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High-density polyethylene (HDPE) tiles

Conference Paper  in  AIP Conference Proceedings · November 2022

DOI: 10.1063/5.0110960

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High-density polyethylene (HDPE) tiles
Cite as: AIP Conference Proceedings 2532, 080002 (2022); https://doi.org/10.1063/5.0110960
Published Online: 28 November 2022

Kishan Gunesegeran, Rajkumar Annamalai, Muhammad Izzat Nor Ma'arof, et al.

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AIP Conference Proceedings 2532, 080002 (2022); https://doi.org/10.1063/5.0110960 2532, 080002

© 2022 Author(s).
 High-Density Polyethylene (HDPE) Tiles
Kishan Gunesegeran1, a, Rajkumar Annamalai1,, Muhammad Izzat Nor Ma'arof 2,
Nurharniza Abdul Rahman1 and Narendran Nadarajan 2
1
Department of Civil Engineering, Faculty of Engineering and Quantity Surveying, INTI International University,
Negeri Sembilan, Malaysia
2
Department of Mechanical Engineering, Faculty of Engineering and Quantity Surveying, INTI International
University, Negeri Sembilan, Malaysia
a)
Corresponding author: [email protected]

Abstract. This project mainly focuses on producing the tiles using waste materials 100% from HDPE plastic bottles. The
study is to overcome some problem which ceramic tiles is can easily cracked, fade away in time. To be in line with The
Global Challenge for Government Transparency: The Sustainable Development Goals (SDG), this research project is
aiming to score three out of seventeenth goals set by SDG which is SDG 09, SDG 11 and SDG 12. The goal of this study
by choosing High-Density Polyethylene as product to produce tiles by improving the quality due to the strength is showing
better than ceramic tiles. It helps to cut the plastic pollution in Malaysia and it would be great to apply in future. The method
of study used the metal mold size of 150mm x 150mm x 5mm and 150mm x 150mm x 7mm to melted HDPE plastic and
compressed by a wooden block by using a G-clamp. HDPE plastic melted with the temperature of (200-250) °C in the
range about 30 minutes. The time that taken for the cooling process of this tiles is in the range between 40 to 50minutes in
room temperature (27◦C). Lab test for the tiles conducted during this project. The testing based on the goal which were to
achieve. First, would be Flexural Strength Test (Modulus Rupture), where it been proved that the HDPE plastic has a better
strength and modulus of rupture if compared to ceramic tiles. The average breaking strength value for 5 mm thickness of
HDPE Tiles is 740 N which is higher than 721 N ceramic tiles thickness of 5mm. While the average breaking strength for
7 mm thickness of HDPE Tiles is 1307 N where it is also higher than ceramic tiles of 7 mm thickness which is 1165 N.
The values of breaking strength of ceramic tiles are found from the past researcher. Next, from the past researchers, the
data for water absorption test for HDPE plastic is low which it is only 0.01%. Thus, there is no need of high temperature
to vaporize the water content away from it. Therefore, based on the results obtained this HDPE is tough and well suitable
for table top and for marketing purpose due to good strength and water absorption data. This HDPE tiles to commercial in
our global market.

INTRODUCTION

Tiles is a thin rectangular slab of baked clay, concrete, and other materials, used in overlapping rows for covering
roofs. Tiles is manufactured piece of hard-wearing material such as ceramic, stone, metal or glass. Tiles are generally
used for covering roofs, floors, and walls. Plastic floor covering materials been classified into floor tiles, which can
either composition tiles or homogeneous tiles, and long-sized sheets, which maybe either vinyl sheets without a foam
layer and vinyl sheets with a foam layer. The time required to produce a plastic tile is lesser than to make a cement
tile. The weight of plastic tiles is very light and easy to handle. The plastic tiles also is recyclable. The shape of plastic
tiles also can change by heat it and transform it into the desired shape [1].
In the last few years, many innovations have revolutionized in the tiles industry. Nowadays, tiles industry uses
digital ink-jet technology in the Porcelain body floor and white body ceramic wall tiles to meet authentic stone
appearances and very refined designs. Most of the tiles production works done by computers, machines and robotics.
Besides providing the world with a stunning variety of sizes and styles, European tile manufacturers are proactive in
using recycled materials and taking other measures to keep the environment. Today, interior design encourages new

Proceeding of the International Conference on Advances in Civil Engineering and Science Technology (ICACEST2021)
AIP Conf. Proc. 2532, 080002-1–080002-8; https://doi.org/10.1063/5.0110960
Published by AIP Publishing. 978-0-7354-4274-0/$30.00

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trends and changes more rapidly than ever before. At Tile master, we aim to keep informed and educated so that we
can bring the best selections to you from around the world.
Thus, this project is to make tiles by using 100% recyclable High-Density Polyethylene (HDPE) plastic bottles.
The time for making of plastic tiles is just within a 1 hours compared to normal ceramic tiles. It is also taken from
waste product and turning them into a useful product. HDPE is prepared from ethylene by a catalytic process. Absence
of branching result in a more closely packed structure with a higher density and higher chemical resistance than LDPE.
HDPE is also harder and opaquer, and it can withstand higher temperature of 120° C [2, 3, 4]. It is simply food
acceptable contact. HDPE also is very popular in the industry thus it can reused again such as many new products
been made using recycled HDPE, including ropes, toys, pipes, recycling bins and trash cans [5, 6].
In 2015, 195 nations agreed with United Nation to change the world for the better by the year 2030 through The
Global Challenge for Government Transparency: The Sustainable Development Goals (SDG). To be in line with the
campaign, this research project is aiming to score three out of seventeenth goals set by SDG which is SDG 09, SDG
11 and SDG 12.
SDG Goal 09: Industry, Innovation and Infrastructure where Malaysia as developing countries gave a huge
potential incentive for Industrialization on Innovation and Research & Development (R&D). According to United
Nation facts the global share of manufacturing value added in GDP increase from 2005 to 2017 by 1.1% from 15.2
per cent which driven by fast growth of manufacturing,
SDG Goal 11: Sustainable Cities and Communities where the purpose is to make cities and communities secure,
resilient and sustainable by the year of 2030, by ensuring sufficient access to safe and affordable housing and basic
services and
SDG Goal 12: Responsible Consumption and Production where overexploitation and overuse of natural resources
should avoid because depletion of natural resource will happen, and it is happening. On focusing this Goal 12 mainly
ensuring the responsible consumption and production patterns in promoting sustainable infrastructure, energy and
resource efficiency, giving access on basic services and better living standard. Substantially reduce waste generation
through prevention, reduction, recycling, and reuse hit the target of this research project.

METHODOLOGY AND LABORATORY ANALYSIS

This project conducted by using recycle materials where recycle item collected from the recycle centers and
laundry. The product will be produced by using compression molding process. Then, the samples will be tested in the
laboratory to check quality of tiles.

Colleting and Cleaning of Materials

FIGURE 1. Cleaning the bottles

The first step in this process is to collect recycled HDPE plastic such as from home trash, recycling bins, laundry
and recycling centers. The most common HDPE products that commonly used by human in their house are milk
pitcher, detergents bottles, shampoo bottles and so on. To find whether the plastic is HDPE, there will be symbol “2”
at bottom or side of bottles. Moreover, after collecting all the HDPE plastics, wash with proper soap to remove dirt
and make sure no stains. [7] Additionally, scrap the labels behind the containers or bottles to make sure that the liquid
is as good as possible, and it not affected the melting process. For example, if the papers contain with the plastic during
the melting process it will cut the integrity of the final product. [8, 9]

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 Cutting of the Materials

(a) (b)
FIGURE 2. (a) Jaw crusher machine (b) Plastic after grind

The last step before the melting process is cutting the HDPE plastic into small pieces because it will be easier to
melt if compared to big pieces. There are 2 methods of cutting the material which is using human power and machine.
For human power is by cutting the plastics using sharp scissors, hand prunes into lengthy strips. After that, to cut in
smaller pieces around 5mm to 7mm. This method will be more effective with help of group of people. While the other
method is using Crushing Jaw Machine. First thing first, cut the plastic bottles into 5 to 6 pieces. After that, place into
the jaw crusher machine where it will crush the plastic particle into 1mm to 2mm in size. This method will be effective
than human power because, it can save time, more safety and smaller pieces of plastics makes the melting process
very effective.
Melting of HDPE Plastic

FIGURE 3. The plastics is melted

After the mould is prepare, melting process will take place where the grinding of HDPE into small pieces should
put in the mould and let it melt until reach its melting point. Before that, the amount of plastics should weighed
according to the size and thickness of the tiles. Melting points of HDPE is 130 degrees Celsius.

Cooling Process of the Tiles

FIGURE 4. Cooling of the tiles

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 Once melting process finished, the plastic should continue to be compressed while cooled using G-clamp or
Hydraulic Machine. Cooling can have a significant impact on the structure of the HDPE material of the final recycling
product. When it is slowly cooled from dilution, HDPE produces a more elastic crystalline structure than produced
from a faster cool, therefore, it benefits to cool the material as slow as possible to allow greater elasticity in the final
product. Then tiles will leave to cool approximately for 40 minutes to 50 minutes.

Finishing Process

(a) (b) (c)

FIGURE 5. (a) Process 1 (b) Process 2 (c) Process 3

Once the tiles been removed from the mould, sandpaper or grinder machine used to smooth the edges of the tiles.
Applying the gel coat is an optional step to make it shines of the tiles. The gelcoat that will be recommended is ISO
NPG 9359-S and the catalyst is Methyl Ethyl Ketone Peroxide KP-9 (MEKP). Before applying the gelcoat, 1% of
MEKP catalyst should added to the gel coat to speed up the drying process. The purpose of catalyst been used in
MEKP is to speed up the drying process after gelcoat applied on tiles. Therefore, applying gelcoat on tiles is just an
optional way to make the tile looks better.

RESULTS AND DISCUSSION

Flexural Strength for HDPE Tiles at 5 mm thickness

Figure 6. shows the comparison of the flexural load withstand by 5 mm thickness will be in units of Newton while
flexural extension specified in units mm. The second specimen indicates the lowest bending which is 6.728 mm and
the highest bending specimen shows is 12.688 mm. Therefore, the third sample is neither the highest nor the lowest
level of flexural extension. The average of the bending of the 5 mm thickness HDPE tiles is 9.183 mm. From the
results, it shows that 5 mm HDPE tiles is good in bending. From flexural tension test at maximum load results show
the sample lack of consistency due to some error during the producing of the product such as improper compression
because it can lead to uneven surface of the tiles which it can affect the test results.
From the Table 1. and Table 2., the maximum flexure load and flexure stress at maximum flexure load of the
specimens is undoubtedly an important parameter should focus because these two (2) data is required to compared
with the International Standard Organization (ISO 10456 Part 4: Determination of yield stress and breaking strength).
Maximum flexural load is load that required to break the sample. While the flexure stress at maximum flexural load
is the yield stress of the samples. First specimen requires the highest load to break the 1022.634 N followed by a third
specimen 605.195 N and the second sample 588 N. Whereas yield stress for the first specimen is the highest number
of 32.724 𝑁/𝑚𝑚! , followed by the third specimen is 19.366 𝑁/𝑚𝑚! . Yield stress for second specimen
is 18.826 𝑁/𝑚𝑚! . Therefore, the average values of breaking strength, yield stress of the HDPE tiles was considering
which is 739 N and 24 𝑁/𝑚𝑚! . The values of the yield stress of the HDPE tile samples calculated manually using
the following formula for yield stress with; F is the load (force) at the fracture point (N), L is the length of the support
span, b is width and d is thickness.
3𝐹𝐿
𝜎 = (1)
2𝑏𝑑!

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 HDPE 5 MM

FIGURE 6. The graph shows the flexural load against the flexure extension for 5mm

TABLE 1. Results after the 5mm tiles had been tested (Flexure Load)
Flexure Strain at Max
Modulus Max Flexure Load Flexure Strain at Max
Flexure Load
(MPa) (N) Flexure Load (%)
(MPa)
1 1,345.48 1,002.63 5.947 32.724
2 1,095.66 588.300 3.154 18.826
3 911.847 605.195 3.813 19.366
Mean 1,117.66 738.710 4.305 23.639
Median 1,095.66 605.195 3.813 19.366
Standard Deviation 217.65007 246.03064 1.46029 7.87298

TABLE 2. Results after the 5mm tiles had been tested (Flexure Extension)
Flexure Extension at Flexure Extension at Flexure Extension Energy at
Max Flexure Load Break (Standard) at Break (Standard) Maximum
(mm) (mm) (N) Flexure Load (J)
1 12.688 29.993 187.85971 9.009
2 6.728 27.605 4.26312 2.630
3 8.135 28.019 64.98690 3.184
Mean 9.183 28.539 85.70324 4.941
Median 8.135 28.019 64.98690 3.184
Standard Deviation 3.11529 1.27629 93.53503 3.53398

Flexural Strength for HDPE Tiles (7 mm thickness)

Figure 7. shows the comparison of the flexural load withstand by 7 mm thickness expressed in units of Newton
while flexural extension specified in units mm. Based on the graph above, the second specimen indicates that advanced
the lowest which is 4.584 mm, and the highest bending specimen shows the third sample which is 10.033 mm
meanwhile first sample is neither the highest nor the lowest level of flexural extension. The average of the bending of
the 7 mm thickness HDPE tiles is 6.982 mm. From flexural tension test at maximum load results show the sample
lack of consistency due to some error could happen during the process of production of the product such as the plastic
is not cleaned properly, the plastics not grinder very well and so on. This form of error can affect the product's test
results.
Based on Table 3. and Table 4., the third specimen requires the highest load to break the 1954.439 N followed by
a second specimen 1408.109 N, while the first sample is about 558.780 N. Whereas the yield stress for the third
specimen is the highest number of 31.909 𝑁/𝑚𝑚! . 2, followed by the second specimen is 22.990 𝑁/𝑚𝑚! . Yield

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stress for first specimen is 9.123 𝑁/𝑚𝑚! . Therefore, the average values of breaking strength, yield stress of the HDPE
tiles was considering which is 1307 N and 22 𝑁/𝑚𝑚! .

FIGURE 7. The graph shows the flexural load against the flexure extension for 7 mm

TABLE 3. Results after the 7 mm tiles had been tested (Flexure Load)
Modulus Max Flexure Load Flexure Strain at Max Flexure Strain at Max Flexure Load
(MPa) (N) Flexure Load (%) (MPa)
1 594.504 558.78 4.154 9.123
2 1,302.416 1408.109 3.008 22.99
3 1,482.288 1,954.439 6.584 31.909
Mean 1,126.403 1,307.109 4.582 21.341
Median 1,302.416 1,408.109 4.154 22.99
Standard Deviation 469.33543 703.29034 1.82 11.48229

TABLE 4. Results after the 7mm tiles had been tested (Flexure Extension)
Flexure Extension at Flexure Extension at Flexure Extension Energy at Maximum
Max Flexure Load Break (Standard) at Break (Standard) Flexure Load
(mm) (mm) (N) (J)
1 6.330 28.530 110.16972 2.665
2 4.584 28.667 101.25957 4.237
3 10.033 32.60 909.43494 14.704
Mean 6.982 29.932 373.62141 7.202
Median 6.330 28.667 110.16972 4.237
Standard
2.78254 2.31121 464.04951 6.54420
Deviation

Comparison of HDPE Tiles with Ceramic Tiles

From the Figure 8. the ceramic tiles categorized into several groups. The highest Breaking Strength that required
for more than 7.5 mm of thickness for ceramic tiles is in Group AI which is 1100 N. Since, this product have two
different thickness of 5 mm and 7 mm, the Breaking Strength compared to less than 7.5 mm of thickness since both
are less than 7.5 mm. Therefore, the highest Breaking Strength that required for the ceramic tiles is from Group AIIb
P.1 which is not less than 900 N. Thus, the average value of breaking strength of 5 mm and 7 mm of thickness is 739
N and 1307 N. So, it shows that the 7 mm thickness of HDPE tiles passed all the requirement for every group that
based on the figure above.
While the 5 mm thickness of HDPE tiles is also satisfied except for the Group AIIb P.1 and Group AIIb P.2.
Besides, the individual values of Yield Stress for 5 mm and 7 mm thickness of HDPE tiles (each samples) compared
according to the International Standard Organization of the Ceramic tiles. From the comparison, it passed all the group

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of ceramic tiles except for the first sample of 7 mm thickness of HDPE tiles that was tested. So, it clearly showed that
this is due to the error during producing of the sample because other samples passed the requirement.

FIGURE 8. Values of breaking strength that required for ceramic tiles according to International Standard organization.

The data in the Table 5. and Figure 9. is from the past researchers [2] the one who explain that the HDPE plastics
only absorb 0.01% percentage, and it is one of the properties of HDPE plastics. By comparing the rate of absorption
of HDPE with Figure 10.0, it shows that the HDPE plastics can satisfy all the requirement that required for ceramic
tiles. Thus, it can referred to this product because HDPE is a thermoplastic where it can re-shaped into any type of
shape. Therefore, the properties of the HDPE will not change if the re-shaped process occur successfully. If the water
absorption is higher, the tile may loosen each other and causing damages to the tiles. Since, the HDPE tiles is low
water absorption it is suitable to use in the kitchen, because low water absorption has good internal stability. The water
absorption of this HDPE data collected from past researchers which it is mentioned 0.01% water absorption, since it
is low water absorption, it is suitable use in the kitchen, because low water absorption has good internal stability.
HDPE is thermoplastic, which it can heated and re-used again. The studies show that, the HDPE can be recycle at
least 10 times. As long as the strength of the HDPE tiles is better than other tiles in market, it would be fine. Some
standard tests were conducted on the HDPE tiles; hence the result proved the strength of the bond after recycled.
TABLE 5. Physical properties of the various plastics
𝒈
Name Density ( $ 𝟑 ) Melting Point (ºC) Tensile Strength (PSI) Water Absorption (%)
𝒄𝒎
HDPE 0.95 130 4500 0.01
LDPE 0.92 120 1700 0.01
PP 0.94 160 5000.00000 0.01 - 0.03
PS 1.05 240 6671 - 8702 0.03 - 0.1

FIGURE 9. Percentage of water absorption that required for ceramic tiles according to International Standard

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 CONCLUSION AND RECOMMENDATIONS
This research is to innovate new product by using waste materials and compared quality with the current product
in the market. For the first goal, which is producing plastic tiles using High-Density Polyethylene (HDPE) plastic
where it is clear that the results of new innovation to produce plastic tiles using High-Density Polyethylene (HDPE)
successfully made it. Full plastics ware used to produce the HDPE Tiles because it is the first steps to reducing the
plastic pollutions on the earth [10]. Because the plastic pollution causing marine life in danger [11]. Furthermore, for
the second goal have been met through the works undertaken in experimental test to determine the Strength of HDPE
tiles by using Modulus of Rupture Test and compared with ceramic tiles. Three (3) samples of each 5 mm and 7 mm
thickness of tiles tested to determine the breaking strength and after the comparison with ceramic tiles, the results
prove that HDPE tiles has better strength than Ceramic tiles. In addition, water absorption of the HDPE also compared
with the ceramic tiles from the data analyse. The testing results differentiated between ceramic tiles and with HDPE
tiles, it proven that the new innovative HDPE tiles had achieved with low water absorption and satisfy the International
Standard Organization.
Recommendations made based on the findings obtained from the experimental and analytical result analyses as
for compaction, hydraulic compressor will be more efficient if compared to the G-Clamp compression because the
force that used in G-Clamp compaction is the number of turns of G-clamp where it can lead to error at the end of the
results. Therefore, for hydraulic compressor, specific amount of force will be used for compaction process which it
results an even surface of tiles. The lack advance tools to produce this product, commercialize heavy tools needed to
use to produce fast and more quantity of HDPE tiles.

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