National Academies Press: OpenBook

Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content (2011)

Chapter: Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe

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Suggested Citation:"Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe." National Academies of Sciences, Engineering, and Medicine. 2011. Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content. Washington, DC: The National Academies Press. doi: 10.17226/14570.
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Suggested Citation:"Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe." National Academies of Sciences, Engineering, and Medicine. 2011. Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content. Washington, DC: The National Academies Press. doi: 10.17226/14570.
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Suggested Citation:"Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe." National Academies of Sciences, Engineering, and Medicine. 2011. Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content. Washington, DC: The National Academies Press. doi: 10.17226/14570.
×
Page 72
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Suggested Citation:"Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe." National Academies of Sciences, Engineering, and Medicine. 2011. Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content. Washington, DC: The National Academies Press. doi: 10.17226/14570.
×
Page 73
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Suggested Citation:"Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe." National Academies of Sciences, Engineering, and Medicine. 2011. Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content. Washington, DC: The National Academies Press. doi: 10.17226/14570.
×
Page 74
Page 75
Suggested Citation:"Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe." National Academies of Sciences, Engineering, and Medicine. 2011. Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content. Washington, DC: The National Academies Press. doi: 10.17226/14570.
×
Page 75
Page 76
Suggested Citation:"Appendix E - Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe." National Academies of Sciences, Engineering, and Medicine. 2011. Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content. Washington, DC: The National Academies Press. doi: 10.17226/14570.
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Page 76

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E-1 A P P E N D I X E Proposed Draft Standard Specification for PCR MCR High-Density PE Bottles for Use in AASHTO-Approved Corrugated Drainage Pipe

E-2 DRAFT ____________________________________________________________ Draft Standard Specification for Post-Consumer Recycled Mixed-Color Reprocessed High Density Polyethylene Bottles for Use in AASHTO Approved Corrugated Drainage Pipe AASHTO Draft Standard XXX-XX ____________________________________________________________ 1. SCOPE 1.1 This specification covers the quality of post-consumer recycled, mixed-color, reprocessed, high density polyethylene bottles for use in AASHTO approved corrugated drainage pipe. 1.2 This specification presents a set of properties to be met for the resin. 1.3 This specification can be used by recycled resin suppliers as part of manufacturing quality control (MQC), or by pipe manufacturers or independent bodies as manufacturing quality assurance (MQA). ______________________________________________________________________ 2. REFERENCED DOCUMENTS 2.1 ASTM Standards: D638, Test Method for Tensile Properties of Plastics D792, Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement D1238, Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer D1505, Test Method for Density of Plastics by the Density-Gradient Technique D4218, Test Method for Determination of Carbon Black Content in Polyethylene Compounds By the Muffle-Furnace Technique D4703, Practice for Compression Molding Thermoplastic Materials into Test Specimens, Plaques, or Sheets D5630, Test Method for Ash Content in Plastics ______________________________________________________________________ 3. TERMINOLOGY 3.1 Post-Consumer Recycled HDPE (PCR-HDPE) – Polyethylene that has been discarded by consumers after use, then collected, cleaned, and washed. The density is greater than 0.940 g/cm 3 and typical sources include primarily bottles and some bags.

E-3 3.2 PCR-HDPE Regrin d – Post-Consumer Recycled HDPE that has been cleaned, washed and ground into plastic chips. 3.3 Reprocessed PCR-HDPE – Post-Consumer Recycled HDPE that has been cleaned, washed, melt-filtered, and pelletized. Commonly known as “Repro.” 3.4 Mixed-Color PCR-HDPE – Post-Consumer Recycled HDPE that is composed of mostly colored detergent bottles. 3.5 Natural PCR-HDP E – Post-Consumer Recycled HDPE that is composed of milk bottles . ______________________________________________________________________ 4. PROPERTIES 4.1 The required properties for PCR mixed-color reprocessed resin are given in Table 1. 4.2 Specific details of the tests are found in Section 7. Table 1. Required properties for PCR mixed-color reprocessed resin. Property Test Method Sample Specified Value Frequency Density ASTM D1505 ASTM D792 Pellets/Plaque 0.945-0.960 g/cm 1 per shif t Melt Index ASTM D1238 190°C/2.16 Kg Pellets/Plaque <0.60 g/10 min 1 per shift % Volatiles 175°C/1 Hour Pellet s a <0.2 % Certif y b % Ash ASTM D5603 Pellets/Plaque <1.5 % 1 per shift % PP DSC Plaque <10.0 % 1 per lot c Yield Stress (psi) ASTM D63 8 d Plaque >3500 psi 1 per lot Break Strain (%) ASTM D63 8 e Plaque >100 % 1 per lot a Tested on pellet samples before melt blending. b Manufacturer will provide a certificate stating their material will lose less than 0.2% of its weight when a 2.000 ± 0.100 g sample is heated at 350°F for 1 hour. c A production lot is defined as either a truckload, or one compartment of a railcar. Its weight is generally between 40,000 and 50,000 lb. d Strain rate shall be 2.0 in. per minute. e Assume 2.0-in. gage length.

E-4 ______________________________________________________________________ 5. SAMPLING 5.1 A production lot shall be considered as a truckload or shipping container full of 1,500 lb boxes of resin, or one compartment of a railcar. The weights normally fall between 40,000 and 50,000 lb. 5.2 A truckload shall be sampled by obtaining 0.5 lb of material from each of eight boxes, for a total of 4 lb of resin. Combine the eight samples to form a lot sample. 5.3 A compartment of a railcar shall be sampled by obtaining 2 lb from the top and 2 lb from the bottom of the compartment. Combine the two samples to form a lot sample. 5.4 The entire lot sample shall be dry blended before sample preparation. A convenient way to do this is by hand in a 5-gallon plastic pail. 5.5 Divide the lot sample into two; one for immediate testing and the other for validation testing, should the need arise. The back-up sample shall be kept for 90 days after the resin is sold. 5.6 Clearly label the sample and include a traceable production number and a date. ______________________________________________________________________ 6. SAMPLE PREPARATION 6.1 Homogenize about 2 lb (900 g) of material by melt blending without filtration, preferably with a twin screw laboratory extruder. A two roll mill is also acceptable. 6.2 The blended material shall be compression molded according to ASTM D4703, with the use of a 15°C/min cooling rate. 6.3 The plaque shall be 1.9- 0.08-mm (0.075- 0.003-in.) thick. 6.4 The plaque shall be allowed to equilibrate at standard laboratory conditions (72°F, 50% RH) for at least 12 hours before tensile testing. ______________________________________________________________________ 7. TEST METHODS 7.1 Test Conditions – Unless otherwise specified in the test methods or in this specification, conduct tests at the standard laboratory temperature of 23 2°C (73.4 3.6°F). 7.2 Density – Test methods ASTM D1505 or D792 are acceptable. Make three separate determinations using separate homogenized pellets or separate

E-5 portions of a plaque. The plaque thickness shall be 1.9 0.08 mm (0.075 .003 in.). Calculate and report the average and standard deviation from the mean. 7.3 Melt Index – Test method ASTM D1238, using Condition 190/2.16. Make duplicate determinations on either pellets or a plaque and calculate the average. 7.4 % Volatiles – This test will be performed in aluminum pans that have been heated at 350°F (177 °C) until they obtain a constant weight. 7.4.1 Test duplicate samples. 7.4.2 Weigh 2.000 ± 0.100 g of pellets or a plaque to an accuracy of three places past the decimal point into an aluminum pan. 7.4.3 Place the pan in a forced-air recirculating oven preheated and stabilized to 350 ± 5°F (177 2°C) for a period of 1 hour. 7.4.4 Remove the pan and let it completely cool to room temperature in a desiccator. 7.4.5 Reweigh the pan and calculate the percentage weight loss of the sample. Report the average to the nearest 0.01%. 7.5 % Ash - Test method ASTM D5630, Procedure B. 7.5.1 Sample size shall be 1g. 7.5.2 Heat at least 10 minutes at 800°C. 7.5.3 Test in triplicate samples. 7.6 % Polypropylene 7.6.1 Generate a melting curve by differential scanning calorimetry (DSC) at a heating rate of 10°C/min. See Figure 1. 7.6.2 The curve shall be expanded to a range that includes the end of the HDPE peak and the complete PP peak. See Figure 2. 7.6.3 Integrate the curve from a flat point before the PP melting to a point where the PP curve returns to baseline.

E-6 Figure 1. DSC curve of HDPE containing PP generated. 7.6.4 Mark the point where the HDPE melt returns to baseline. The end of the HDPE melt and the beginning of the PP melt will not necessarily be the same point. Figure 2. DSC curve of HDPE containing PP expanded. 7.6.5 Record the HDPE end-of-melt temperature and the PP heat of fusion in J/g. 7.6.6 Calculate the theoretical heat of fusion for 100% polypropylene for the portion of the PP melting curve that does not overlap with HDPE by: -4 -3 -2 -1 0 H ea t F lo w (W /g) 20 40 60 80 100 120 140 160 180 200 Temperature (°C)Exo Up Universal V4.5A TA Instruments 162.84°C 150.59°C 2.568J/g 142.71°C -0.66 -0.64 -0.62 -0.60 -0.58 -0.56 H ea t F lo w (W /g) 130 140 150 160 170 180 Temperature (°C)Exo Up Universal V4.5A TA Instruments

E-7 Y = -0.035X 2 + 8.851X – 475.6 (1) Where: X = HDPE end-of-melt temperature (°C) And Y = H f of 100% PP not overlapped with HDPE. For X = 142.7, Y = 74.7 J/g. 7.6.7 Calculate the percentage PP by: %PP = H f sample/ H f 100% PP x 100 (2) For H f sample = 2.57 J/g, %PP = 3.4 % 7.6.8 Test two specimens from different parts of the molded plaque and report the average. 7.7 Yield Stress/Break Strain – Test ASTM Method D638, with Type IV dumbbell, 2- in./min crosshead speed. 7.7.1 Test five specimens, individually measured for thickness. 7.7.2 Assume 1.3-in. gage for yield stress and 2.0-in. gage length for break strain. Use crosshead to follow displacement. 7.7.3 Report 5 results, average, and standard deviation. ______________________________________________________________________ 8. RETEST AND REJECTION 8.1 If any failure occurs, the material shall be retested to establish conformity in accordance to the specified property. A second failed result will result in rejection of the lot for the purposes of this specification. ______________________________________________________________________ 9. CERTIFICATION 9.1 Upon request of the purchaser in the contract or order, a manufacturer’s certification that the material was manufactured and tested in accordance with this specification, together with a report of the test results, shall be furnished at the time of shipment.

Next: Appendix F - Proposed Draft Standard for Recycled Content Containing HDPE Resin Formulations for Corrugated Pipe Made to AASHTO Standard M252-Recycled »
Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content Get This Book
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TRB’s National Cooperative Highway Research Program (NCHRP) Report 696: Performance of Corrugated Pipe Manufactured with Recycled Polyethylene Content provides potential specifications for corrugated drainage pipe manufactured with recycled high-density polyethylene (HDPE). The report includes proposed draft specifications for recycled HDPE, formulations of virgin and recycled HDPE, and drainage pipe containing recycled HDPE.

The following three appendixes of NCHRP 696 are available in electronic format only.

Appendix B: Recycled Polyethylene Resins

Appendix C: Recycled-Resin Blends

Appendix D: Pipe Containing Recycled HDPE

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