Demonstration and Validation of Structural Grade Recycled Plastic Lumber (SGRPL) using Forward Waste in Sustainable Manufacturing

The proposed work involves developing prototype structural building and constructions materials from waste thermoplastics at Army bases both in the CONUS and OCONUS thereby reducing the overall carbon/climate footprint of the Army. ĀSpecifically, this project builds upon the feasibility of the agile and mobile manufacturing technologies established during the Department of Defense (DoD) Strategic Environmental Research and Development Program (SERDP) project conducted with the U.S. Army Corps of Engineers (USACE), Engineering Research & Development CenterÆs (ERDC) Construction Engineering Research Laboratory (CERL) as a team member. Ā The project offers a safe and environmentally responsible way to reduce disposal requirements and to turn specific thermoplastics waste-streams into value-added products for use by servicemembers. ĀOf the various plastics in the waste stream at forward operating bases (FOBs), Polyethylene Terephthalate (PET, #1) and Polyethylene (PE, #2 and #4) constitute the most significant portion. ĀThis research effort focuses on reclaimed PET, (rPET) from beverage containers (such as water and beverage bottles) and involves waste stream characterization, source separation, sorting and cleaning technologies, development of rPET based material formulations, and processing technologies to convert rPET into high-valued, much-needed products at the Point of Need (PON) by servicemembers. ĀThe demonstration and validation project with prototype development and testing directly addresses at least two of the goals specified in the solicitation ĢĀĀ ĀScalable sustainable building material technologies, andĀ ĢĀĀ ĀForward waste utilization for sustainable low-logistics manufacturingĀ During the SERDP project it was established that rPET from waste beverage containers could be successfully used to make structural grade plastic lumber (SGPL) in standard dimensional lumber geometries with very high strength and stiffness and other properties ¢ much higher than those currently available commercially for decking and other outdoor applications. ĀThis SGPL technology will be expanded further in this project with prototype engineered designs for specific components, material formulations for addressing Army construction needs and design and best practice recommendations for use of these SGPL components in structures based on testing per ASTM standards and assessment of lifecycle durability and sustainability. ĀIn coordination with USACE several demonstration projects with SGPL materials and technology developed in this work will be executed to support technology transition and commercialization for both DoD and commercial markets. Ā