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PROPERTY CHARACTERIZATION OF VINYL PLASTIC ROOFING USING

CHICKEN FEATHER FIBERS AND NYLON FIBERS AS PARTIAL REPLACEMENT

TO REINFORCING FIBERS

C.J. Collamat, W. Ochavez Jr., M. Ronquillo, A. Seban, A.R. Sia, D.M. Tabios
Department of Civil Engineering
Technological University of the Philippines – Manila

Chicken feathers are considered as a waste product of


Abstract - Chicken Feathers are considered as a waste the poultry industry. Tons of waste feathers are
product of the poultry industry. Tons of waste
feathers are generated each year by poultry
processing plants, creating a serious solid waste generated each year by poultry processing plants,
problem. Research has shown that chicken feathers creating a serious solid waste problem (Parkinson,
are water and moisture resistant, has good thermal 1998; Schmidt, 1998). The Philippines, on the other
and acoustic properties, has a very low density, and hand, has well-attained self-sufficiency in poultry, an
lastly chicken feather, being mostly keratin, has a abundant producer of poultry products generating for
very long degradation period making the product about 800 million broiler chickens annually
long lasting. This study aims to characterize the regardless of continuous rise in population, the
properties of a plastic roofing which has vinyl supply continues to meet the consumer demands
chloride as the main polymer, along with it are the (Bansal and Singh, 2016). With the arising large scale
other compositions needed especially the of chicken feathers, it has come to a point that the
incorporated fibers: chicken feather fibers, nylon disposal of such wastes became difficult and
fibers and fiberglass. Figuring the best proportion on expensive. Usually, feathers are roasted or treated at
the existing mixes, it asks: What is the best mix raised temperature and pressure. After drying, it is
design among all the mix designs developed? In this ground to make powder for further use as a feed
context, having the best mix design not only means supplement for livestock. This process is quite
having the best physical properties nor having the expensive and contains protein with low nutritional
best mechanical properties, as it should be deemed to value (Ekta and Rani, 2012). Disposal methods such
be the best both in physical and mechanical as burning, or burying are also occasionally used but
properties. they are not environment friendly (Valtcho and
Based on a review of the literature of ways Zheljazkov, 2005). Meanwhile, in today's scenario,
to utilize chicken feather fibers, the natural fiber reinforcing fibers is commonly used as reinforcement
reinforced composite is reasonably strong, in commercial plastic roofing. Since plastic roofing is
lightweight and free from health hazard, and hence it exposed to weather, the material greatly needs a type
has the potential to be used as material for strong of glass that has high melting point capable enough to
components such as building materials, shipping, withstand ultraviolet rays through the test of time.
automotive, etc. Natural fiber source is renewable Apparently, for this matter, glass with higher melting
where it is considered being green and point induces higher cost (E. Jarquio, 2007).
environmentally friendly. The fact that it causes less The innovative way of using plastic as a
impact on the environment is proven since natural roofing material has a wide selection of material
fiber can be recycled thermally. Therefore, according based on plastic; all of which differ in mechanical
to good mechanical properties, the usages of the property and global abundance. One of the most
natural fibers were retained in all sorts of common plastic materials is the vinyl chloride also
applications. Further research is needed to support known as vinyl. Vinyl is a very versatile plastic
and identify other factors to consider strengthening among thermoplastics in use today. It is produced by
such claims. the fusion or polymerization of vinyl chloride
monomer. The properties of vinyl material compared
INTRODUCTION to other polymer of plastics are exceptional at some
points making it more applicable for roof The study was designed to produce vinyl
construction setting (Whelan et al., 1990). plastic roof using chicken feather fibers and nylon
However, considering plastic alone isn't fiber as partial replacement to reinforcing fibers that
sufficient. Excellent coupling of fiber reinforcement has the positive characteristics such as flexibility,
to the vinyl matrix is required for good retention of lightweight and thermal resistance. Chicken feather
tensile strength. Addition of glass fibers results in a fibers have the property to enhance the thermal
significant decrease in coefficient of linear thermal resistance and reduce the density of the material due
expansion. When properly formulated and managed to its light weight. Moreover, to enhance its flexural
for weather resistivity, the vinyl and glass fiber excel property, incorporation of nylon was considered.
in good color retention, impact retention, and Nylon has been known to have high flexural and
outstanding dimensional stability (Summers et al., tensile property, hence its application as
1999). Overall, utilizing glass fiber yields great reinforcement to various composite studies is
stabilization and a perfect balance in performance common.
and aesthetic. Conversely, reinforcing fibers needs to
be regel-coated about every five years that can result METHODOLOGY
to airborne particles which may be an issue to
persons who have asthma (Amer et al., 2018). 1. Preparation and Sourcing of Materials
Chicken feather, on the other hand, can be a
more durable and substantial material than 1.1. Vinyl Resin
reinforcing fibers. Chicken feather fibers are The vinyl resin was bought from Unilox
affordable and economical due to chicken feathers Industrial Corporation. Located at 194 M.
being a waste product in the poultry industry. Using it Concepcion Ave, Pasig, 1601 Metro Manila. Vinyl
will make a sufficient and easily attainable product in resins are always cured with heat-activated benzoyl
the market. It is mostly made up of keratin, usually peroxide catalysts, which generate sufficient ‘free
seen in claws and nails, making it very sturdy. It is radicals’ to cause the double bonds in the resin and
water and moisture resistant, so it has minimal monomers to crosslink.
swelling due to water content. The fiber has good
thermal and acoustic properties that make it tough 1.2. Fiberglass
and resilient to weathering. It has a very low density The fiberglass was obtained from Polymer
making it lightweight. Lastly, it has a very long Products (PHIL), Inc. Located at 438 EDSA Cor. B.
degradation period making the product long lasting Serrano Street, Caloocan. The E-glass was cut to a
(Ramos et al., 2007). Despite the advantages, it also length of 7 mm to 8 mm as suggested by DOST
has downsides compared to reinforcing fibers. It has management.
significantly lower mechanical properties, namely, The material was then conditioned through
the tensile and flexural properties compared to immersion in distilled water for 24 ± ½ h with a
reinforcing fibers (M. Zhan, R. P. Wool, 2016). temperature of 20 ± 1ºC at 69 ± 2% relative humidity
With that, another variable was added to the conforming to ASTM D618 (Standard Practice for
design to compensate for the mechanical properties Conditioning Plastics for Testing).
of the chicken feather fiber. Nylon has also one of the The tensile property of fiberglass was tested by
highest flexural and tensile strength of the plastic breaking single-fiber specimens on a constant-rate-
kinds. It is also very durable and can withstand of-extension (CRE) type tensile testing machine from
weathering as much as chicken feathers. Its surface ASTM D3822 (Standard Test Methods for Tensile
area is almost the same as polyvinyl chloride making Properties of Single Textile Fibers).
the binding process much easier. It is inflammable
but has a low resistance to heat with a lower melting 1.3. Chicken Feathers
point just like plastic. This is where the heat and Feathers were obtained from poultries raising
water absorption of the chicken feather plays a broiler chicken, commonly known as the 45-days old
significant role making the combination efficient and chicken (a specific type of chicken for meat
reliable. Nylon is a useful plastic for applications that production). The feathers were drawn from the
require both a plastic material as well as a high chicken of a slaughterhouse located in 726 Bagong
melting temperature. Nylon can be adapted to a wide
Silang Sala, Cabuyao, Laguna.
variety of uses because of the different variants in
To overcome the issue of feather wettability,
production and the adjustable material properties of
these variants resulting from the different materials ethanol with a known density was used instead of
nylon can be combined with (Song et al., 2005). water to reduce the hydrophobic nature of feathers.
After the thorough preparations, the feathers were cut ingredients to satisfy the physical property and
with the length ranging from 10 mm to 15 mm. mechanical property requirements as maintained in
The chicken feather fibers were then placed in a ASTM D4434 (Standard Specification for Polyvinyl
conditioning rack for 8 h and to be exposed at a Chloride Sheet Roofing).
conditioned temperature of 20 ± 1ºC at 69 ± 2%
relative humidity as stated in ASTM D1776
(Standard Practice for Conditioning and Testing Table 1 Mix Design
Textiles).
The chicken feather fiber’s linear density was
supposed to be taken by using ASTM D1577
(Standard Test Methods for Linear Density of Textile
Fibers). Average linear density of single fibers in a
bundle was calculated from mass and length
measurements on the bundle and the number of single
fibers in the bundle. A bundle of fibers with the same
length was assumed to be weighed using a template, 3. Fabrication of Plain Sheet Specimens
die or cutting device. The bundle was scheduled to be The methods by which sample materials were
weighed on a balance with a sensitivity of 0.005 mg, apparent to be prepared and molded influence the
then the number of fibers was expected to be counted. mechanical properties of the specimen. Unlike
The tensile property of the chicken feather fibers injection molding, the objective of compression
was tested by breaking single-fiber specimens on a molding is to produce test specimens or sheets that
constant-rate-of-extension (CRE) type tensile testing were both homogeneous and isotropic. The powder,
machine from ASTM D3822 (Standard Test Methods pellets, particles, preform, or sheet were supposed to
for Tensile Properties of Single Textile Fibers). be melted and molded in a mold designed to produce
a finished specimen of a given geometry, size, and
1.4. Nylon Fibers thickness, or melted and molded in the form of a
The nylon fibers were bought from Polymer smooth plaque or sheet of uniform thickness from
Products (PHIL), Inc. Located at 11 Joe Borris St., which desired specimens will be cut, punched, or
Bagong Ilog 1600, Pasig, Metro Manila. machined. Working a compound on a two-roll mill
The material was conditioned through immersion prior to molding would disperse and distribute the
in distilled water for 24 ± ½ h with a temperature of compound additives in a manner that would affect the
20 ± 1ºC at 69 ± 2% relative humidity conforming to physical properties of the compound.
ASTM D618 (Standard Practice for Conditioning
Plastics for Testing). 3.1. Preparation of Molding Material
The tensile property of nylon was tested by
breaking single-fiber specimens on a constant-rate- 3.1.1. Drying of Granular Material and Preparation
of-extension (CRE) type tensile testing machine from of Preforms
ASTM D3822 (Standard Test Methods for Tensile Dry the granular material for 24 ± 1 h at 70
Properties of Single Textile Fibers). ± 2°C in an oven. The molded specimen, plaque, or
sheet should be free from surface irregularities and
1.5. Pigments internal imperfections to obtain a sufficient
The green pigments that were expected to be homogeneous sheet. For that, polyvinyl chloride
used in this study was acquired from ROHA (PVC) compounds would generally require milling to
Specialties Philippines, Inc., located at 1416 -1418 obtain a preform for the final molding procedure.
Mayhaligue cor., Masangkay Street Manila, Manila,
1008 Metro Manila. 3.2. Milling
Direct molding from powder or granules may
2. Mix Design sometimes require melt homogenization using a hot
The sheet shall consist of polyvinyl chloride melt milling or mixing procedure to achieve a
resin in amounts greater than 50 % of the total satisfactory final sheet. Where such is required, a
polymer content suitably compounded with two-roll mill will usually perform satisfactorily. Take
plasticizers, stabilizers, fillers, pigments, and other
the milled material from the mill and cut or shape it test is scheduled be conducted in the CMT laboratory
to become a preform for the compression mold in of TUP Manila. The aim of this test is to determine
which it ultimately will be molded. Milling condition the rate of water absorption of a specific plastic
should not exceed a temperature of 30°C to avoid sample by acquiring the accumulated weight of the
degradation of the main polymer. The preform water absorbed after 24 hours of submerging the
prepared by milling should normally be thicker than sample. The specimen size is 76.2 mm x 25.4 mm
the specimen, plaque, or sheet to be molded to enable and 3.2 mm thick.
the molding to be done properly. For this test, the specimens were supposed to be
3.3. Molding dried in an oven for a specific amount of time and
Adjust the mold temperature to within 65°C of temperature. The oven-dried specimens are to be
the molding temperature indicated in the relevant weighed immediately the moment it cools. The
material specification. With picture-frame molds or specimens are then submerged in water considering
large, heavy molds it may not be necessary or the conditions required are met, often 23oC for 24
desirable to preheat the mold itself. This will then hours or until equilibrium.
require slight increases in the preheat time of the
cycle; the temperature stability of the material shall 4.2. Flammability Test
be considered. This test was based on UL 94 (Standard for Tests
Place a weighed quantity of the material in the for Flammability of Plastic Materials for Parts in
preheated mold. Make sure that it is evenly spread Devices and Appliances). The test was scheduled to
over the mold surface. The mass of the material shall be conducted in the Chemistry Laboratory of TUP
be sufficient to fill the cavity volume when it is Manila. The test aims to identify the rate of burning
melted and allow about a 10 % loss for a flash mold. of materials in terms of length per unit time
With flash molds, cover the mold with the top (mm/min). The size of the specimen is 127 mm x
ferrotype plate and then place the mold in the 12.7 mm and 3.2 mm thick.
preheated press. In this test, the specimen must be supported
Close the press and preheat the material charge horizontally and is tilted at a 45o angle. The
by applying a contact pressure for 7 minutes. Then specimen is to be subjected to a flame at the lower
apply full pressure for a minimum of 2 minutes and end for 30 seconds or until the burning reaches the 1-
then cool down. inch mark. If the specimen continues to burn after
removing the flame, the time it takes the specimen to
3.4. Cooling burn from the 1-inch mark towards the 4-inch mark is
With some thermoplastics, the cooling rate to be recorded. If the specimen prevents the spread of
affects the ultimate physical properties. The method burning from reaching the 4-inch mark, the time of
of cooling shall always be stated together with the combustion and the burned length between the two
final physical properties. The molded material will be marks are to be recorded instead.
cooled with an average cooling rate of 15 ± 5 °C/min
The demolding temperature shall be less than 4.3. Linear Dimensional Change
40°C. This test method was based on ASTM D1204
(Standard Test Method for Linear Dimensional
3.5. Inspection of the Molded Specimens Changes of Nonrigid Thermoplastic Sheeting or Film
After cooling, check the molded specimens, at Elevated Temperature). The method covers the
plaques, or sheets for appearance (such as sink marks, measurement of changes in linear dimensions of
shrink holes, discolorations) and for conformance to nonrigid thermoplastic sheeting or film that result
specified dimensions. Discard any test specimens or from exposure of the material to specified conditions
sheets having molding defects. Make sure there is no of elevated temperature and time.
degradation or unwanted crosslinking. The test specimens are assumed to consist of two
pieces of the sheeting or film 25 by 25 cm (10 by 10
4. Testing in.), cut with the aid of the template, one from either
of the two transverse edges and one from the center
4.1. Water Absorption Test of the sheet. Each specimen was supposed to be
This test was based on ASTM D570 (Standard marked to show the direction of extrusion. The
Test Method for Water Absorption of Plastics). The midpoint of each edge was purported to be marked
for use as a reference point when final measurements single metal ferrotype plate as a top cover. The cavity
are made. was to be constructed to mold the prototype into
corrugated sheet.
4.4. Tensile Strength Test
This test was based on ASTM D638 – 14 5.2. The Expected Output
(Standard Test Method for Tensile Properties of After the thorough process of the production, the
Plastics). This test was expected to be done in CMT expected total output of this study was presupposed
Laboratory of TUP Manila. The aim of this test is the to be in the form of corrugated sheet as shown in
determination of the tensile properties of specific figure 3.6. The method to be used in this phase was
samples. The size of the specimen is 165 mm x 13 supposedly the same method to be used in the
mm and 3.2 mm thick. fabrication of specimens conforming to ASTM
In this test, the specimen was supposed to be D4703 (Standard Practice for Compression Molding
held at place using the grips of a UTM (Universal Thermoplastic Materials into Test Specimens,
Testing Machine) and is pulled until failure. For Plaques, or Sheets) as detailed in the section of
ASTM D638, the test speed varies from the material Fabrication of Specimens.
classification where it is categorized as Type I: Rigid
or Semi-rigid plastics whose width is below 7 mm.
The default test speed is 5mm/min ± 25 % but
modulus determinations may be made at 2mm/min.
An extensometer or strain gauge was supposed to be
used to determine the elongation and tensile modulus
of the specimen. The properties should be considered
in this test are the specimen’s overall thickness,
breaking strength, elongation at break, and tensile
strength. Figure 1 Prototype of Corrugated Sheet

4.5. Flexural Strength Test RESULTS AND DISCUSSION


This test was based on ASTM D790 (Standard
Test Methods for Flexural Properties of Unreinforced 6. Mechanical Properties of Fiber Reinforcements
and Reinforced Plastics and Electrical Insulating The three fibers, namely fiberglass, nylon, and
Materials). This test was assumed to be conducted in chicken feather, was tested on the Philippine Textile
CMT Laboratory of TUP Manila. The aim of this test Research Institute on February 27, 2020. The institute
is to identify the flexural capacity of a specific used ASTM D3822 (Standard Test Method for
sample. The specimen size is 127 mm x 12.7 mm and Tensile Properties of Single Textile Fibers) in
3.2 mm thick. characterization of the fibers’ mechanical properties.
In this test, the specimen commonly rests on a Two properties were determined: Breaking Strength
support span then the loading is applied towards the in Newton and Average Elongation at Break by
center by the loading nose producing three-point percentage. Thirty specimens were required, and
bending at a specified rate. The parameters every sample was tested conforming to ASTM
considered for this test are the support span, the D3822.
loading speed, and the maximum deflection for the The breaking strength of the fibers was
test. These are based on the specimen thickness. The determined using the Zwick/Roell Tensile Strength
test was supposed to be stopped when the specimen Tester Z005 (CRE) which is a Constant-Rate of
reaches 5% deflection or if the specimen breaks Elongation Machine. A full-scale load of 5N was
before reaching the 5% deflection. applied into each fiber having 30 specimens with a
25mm gage length.
5. Fabrication of the Prototype Along with the determination of the fibers’
breaking strength using the Zwick/Roell Tensile
5.1. Preparation of Mold Strength Tester Z005 (CRE), the percentage
The mold to be used as expected to be machined elongation of the three fibers were also acquired,
cavity under flash-type mold, where the mold having the same testing parameters.
consists of a cavity machined in a metal plate with a
6.1. Mechanical Properties of Fiberglass
Fiberglass ranks second to nylon in terms of
strength. It bears an average load of 1.05 kgf.
However, the fiberglass with 2.6% elongation marks
lowest among the three specimens which means it has
an average strength and lowest elongation due to
force applied. This proves that fiberglass is a reliable
fiber for the composite roofing conforming to 6.3. Mechanical Properties of Chicken Feather
Vaughn, 2018. In which in his study about the Chicken feather fiber is one of the experimental
properties of fiberglass shows that it is indeed a very fibers of the study. Among the three types of
efficient reinforcement in most composite or concrete specimen given, it shows the lowest amount of
products. Fiberglass has an exceptionally high tensile bearing strength which amounts only to 0.05 kgf.
strength compared with other textile fibers. This means that the two other fibers that will be
applied will be a benefit to chicken feather fiber
Table 2 ASTM D3822 Result for Fiberglass considering that It has low strength. It also showed an
average of 5% elongation which translates to it being
the second of the three fibers.

Table 4 ASTM D3822 Result for Chicken Feather

6.2. Mechanical Properties of Nylon


Nylon showed the highest load capacity
compared to that of fiberglass and chicken feather,
having an average of 3 kgf. This shows that nylon is a
very strong type of fiber that can handle ample CONCLUSION
amounts of load for the roofing. However due to its
plastic property, nylon showed the highest value of % Based on the analysis of the results of the tensile
elongation (17.0%). This means that even if it has a property test made for the reinforcing fibers, the
high strength capacity, its plastic properties will be chicken feather fibers do not have high tensile
noticeable when the force applied is greater than the strength making it weak against the bearing stress.
magnitude it can handle. Spadea et al. (2015) also For this instance, it is safe to assume that, for the
shows that the outcomes of the experimental study roofing material to sustain against external stresses, a
indicated that nylon fibers can be safely used as fiber strong enough should be incorporated as well in
reinforcement in cement and composite materials; the roofing material for the improvement of
present adequate alkali resistance of recycled nylon mechanical properties. In line with that, based on the
fibers according to currently recognized standards; data analysis driven the nylon fibers was proven to
may significantly improve the tensile strength (up to have strong mechanical properties that can render
+35%) and fracture properties of cement mortars; support to the chicken feather fibers and the vinyl
systematically cause the transformation of a brittle plastic roofing for sustaining tensile property. Lastly,
failure mode (unreinforced mortar) to a more ductile the inorganic material which is the fiberglass shows
failure mode (fiber reinforced mortar). high tensile property validating the claims made by
Vaughn (2018) about its good mechanical properties.
Table 3 ASTM D3822 Result for Nylon As a conclusion, it is not safe to have the chicken
feather fiber alone as reinforcing fibers of the vinyl
plastic roofing, it must have other high-strength fibers
such as nylon and/or fiberglass along with it in each
mix for it to resist external stresses.
RECOMMENDATIONS suggestions and recommendations for the
improvement of the manuscript.
Based on the observation and analysis of the results
accomplished in this study, the following To Ms. Patricia Manalaysay and Mr. German
recommendations are suggested for the continuation Trinidad, their found mentors and silent heroes, from
of the study: Unilox Industrial Corporation, for guiding them like
their own, whose words of appreciation and
1. To plan for the acquisition of materials suggestion gave them drive and motivation; for the
ahead of time as certain materials needed requires assurance of help, for sharing them tips based on their
treatment prior to fabrication and some are not experience and expertise on the topic; for their
available in the Philippines. inspiring attitude and undying support all throughout
the accomplishment of this study.
2. To use hot compression molding method in
the fabrication of specimens as it has been claimed to To Laguna people namely Alice, Jessalyn, and
have a good mechanical strength results good for the Theresa of Alipala family and Abner Dumpit, who
composites with long fibers compared to that of the has been very accommodating, for the proactive offer
plastic injection molding. of help and guidance in gathering chicken feathers
from the poultries.
3. To utilize only the CFF found in the wing-
part for the maturity and aspect ratio considerations To their beloved families and friends who have been
for better strength results. the constant source of financial support, wisdom, and
strength in every step of this research.
ACKNOWLEDGEMENT
Lastly, to themselves, many times, they were
First and foremost, the authors would like to express confronted of not being good enough, life have has
their gratitude and praise to the Almighty and been hard, still they strived hard to surpass their
Sovereign God for the strength, guidance, and limits; for the cooperation and extra mile each of
blessings He has bestowed upon them. them made to meet the accomplishment of this study.

The Authors wish to extend their deepest gratitude to REFERENCES


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