Grant: CCI Applied Research and Development Grants

Global plastic waste production is projected to reach 460 million tons by 2030, double the amount generated by consumers in 2016. Given their poor biodegradability, recycling and repurposing these materials is essential to reduce their environmental impact, prevent bioaccumulation of plastic wastes and contribute to the ongoing global efforts towards achieving a circular economy. An example of low-cost and technically accessible method of repurposing thermoplastic wastes consist of incorporating them in construction materials. Specifically, artificial thatch roofing systems (ATRS) emulate the look of traditional palm leaves employed for construction of exotic housing in the tropical regions. This project focuses on enhancing artificial thatch roofing systems (ATRS), which replicate the traditional palm leaf roofing seen in tropical regions. ATRS, made from high-density polyethylene (HDPE) through extrusion and compression molding, offer lightweight, waterproof, and low-maintenance alternatives to natural palm leaves. The project has two key goals: firstly, the project intends to increase the incorporation of recycled HDPE (rHDPE) in ATRS formulations, with a target of up to 50% rHDPE content. This endeavor seeks to maintain or even improve mechanical strength, UV resistance, and fire-retardancy (FR) performance compared to ATRS made from virgin thermoplastic polymers. Nevertheless, the introduction of rHDPE presents challenges related to surface properties and adhesion of protective coatings used in ATRS. The second phase of the project focuses on pioneering an innovative surface treatment method using atmospheric plasma treatment to address these adhesion challenges. This technique offers a cost-effective, material-independent solution that enhances surface characteristics while preserving bulk material properties. By achieving these objectives, this project aims to significantly boost the sustainability of ATRS, reduce long-term maintenance costs, and enhance customer satisfaction. This research can provide significant cost savings and performance benefits for Canada with the dual objectives of resource conservation and durability in the construction domain. By utilizing recycled materials, manufacturers can reduce their dependence on virgin thermoplastic materials and contribute to mitigating plastic pollution, in line with Canada's commitment to achieve carbo neutrality objectives.