Plastics in Building

Background
• The use of rubber and plastics materials in buildings, both for
construction and decoration, continues to increase,
particularly as architects, designers and builders appreciate
their advantages in construction terms and in the provision of
so called ‘maintenance free’ structures.
• Today, plastics materials are so widely used in the building
industry that it would be difficult to envisage the construction
of any building without them. Many products are available
which meet the various building and fire regulations.
• Some of the areas in which these materials are used are listed
in table 1.
 Table 1. Application of plastics and rubbers in building
Adhesives Anti-vibration mountings Decorative laminates

Sealants Window frames Geotextiles for earthworks

Roofing materials Glazing Laminates for formwork

Waterproof membranes Pipes and gutters Laminates for decoration

Floor coverings Drainage systems Flexible foams for upholstery

Sound insulation Fascia boards Fibres for carpets and fabrics

Thermal insulation Cladding panels Paints and varnishes

 Pipes and Gutters
• For many years we have seen
the gradual replacement of
traditional materials such as
lead, copper, steel, cast iron and
ceramic waste systems with
plastic pipes and fittings.
• Some of the advantages gained
are a reduction in weight, ease
of fabrication and installation,
ease of repair and in many
cases a reduction in cost.
• Because plastic pipes have a
smoother bore than their metal
counterparts, flow rates can be
increased and scale formation is
reduced. Plastic pipes also offer
advantages in corrosion
resistance.
 Push-Fit Plastic Piping

Within buildings the push-fit

waste systems have made
plumbing much quicker, and
also safer from fire hazards,
since blow lamps are no longer
necessary to wipe lead joints.
Externally, a wide range of soil
pipes and fittings are available
to carry waste to the main
sewers. Here the advantages
of lighter weight, longer pipe
lengths without joints and
ease of fabrication have made
these an absolute boon to the
industry.
 Push-Fit Plastic Fittings
• Whilst the bulk of the
materials used are
thermoplastics, such as
PVC (polyvinyl chloride),
ABS (acrylonitrile
butadiene styrene
terpolymer) and
polypropylene, without
the use of rubber O-rings
and compression gaskets
push-fit systems would be
impractical.
 Polyethylene pipes
• With potable water distribution,
polyethylene pipes are now widely
used. Pipes are available in diameters
from a nominal 8 mm bore up to
1000 mm and above, made from
specially developed grades of MDPE
(medium density polyethylene) which
meet a range of water industry
specifications .
• One advantage of plastic pipes over
more traditional materials is that in
the smaller diameter sizes they are
available in continuous lengths of up
to 100m or even 250m in some
cases. This reduces the number of
joints needed and hence the number
of potential leaks.
• For underground potable
water distribution pipes are
coloured blue. This enables
the contents of a buried
pipe to be immediately
identified on a construction
site. Above ground black
coloured polyethylene is
used to ensure adequate
UV stability.
 Disadvantages of Plastic Piping

• One disadvantage of plastics materials is

their tendency to soften at elevated
temperatures. This has restricted their use
in hot water systems. However, two
materials have found application in
underfloor heating systems and to a
limited extent for hot water distribution.
These are polybutylene (PB) and
crosslinked polyethylene (PEX).
 Polybutylene
• Polybutylene can be used in
systems with a continuous
operating temperature of 82°C
and will survive short peak
temperatures of up to about
110°C but does require
continuous support at these
higher temperatures.
• With underfloor heating systems
continuous support presents no
particular problem. Although
failures have occurred in the USA
where high levels of chlorine are
present in the water supply,
similar problems have not arisen
in the UK and Europe where the
chlorine content is lower.
 Crosslinked Polyethylene
• Crosslinked polyethylene (PEX) is
made from normal polyethylene by,
for example, crosslinking it using a
peroxide catalyst.
• The cross-linking raises the thermal
stability of the material under load.
Thus, the resistance to
environmental stress cracking, creep,
and slow crack growth are greatly
improved over polyethylene.
• PEX pipe is approved for potable hot-
and cold-water plumbing systems
and hot-water (hydronic) heating
systems in all model plumbing and
mechanical codes across the U.S. and
Canada.
• PEX piping systems are durable,
provide security for safe drinking
water, and use reliable connections
and fittings. There are currently
about ten domestic producers of
quality PEX piping.
 Gas distribution
• Yellow coloured polyethylene
pipes are now used for gas
distribution, particularly where
existing domestic supply pipes
have corroded. In this case the
replacement plastic pipe is
threaded through the existing
pipe.
• This overcomes the need for a
trench to be excavated and
considerably reduces the cost
of replacement. Because the
pipe bore is smoother the gas
flow is hardly reduced.
 Electrofusion
• One recent innovation in jointing pipes has
been the introduction of the electrofusion
technique. Here special couplers are
available which incorporate a heating coil.
• The coupler is clamped in . position over the
two pipe sections to be joined and power is
supplied to the heating coil by means of an
electronic control unit. The pipe and coupler
melt at the interface between the two
materials and a permanent fusion bond is
formed. This enables consistent joints to be
made using relatively unskilled operatives.
• Using these couplers, permanent repairs can
be made to buried pipes with minimal
excavation, since only the damaged part of
the pipe needs to be replaced rather than a
complete section.
• Plastic guttering and drainage pipes can be
found on most buildings today, and usage is
such that these products are taken for
granted in the same way as bricks, concrete
and timber are in building construction.

coupler
 Roofing Systems
• Corrugated plastic sheeting
has been used for roofing in
conservatories and
buildings where transparent
panels have been required.
However, in more recent
times double and triple
walled polycarbonate
sheeting has become
increasingly used, since this
provides not only diffuse
daylight for illumination but
also heat insulation and
hence reduced heating
costs.
 Twin or triple walled
polycarbonate
• Provides a number of
advantages during installation
since it can be cut with
conventional tools, is rigid to
handle, does not require
closely spaced supports, is
light in weight and can be
easily fitted. In addition, it can
be cold formed or
thermoformed into a variety
of shapes to provide attractive
and functional curved
surfaces. Edges and joints can
be sealed to prevent draughts.
Another major advantage is its
resistance to breakage.
 Roofing Systems continued
• Polycarbonate sheeting is available
which meets BCA for surface spread
of flame. This has enabled the
material to be used in public areas of
buildings where strict fire regulations
apply. Specially UV stabilised grades
of polycarbonate are used, often with
an additional UV barrier film
incorporated under the outer skins.
• Fixing is usually by means of
aluminium or UPVC (unplasticated
PVC) glazing bars. However, unlike
glass, holes can be drilled through the
material for screw fixings. More
recently, similar twin walled sheeting
made from clear UV stabilised PVC
has become available. Both materials,
polycarbonate and PVC, are available
in clear and bronze colours.
 Cladding Panels

• UPVC products are now frequently used in

place of the more traditional timber products
for external cladding panels, fascia and soft
boards, particularly on new buildings. Some
of the advantages offered by UPVC are lighter
weight, resistance to rot, lack of warp and
lack' of need for regular maintenance
painting. In addition, UPVC meets BS 476:
Part 7: Class 1' for surface spread of flame.
• Products are available in a variety of colours,
including wood grain finishes. These may be
of solid UPVC, double skin or foam filled
double skin construction.

• When fixing UPVC products, unlike their

timber counterparts, due allowance must be
made for expansion and contraction to
prevent buckling of the sheets due to the
heating effect of sunlight. Normally an
allowance of 2 mm per metre length must be
provided between sections. To allow for this
special UPVC jointing and corner sections are
available.
 Unitex cladding fixtures
• The Unitex range of lightweight cladding
solutions has been tailored to suit the
needs of specifiers, designers,
developers, builders and most
importantly the home owner.
• The Uni-EIFS™ (External Insulation
Finishing System) range is designed so
that the insulation is placed on the
exterior of the building, equalising the
effects of outside temperatures and
reducing thermal stresses and strains in
the structure.
• Cold spots and drafts are eliminated
because the entire surface is insulated.
• With Uni-EIFS your house is insulated in
summer against heat from the outside,
insulated in winter against cold from the
outside which means true living comfort
all year round.
Plastic Fascia
 Rubber Anti‑Vibration Mounts
• In many buildings there is a need to prevent external vibrations
from affecting sensitive equipment within the building. This
necessitates the incorporation of anti-vibration mounts during the
construction of the building. In the UK, laminated elastomeric
bearings are usually chosen but in France and Germany, steel coil
springs are more often used. Although rubber vibration isolating
systems have been known for many years, it is only in the last 10
years or so that methods have become available for designing and
analysing high efficiency compound systems.
• Rubber springs tend to be less massive than the equivalent steel
springs for any particular application. In addition, the dynamic
properties of rubber can result in such mounts providing protection
over a wider range of frequencies, particularly at high frequencies.
• Rubber mounts are also used to isolate individual items of
equipment, such as air conditioning and refrigeration equipment,
from the main structure of the building.
Plastic anti-vibration mounts
 Sound Insulation

• Sound within buildings may be general noise

transmitted through walls and floors or a
specific noise from vibrating machinery. The
latter can be dealt with by using vibration
mounts as mentioned above. Air-borne noise
can also present problems and must be taken
into account when designing sound insulation
systems.
• With general noise, the traditional method
was to build very thick and heavy walls and
floors. However, as buildings have become
lighter, other methods of sound reduction
have become necessary. As a general
principle, sound insulation can be provided by
either a simple and heavy or a light and
complex construction. It is in this latter area
that rubber and plastics materials have come
to the fore.
• The performance of party walls and
floor is controlled by the BCA which give
typical constructions that meet the
performance requirements. To meet
the regulations with light weight
constructions some form of dry lining,
floating floor or suspended ceiling is
needed. However, in all these cases the
method of fixing can reduce the
efficiency of the system.
• With floating floor construction, an air
gap, created by placing a resilient
material such as rubber or foamed
plastic between the timber raft and the
concrete floor, can achieve the desired
result. Since the demand for light
Rubber placed under the timber floor
weight constructions is increasing, this
will provide a steadily increasing outlet
for rubber and foamed plastics.
• With walls in housing,
dry lining is often used
but in offices and
factories, composite
wall panels
incorporating foamed
plastics are available
that are easily installed
and that provide
adequate sound
insulation.
 Thermal Insulation
• As well as sound insulation, buildings need thermal insulation. This
can be met by using light weight aerated concrete building blocks
during the construction of the building or by incorporating foamed
plastic sheeting within the structure. Typical foamed plastics
include rigid polyurethane foam and expanded polystyrene,
although various other foamed plastics may also be used.
• Plasterboard can be readily obtained with a 25 mm foamed
polystyrene backing. Other composite sheet building products can
be obtained with polyurethane foam cores. One particularly
important use of polyurethane foams is in the construction of cold
rooms for food storage. Here a 100 mm thick sheet of polyurethane
foam is sandwiched between two layers of glass fibre reinforced
polyester (GRP) or two layers of sheet steel. The surface of the GRP
can be flat or lightly embossed to give a semi-decorative
appearance. Such surfaces are ideal for use in food storage areas
since they can be kept clean with very little effort.
• For all these applications, whether for sound or thermal insulation,
fire retardant foams are available which meet the appropriate
building and fire regulations.
Polyester Thermal Insulation
 Window Frames
• UPVC has been in use for many years for the manufacture
of window frames and in particular, frames used for double
glazed windows. These comply with BS 5720. One of the
major advantages is the reduced thermal conductivity over
equivalent metal frames. This in turn reduces condensation
on the frame. UPVC frames can be easily assembled and do
not require regular maintenance. Neither do they need a
wooden surround or sub-frame, which can rot. Frames
come complete with window as well as other parts of the
frame and surround, all manufactured from the same grade
of white UPVC. With larger frames, steel reinforcement is
often added for extra strength and security.
• A water tight seal to concrete and brickwork is achieved by
bedding the frame in silicone rubber and by injecting a
silicone rubber bead along all joints.
Plastic Window Frames
 Plastic Decorative Laminate
• The normal structure of a plastic
decorative laminate includes a sheet
of decorative paper impregnated
(saturated) with one or several
aminic resins,
• covering the surface of a supporting
structure formed by a particleboard
(for low pressure laminates) or by
• kraft paper sheets impregnated with
Phenolic resin (high pressure
laminates).
• Plastic decorative laminates have a
wide range of uses, they can be used
in the furniture industry for kitchen
cabinet counters, bookshelves and
door linings, among many other
things. In the building industry they
can be used for partitions screens in
order to divide space in offices,
houses, etc
Plastic Decorative Laminates
  
Construction adhesives
• There are also water-based
versions that can provide better
heat resistance, and for superior
heat and water resistance, special
purpose products such as Selleys
Liquid Nails Landscape or Liquid
Nails Mirror, Metal and Glass are
available.
• Construction adhesives lose solvent
or water to gain strength – they will
be slow to cure between non-
porous materials such as metals,
plastics, dense timbers and painted
surfaces. Water based adhesive
• When bonding big broad sheets to
flat surfaces, apply beads in one
direction only, leaving channels for
evaporation.
 Construction Adhesive
• Generally solvent-based, these cost
effective, gap-filling adhesives are
suitable for bonding sheet flooring,
adhering skirtings and architraves,
signs and wall panels.
• They have good adhesion to most
substrates (especially porous
materials such as wood, concrete,
brick, fibre cement and
plasterboard).
 Stud’ adhesives
• A stud adhesive is a thick,
ready-to-use, water-
based, gap-filling
adhesive which dries
hard. Apart from bonding
plasterboard to timber
and metal frames, stud
adhesives are quite good
general purpose
adhesives for porous
materials in internal (not
water-exposed)
applications.
 Adhesive-sealants

• Sealants must
stick/adhere in order to
perform the sealing
function and tough
polyurethane sealants,
such as Selleys
Proseries Adhesive +
Sealant, create a
flexible, durable bond
which is vibration- and
shock-resistant.
 Two-part epoxy glues

• These two-part systems must

be measured and thoroughly
mixed before use. The mixing
process starts a chemical
reaction which causes the
adhesive to gain strength
quickly, so jobs can be
completed faster. Epoxy glues
produce rigid, high-strength
bonds and work well
• on porous surfaces. Non-
porous surfaces such as metals
should be roughed for better
results. Not all have high heat
resistance and can be ‘undone’
by high temperatures.
 Two-part tile adhesives
• These adhesives work
when a powder
(cement) and a liquid
(polymer emulsion) are
mixed together. Mixing
in the liquid can make
the cement component
stronger, better
bonding, more flexible,
or more chemical-
resistant.