometry of the mold.

 Thermoforming

Involves sheets of thin thermoset or thermoplastic plastic that are pressed into

the mold through the use of a vacuum. Machines that perform thermoforming

generally move a sheet of plastic over a mold so the plastic hermetically seals to

the pattern. The plastic is heated until it is malleable. Then, a vacuum is applied,

which sucks the plastic into the mold. Cutting devices trim excess plastic around

the mold edges and the plastic is removed from the mold. The molded plastic is

distributed down the line as a fresh sheet of plastic moves into position.
 Figure 12: (Thermoforming Machine)

 Vacuum forming, or vacuforming

A type of thermoforming for thermoplastics that differs in the gauge capability

and application. Vacuforming is typically only used for thin plastic sheets, or

“film.” The film is stretched over a mold, the inverse of thermoforming, and then

the vacuum is applied to suck the film around it.

Figure 13: (Vaccum Forming Machine)

 Injection Molding

Injection Molding can use thermosets or thermoplastics. A machine heats and

mixes the plastic until it is in a pliable molten shape, then a screw device turns to

force the plastic into an outlet that leads to the mold. Once the plastic sets, the

mold opens to eject the product.

Figure 14: (Injection Molding Machine)

 Reaction Injection Molding

Reaction Injection Molding uses only thermosets and involves a special curing

operation that takes place within the mold. It is also slightly slower than standard

injection molding.
 Figure 15: (Reaction Injection Molding Machine)

 Compression Molding

Compression molding is, in some ways, the opposite of injection molding. The

molten plastic is deposited into a mold, which then closes. There is an inlet hole

somewhere in the mold through which another device applies pressure. The

pressure forces the plastic outward into the hollow cavity of the mold, achieving

the final shape. Compression molding often produces items that feature a great

deal of “flashing,” or excess plastic, that must be trimmed off. Compression

molding can also be used to form rubber items.

 Figure 16: (Compression Molding Machine)

 Transfer Molding

Transfer Molding is similar to compression molding but involves a metal plunger

to apply pressure. The molten material is deposited into the mold and sealed

within. A metal plunger, which is like a large shaft, is pressed deep into the mold,

forcing the material to spread outwards and fill in the geometry of the mold.

Transfer molding can be used on plastics or rubber.

 Figure 17: (Transfer Molding Machine)

 Extrusion

Extrusion is one of the few molding methods that can be performed on hot or

cold material. In extrusion processes, a die is used as opposed to a three-

dimensional mold. A die is a two-dimensional hole with a defined geometry

through which a material is forced, or extruded. The extruded material, usually

metal like aluminum or a plastic, takes on the shape of the die geometry.

Continuous extrusion involves the production of very long extruded pieces, while

semi-continuous extrusion produces several similarly-sized pieces.

Figure 18: ( Extrusion Molding Machine)

 Blow Molding
 Blow molding resembles compression molding but involves the use of

pressurized gas to pressure the plastic into the geometry of the mold. A mold is

filled with molten plastic and sealed. The sealed mold has a small hole, into

which the pressurized gas is pumped. Although the gas compresses, it

eventually creates so much outward pressure that the plastic fills in the geometry

of the mold.

Figure 19: (Blow Molding Machine)

 Rotational Molding

Rotational molding involves rotational motion to effect the pressure needed to fill

the mold. Molten plastic is poured into a mold and sealed. The mold then rotates,

allowing the molten plastic to drip down the sides and fill in all the crevices and

patterns of the mold.

 Figure 20: (Rotational Molding Machine)

 Hydro forming

Hydro forming is a metal-specific molding technique that uses water pressure to

force metal into a dye or mold. The metal, which is heated to a pliable

temperature but is not molten, is inserted into the mold or dye machine and

sealed within. A small opening allows water to be pumped in at high hydraulic

pressure. The extreme pressure of the water in the mold forces the metal to fill

the mold geometry. The water is then drained and the workpiece ejected. A

variant of hydroforming involves the use of explosives, called explosive

hydroforming. In this method, the pressure on the water is caused by an

detonation of a mild explosive. The sudden pressure of the outward moving

explosion causes the water to be forced into the metal, which is then forced into

the mold geometry.

 Figure 21: (Hydroforming Machine)

Related Studies

Evaluation of Plastic Aggregates used as hollow blocks

Advantages of Concrete Hollow Blocks

Highly Durable: The good concrete compacted by high pressure and

vibration gives substantial strength to the block. Proper curing increase

compressive strength of the blocks.

Load Bearing, strength can be specified as per the requirement.

Fire Resistant

Provide Thermal and sound insulation: The air in hollow of the block, does

not allow outside heat or cold in the house. So it keeps house cool in

summer and warm in winter.

Economical

Environment Friendly, fly ash used as one raw materials.

Low Insurance Rates

Constructional Advantages

No additional formwork or any special construction machinery is required

for reinforcing the hollow block masonry.

Only semi-skilled labour is required for this type of construction.

It is faster and easier construction system , when compared to the other

conventional construction systems.

It is also found to be cost-effective disaster resistant construction system,

as explained in the next section.

Standards of CHB (Concrete Hollow Blocks)

Hollow and solid load-bearing concrete masonry unit standards:

ASTM C 90 and as Follows:

A. Type II

B. Weight Classifications: lightweight (maximum density of less than 105 PCF)

and a maximum linear drying shrinkage of 0.065% when tested in accordance with

ASTM C 426. Fabricate using lightweight aggregate that strictly conforms to ASTM C

331. Normal weight aggregates, when used in blending with lightweight aggregates to

achieve a smooth, tight texture, shall conform to ASTM C 33.

C. Unit compressive strength not less than 1900 psi average net area to

provide system performance requirement of FM 150

The hollow block sizes in the Philippines are the following:

 40cm (length) X 20 cm (width) X 4 in (thickness)

40cm (length) X 20 cm (width) X 5 in (thickness)

40cm (length) X 20 cm (width) X 6 in (thickness)

PVC's Physical Properties

PVC, PE, PP and PS are general purpose plastics. The features of the particular

plastic are determined by its chemical composition and type of molecular structure

(molecular formation: crystalline/amorphous structure).

PVC has an amorphous structure with polar

chlorine atoms in the molecular structure. Having

chlorine atoms and the amorphous molecular

structure are inseparably related. Although

plastics seem very similar in the context of daily

use, PVC has completely different features in

terms of performance and functions compared

with olefin plastics which have only carbon and

hydrogen atoms in their molecular structures.

 Durability

Under normal conditions of use, the factor most strongly influencing the durability of a

material is resistance to oxidation by atmospheric oxygen. PVC, having the molecular

structure where the chlorine atom is bound to every other carbon chain, is highly

resistant to oxidative reactions, and maintains its performance for a long time. Other

general purpose plastics with structures made up only of carbon and hydrogen are more

susceptible to deterioration by oxidation in extended use conditions (such as, for

example, through repeated recycling).

Synthesis

The literature cited in this study equipped the researchers with the needed

information in developing hollow blocks using plastic wastes.In the conceptual literature,

the composition of raw material plastics is being elaborated. The process include in the

machine are also cited including the shredding, mixing and molding.

The prior information and data used and presented on previous studies about the

shredding, mixing and molding helped the researchers conceptualize the design of the

machine. The reviewed theoretical and research literature has an extremely close

relationship because it tackles about using plastics in making hollow blocks. These

aided the researchers to have an enhanced perceptive thoughts and concepts.

 CHAPTER III

RESEARCH METHODS AND PROCEDURES

This chapter presents the discussion of the methods and procedures employed by the

researchers to design and develop of a machine to produce hollow blocks from plastic

wastes.

Research Design

Development Stages

The development of the machine and the procedures used to accomplish the

objectives of the study are as follows:

1. Design Stage

This stage includes the design of the machine, considering the proper materials

used according to its availability in the market. All components of the machine were

designed based on the systematic assessment of the parameters and principles involved

in the processes. The design of system components and materials selection required

proper knowledge and skills and development of the system. It also involved useful

drawings, schematic diagrams, and design layout. The design of the machine will be

based on the selection of the appropriate materials for the major components of the

machine considering the available resources and possible costs. The design was simple,

convenient and an achievable machine.

 2. Fabrication Stage

The required key components of the machine including its specifications were designed

base from the studied concepts and theories. The researchers made several

considerations and other important parameters to comply with the requirements

3. Preliminary Testing

In order to arrive with the Plastic Wastes Hollow Block making machine with a high

efficiency, series of test and experiments will be conducted and performed to the system.

Also, it will cover the preliminary testing of the fabricated prototype to ensure that the

apparatus will work properly. The problems that were encountered during the actual

testing were given immediate action to have a better output. Necessary modifications will

be adopted to attain the optimum performance of the machine.

4. Final Performance Testing

Final testing will be done to evaluate the operating time, production rate, machine

efficiency and machine’s performance.

Methods of Testing

A. Preliminary Testing Parameter

1. Method of Determining the Maximum Loading Capacity

Maximum loading capacity will be determined by feeding different mass of chico to

the machine by 10 kg, 15 kg and 20 kg. The mass of chico loaded the machine that will

have the highest efficiency.

2. Method of Determining the Operating Speed

This refers to the rotational speed of the roller drum required for optimum

operation of the fruit washing machine. Trials will be conducted to obtain maximum

efficiency of the machine. The roller drum will be rotating at 6 rpm, 9 rpm and 12 rpm.

The operating speed with the maximum washing efficiency will be considered.

3. Method of Determining the Operating Time

This refers to the time of the operation of the chico fruit washing machine. The

washing time will begin when all the chico fruits are already inside the rotating roller

drum. The roller will be stopped after the indicated time for testing.

Methods of Testing

To conclude the machine’s performance, operating time and machine efficiency

will be determined the following will be utilized to determine the different parameters set.

1. Method of Determining the Packing Rate

In determining the machine’s packing rate, the number of total packs per

operation divided was by the total time the machine ran.

number of total packs

Repacking Rate = × 100%
total time
2. Method of Determining Machine Efficiency

In determining the machine efficiency, the number of good packs is

selected and is divided by the total number of packs. The equation was:

number of acceptable packs

Machine Efficiency = × 100%
total number of packs