Black Masterbatch Selection Guide for Geosynthetics

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1 M A S T E R B A T C H E S Black Masterbatch Selectio Guide for Geosythetics

2 Table of cotets Page No. Itroductio 2 Geotextiles 3 Geogrids 3 Geomembraes 4 Ladfill Liers ad Covers 4 Pod Liers 5 Tuel Liers 5 Water Cotaimet/Storage 6 Storage of Chemical Products 6 ad Aimal Waste Cabot Masterbatches for Geosythetics 6 Cabot Laboratories ad Techical Support 9 Characteristics of PLASBLAK Masterbatches for Geosythetics 10 Itroductio This Black Masterbatch Selectio Guide for Geosythetics provides detailed iformatio about Cabot s rage of black masterbatches desiged for use i applicatios collectively kow as Geosythetics. Geosythetics have foud widespread use i the buildig idustry for evirometal egieerig, geotechical applicatios ad water cotaimet. They have may fuctioal uses icludig sealig, as a barrier layer, filtratio, draiage, reiforcemet ad protectio. Applicatios covered iclude Geotextiles, Geogrids ad Geomembraes. Detailed iformatio is give about each applicatio area. Tables are used to assist i the selectio of the correct Cabot masterbatch, which depeds o requiremets of the fial product. Performace iformatio is give for each masterbatch. 2

3 Geotextiles Geotextiles are permeable polymeric materials usually i sheet form ad ca be either wove or o-wove. Their mai fuctios are: Stabilisatio/Reiforcemet: wove geotextiles o soft substrates spread applied loads ad improve structural stability Separatio: keepig apart two layers of a differet ature, such as gravel ad a soft sub-base material Draiage: due to the filterig effect geotextiles allow subsurface water to flow ito drais whilst prevetig cloggig Protectio: mechaical protectio of geomembraes agaist abrasio ad pucture Wove geotextiles are based o polypropylee slit films ad are mostly used i road buildig ad embakmets. They provide good mechaical stregth at low cost. No-wove geotextiles are either heat boded or eedle-puched to form cotiuous mats. They have particularly good water flow performace ad filterig characteristics ad ca be foud i most draiage systems or as highly permeable separatio layers. Geogrids Geogrids are ui- or bi-axially orieted matrix structures of very high stregth. They provide stability i earth retetio systems. Examples are retaiig walls i railway or highway projects. They are also used i various costructio foudatios such as reiforcemet of embakmets o soft substrates. The most importat characteristics of geogrids are high water draiage combied with exceptioal mechaical stregth ad log term creep resistace. Fig 1. Typical earth retetio system Geogrid Reiforcemet 3

4 Geomembraes Geomembraes are flexible or semi-rigid sheets offerig high barrier resistace to water ad gases. They ca be foud i differet applicatio areas such as: Ladfill liers ad covers Pod liers Tuel liers Water cotaimet/storage Storage of chemical products or aimal waste The most commoly used materials are HDPE, VLDPE or PVC. Ladfill Liers ad Covers Muicipal waste ladfills are oe of the most importat ad demadig applicatios for geomembraes ad geotextiles. Their role is to protect the eviromet, i particular the groudwater, from both leachate ad ladfill gas. Multi-barrier cocept Fig 2. Cross-sectio of typical ladfill multi-barrier cocept waste draiage layer protective layer/ geotextile geomembrae Ladfill desigs vary from coutry to coutry ad deped o the characteristics of the solid waste as well as the geologic ad hydrologic coditios at the ladfill site. Most are based o a multi-barrier cocept with a HDPE/MDPE geomembrae as a barrier for water ad ay type of polar substace icludig heavy metals. No-polar or chloriated hydrocarbos that may permeate through the geo-membrae are retaied at the surface of a compacted clay layer actig as a secod barrier. The liig system also icludes a draiage layer above the geomembrae. It is composed of gravel or crushed stoes. To avoid local strais that would evetually result i the perforatio of the membrae, a heavy protective geotextile mat is used (typically a o-wove HDPE or PP geotextile of > 1200 g/m 2 ). For ladfills with steep sided slopes, a high tesile geogrid reiforcemet is eeded to esure stability ad prevet excessive straiig of the geomembrae. compacted clay layers soil 4

5 Requiremets HDPE membraes for ladfill caps ad base liers have exceedigly log life expectatios of 10, 20, 30 or sometimes 50 or more years with a warraty provided by the supplier/producer. I most cases atioal stadards must be met such as GRI- GM13 (USA & UK), BAM stadards (Germay) ad KIWA (Netherlads). This puts severe techical requiremets o the material, especially with respect to the followig: Evirometal stress crackig resistace (ESCR): resultig from the combied presece of surface active substaces ecoutered i the leachate of muicipal or hazardous waste ladfills ad stresses iduced by deformatio of the soil or waste layer. Tesile properties: appropriate log-term tesile properties (especially elogatio at break limit) are essetial. This requires selectio of a suitable polyethylee type as well as a thermal ad ultra violet (UV) stabilisatio package. Severe uiaxial ad bi-axial tesile or break tests eed to be satisfied. Weldability: excellet weld stregth is eeded to esure the tightess of the membrae. Short-term stregth but eve more log-term weld stregth (for example, after ageig for 800 hours i a aggressive media) is a key requiremet. Barrier properties: to maitai separatio of differet chemicals preset i ladfills, such as polar substaces, high crystalliity is required combied with excellet chemical resistace. Pod Liers Pod liers are aother applicatio area for geomembraes i polyethylee, PVC, EPDM or butyl rubber ad ormally icorporate carbo black as the UV stabiliser package. Tuel Liers Aother demadig applicatio for geomembraes is tuel liers. These are required to be waterproof, chemically iert ad o-porous to protect costructio work i the tuel. They also eed to be resistat to breakdow by udergroud deposits of methae gas ad hydrocarbos. Tuel liers ormally require a certai degree of UV protectio. 5

6 A typical tuel liig costructio is cocrete-geomembraecocrete. The outer layer of cocrete holds the tuel ope durig costructio util the waterproofig geomembrae is istalled. The ier layer of cocrete is the put over the geomembrae ad forms the mai structure of the tuel. Water Cotaimet/Storage Geomembraes for water cotaimet ad storage, such as caal ad reservoir liers, eed to have excellet UV resistace, stress crackig resistace, chemical resistace ad mechaical properties. This type of geomembrae is ormally produced from polyethylee for its superior stress crack resistace. Storage of Chemical Products ad Aimal Waste Icreased evirometal awareess has made it ecessary to fid evirometally acceptable ways of cotaiig chemical ad aimal waste products to prevet cotamiatio of groud water. Geomembraes are used to lie holdig lagoos, aaerobic treatmet pods ad evaporatio pods i waste facilities. Geotextiles ca be used i combiatio with the geomembrae to provide additioal cushioig ad protectio. For chemical storage, the essetial techical requiremets are chemical resistace, durability, stress crackig resistace ad UV resistace. Aimal waste requires very low permeability, excellet UV resistace, stress crackig resistace ad resistace to methae gas. Therefore this type of geomembrae is usually produced from HDPE. Cabot Masterbatches for Geosythetics Geotextiles Applicatio Suggested Cabot grades Key characteristics Ladfill lier PE2642 Stadard weatherig grade ad protectio stabilisatio LL4752 Improved compatibility with LLDPE/HDPE Earth retetio systems PE2642 LL4752 PP6190 Stadard weatherig grade Improved compatibility with MDPE/HDPE Suitable for PP based geoets/ geotextiles 6

7 Geogrids Applicatio Suggested Cabot grades Key characteristics Earth ad HD4708 Maximum protectio agaist UV embakmet retetio PP6190 Excellet UV protectio with log term stabilisatio Geomembraes Applicatio Suggested Cabot grades Key characteristics Ladfill liers ad caps PE2642 Stadard weatherig grade. Good process ad log term heat stability PE2747* Good log term heat stability ad ease of dilutio LL4752 Improved compatibility with MDPE/HDPE, high performace log term stabilisatio Pod liers PE2642 Stadard weatherig grade ad waste water lagoos PE2747* Good log term heat stability ad ease of dilutio LL4752 Improved LL/HDPE compatibility UN2016 For compatibility with PVC. Additioal UV stabilisatio recommeded Tuel liig PE2272R Good colouratio ad opacity PE2824 Low cost alterative * PE2747: oly available i Asia-Pacific The geomembrae idustry has traditioally used pre-coloured compouds but icreasigly the geomembrae maufacturers are addig masterbatches to the base polymer. The role of the masterbatch ad carbo black is to provide optimum UV ad thermal protectio of the membrae. I Europe may ladfills for muicipal waste remai ope for periods of several years. This high exposure would cause severe degradatio to the polyethylee aloe ad the resultig deterioratio of physical properties could evetually lead to failure. It is therefore of paramout importace that the correct masterbatch desiged to fulfil these severe performace requiremets is selected. 7

8 High UV absorptio capacity: Carbo black is oe the most effective ad most widely used UV light stabilisers for plastic materials. Sigificat research work at Cabot Corporatio has demostrated the lik betwee carbo black morphology (surface area ad structure) ad dispersio level o weatherability. All black masterbatches for geosythetic applicatios with high UV weatherig demads are based o high performace carbo blacks. The followig graph compares the weatherig performace of 650 µm sheet cotaiig LL4752, a weatherig type carbo black masterbatch with that of a similar sheet cotaiig geeral purpose carbo black masterbatch, PE2272R. Both sets of sheet cotai carbo black at a 2% loadig: QUV-B Weatherig of 650 µm LDPE Sheet 100 Retetio i elogatio at break (%) QUV-B exposure time (hours) 5% LL4752 4% PE2272R Thermal stabilisatio: due to its uique surface chemistry, carbo black limits the degradatio process that occurs i the polymer. Most of the masterbatch types however cotai additioal atioxidat packages that provide log term heat ageig protectio as well as processig safety. Oxidatio iductio time (OIT) measuremets are used as a measure of thermal stability by several major stadards ad testig Istitutes. By the selectio of a appropriate stabiliser package the OIT ca be sigificatly improved. The masterbatch ca therefore cotribute to meetig the expected service life expectatios. 8

9 Ease of dilutio: to achieve optimum efficiecy the masterbatch must be homogeeously diluted i the base polymer. Poor bledig ca lead to weak poits i the membrae as well as delamiatio at high strais. Depedig o the customer s extrusio equipmet ad the base polymer characteristics CABOT ca propose masterbatch types that respod to each specific requiremet ad provide a optimum homogeeity level. Compatibility with dilutio polymer: whilst the role of the masterbatch is to provide log term protectio it should have a miimum ifluece o the mechaical properties, chemical resistace ad stress-crack behaviour of the geosythetic structure. All masterbatches are carefully desiged to miimise the loss i properties of the dilutio polymers. Cabot Laboratories ad Techical Support State of the art testig equipmet at the CABOT Applicatio Developmet Cetre laboratories eables determiatio of the key properties of geosythetic products as follows: Weatherig performace - Natural: outdoor facilities i several locatios coverig a wide rage of irradiatio levels - Artificial: QUV + ATLAS Ci65A Colouratio ad opacity Viscosity: Capillary rheometer, melt idexer, Brabeder Thermal stability (OIT, ove tests, multiple extrusio) Mechaical properties Our Applicatio Developmet Cetre team provides excellet techical service, combiig processig ad applicatio expertise with extesive aalytical services. 9

10 Characteristics of PLASBLAK Masterbatches for Geosythetics Grade % carbo black Carbo black type MFI (g/10 mis) Test coditios Carrier Desity (kg/m 3 ) Stabilisatio package PE Premium weatherig kg/ 190 C LL/LDPE 1150 Yes LL Weatherig kg/ 190 C LLDPE 1150 Yes HD Premium weatherig kg/ 190 C HDPE 1180 Yes PP Weatherig 9 5kg/230 C PPH 1100 Yes PE2272R 50 PE2747 * 35 Geeral purpose Geeral purpose 12 10kg/190 C LDPE 1230 No 35 10kg/190 C LLDPE 1100 Yes PE equivalet Not specified kg/ 190 C LDPE 1560 No UN Medium colour 41 10kg/190 C Uiversal 1220 No * PE2747: oly available i Asia-Pacific 10

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12 Addresses EMEA Cabot Iterleuvelaa 15 i B Leuve BELGIUM Tel.: Fax: ASIA-PACIFIC Cabot (Chia) Limited 558 Shuagbai Lu Wujig, Shaghai CHINA Tel: Fax: SOUTH AMERICA Rua do Paraíso, 148-5th floor Paraíso CeP São Paulo SP BRASIL Tel: Fax: Tel: (Customer Service) MB/Geosyth./05.10/Eglish Notice ad Disclaimer. The data ad coclusios cotaied herei are based o work believed to be reliable; however, Cabot caot ad does ot guaratee that similar results ad/or coclusios will be obtaied by others. This iformatio is provided as a coveiece ad for iformatioal purposes oly. No guaratee or warraty as to this iformatio, or ay product to which it relates, is give or implied. CABOT DISCLAIMS ALL WARRANTIES EXPRESS OR IMPLIED, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AS TO (i) SUCH INFORMATION, (ii) ANY PRODUCT OR (iii) INTELLECTUAL PROPERTY INFRINGEMENT. I o evet is Cabot resposible for, ad Cabot does ot accept ad hereby disclaims liability for, ay damages whatsoever i coectio with the use of or reliace o this iformatio or ay product to which it relates. Cabot Corporatio, MA-U.S.A. All rights reserved PLASBLAK is a registered trademark of Cabot Corporatio. 12

MASTERBATCHES. Masterbatch Selection Guide for Geosynthetics

MASTERBATCHES. Masterbatch Selection Guide for Geosynthetics MASTERBATCHES Masterbatch Selection Guide for Geosynthetics Table of contents PAGE No. Introduction 2 Geotextiles 3 Geogrids 3 Geomembranes 4 Landfill Liners and Covers 4 Pond Liners 5 Tunnel Liners 5