Mechanical Performance of Wood–Plastic Composites from Sawdust and Recycled Bottle Cap Polyolefins (PP/HDPE) for Temporary Concrete Formwork

Abstract

This study quantifies the mechanical behavior of 10–15 mm thick WPC boards compression-molded from post-consumer bottle-cap polyolefins (PP/HDPE, 70/30 wt%) and pine sawdust (0, 10, 20 wt%). Flexural and tensile strength/modulus are determined and application-oriented acceptability assessed for non-structural temporary concrete formwork under ASTM bending and tension protocols. Mechanical performance was evaluated using three-point and four-point bending tests, as well as axial tension. Flexural strengths averaged 17.31, 16.38, and 8.71 MPa for 0, 10, and 20 wt% sawdust (three-points), and 15.23, 13.18, and 9.20 MPa (four-points), with flexural moduli as high as 1.60 GPa (four-points). Tensile strengths averaged 3.60, 3.79, and 3.44 MPa, with tensile elastic moduli of 0.10, 0.33, and 0.36 GPa, respectively. Stress–strain curves showed a nonlinear elastic-brittle response without a defined yield point, followed by fracture, consistent with porous, non-compatibilized WPCs. Variability increased with the sawdust content, reflecting the distribution of filler and matrix-fiber adhesion. Although the properties are inferior to those of conventional building materials, the results are within the application-oriented ranges for non-structural temporary formwork (as established by the reported ASTM tests). UV durability associated with carbon black-pigmented caps is presented as a literature-supported hypothesis for future accelerated aging, rather than as a measured outcome. Overall, the findings demonstrate a circular-economy pathway that converts post-consumer plastics and sawmill waste into WPC panels for sustainable construction.