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Recycling Tyres for Running Tracks

The document discusses the manufacturing process of recycled rubber running tracks from scrap tires. Scrap tires are cryogenically ground into crumb rubber granules between 0.6mm to 4mm in size. These crumb rubber granules are then mixed with polyurethane binder and installed in layers to form the running track surface. First, an asphalt layer is laid on a sub-ballast, then an adhesive is applied before the prefabricated base mat. The pores of the base mat are then closed before a liquid polyurethane coating is applied. Finally, the crumb rubber granules are used to form the wear surface of the track. The recycled rubber running tracks provide a consistent, cushion

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Kelvin Lim
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1K views13 pages

Recycling Tyres for Running Tracks

The document discusses the manufacturing process of recycled rubber running tracks from scrap tires. Scrap tires are cryogenically ground into crumb rubber granules between 0.6mm to 4mm in size. These crumb rubber granules are then mixed with polyurethane binder and installed in layers to form the running track surface. First, an asphalt layer is laid on a sub-ballast, then an adhesive is applied before the prefabricated base mat. The pores of the base mat are then closed before a liquid polyurethane coating is applied. Finally, the crumb rubber granules are used to form the wear surface of the track. The recycled rubber running tracks provide a consistent, cushion

Uploaded by

Kelvin Lim
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
  • Assignment Overview: Introduction to group members and project focus on recycling scrap tyres into running track materials.
  • Recycling Benefits: Exploration of ecological and economic benefits of recycling tyres from landfills.
  • Conversion of Rubber Wastes: Discussion on the necessity and methods of converting rubber wastes into products with value.
  • Manufacturing of Running Tracks: Detailed explanation of the process for creating running tracks from recycled tyres.
  • Structure of Running Tracks: Overview of the construction and materials used in making rubber running tracks.
  • Testing and Properties: Description of testing procedures for durability and safety of running tracks along with performance properties.
  • Cost Comparison: Analyses cost efficiency of recycled tracks versus commercial alternatives based on price comparisons.

School of Material and Mineral Resources Engineering

ACADEMIC SESSION 2013/2014 SEMESTER 2

EBP 308/3

ASSIGNMENT

Group: Member:

1 Amirul Azfar Kamaruzzamah Noor Farahin Mohd Ibrahim Lim Kar Wai Sahfikah Sofian

Topic: Professor:

Recycling of scrap tyres into rubber running tracks Pro. Hanafi Ismail

1. Think one or more rubber wastes and explain how to convert it into valuable rubber products?

Recycled rubber can be adapted into the creation of walking and jogging tracks for indoor or outdoor use in parks, gymnasiums, athletic fields and sports centers. The 100% recycled crumb rubber is mixed with 100% polyurethane binder to create an athletic surface. The rubber jogging surface allows for an incredibly comfortable cushion like surface that is easier on the legs and knees which makes it most preferred by all players and athletes.

2. Explain why you need to recycle this waste product?

Used tires are an environmental hazard. In landfills, a large pile of discarded tires can quickly turn into a dangerous fire that is difficult to extinguish and spews pollution. Improper tire disposal is illegal in many municipalities. Recycled tires may become entirely new products, or a substitute for fossil fuels under certain controlled conditions.

Besides that, discarded tires are an ideal breeding ground for mosquitoes and other disease-carrying animals because their hollow, rounded shape holds water for a long time. When disposed in a tire stockpile, used tires are often burned outdoors, which creates an ugly black smoke that contains toxic compounds (due in part to the oil and other products used in manufacturing tires). Tires are also a problem in landfills: Their hollow, rounded shape takes up valuable shape in landfills. Additionally, tires often don't stayed buried -- they have the unfortunate habit of trapping gases like methane and then "bubbling up" through landfills, ripping through landfill liners in the process.

One alternative to solve many problems about waste tires is recycled the tire to form crumps or shredded. The recycling of scrap tires may be defined under two different categories, using the scrap tires as whole or mechanically modified shapes (in crumps or shredded) and chemical decomposition or separation of scrap tire contents into different materials. Recycling after mechanical process has the advantages of directly using scrap tires without major investment. For example,

smaller crumbs can be bonded together to generate walking or running mats or soft surfaces for playgrounds. Drainage around building foundations, erosion control for rainwater runoff barriers, wetland establishment, crash barriers at sides of race tracks are other uses of scrap tires without much modification.

Many benefits can get by adding crumb rubber to sports surface, it will provide two main benefits which are increased safety and performance enhancement. When applied to running tracks, the rubber modified surface absorbs most of impart thus preventing strain on the body. Other benefits of this products are safer playing surface, reduces mud spots, prevents bare spots, extends lawn growing season, reduces soil compaction, metal free and the most important friendly. 3. Explain the manufacturing of rubber running tracks from recycled tyres. is environmentally

In Sharjah, emirates of the United Arabic Emirates (UAE), the gleaming new running track recently opened at Al Majaz Waterfront Park that is made up from 100 percent recycled tyres. Though track made of recycled tyres are common in Europe, it is the first initiative for the region. The total 6000 recycled tyres were used to make the 3000 square meter running track which is open for public use at Sharjahs new landmark family leisure destination.

The company in charge uses an environmental cryogenic process to recycle scrap rubbers into crumb rubbers and crumb rubber tiles. Cryogenic grinding refers to the grinding of scrap tires at temperatures near minus 80oC using liquid nitrogen or commercial refrigerants. Cryogenic processing generally uses pre-treated car or truck tires as feedstock, most often in the form of chips or ambient produced granulate. Processing takes place at very low temperature using liquid nitrogen or commercial refrigerants to make rubber brittle. It can be a four-phase system which includes initial size reduction, cooling, separation, and milling. The material enters a freezing chamber where liquid nitrogen is used to cool it from 80 to 120 C, below the point where rubber ceases to behave as a flexible material and can be easily crushed and broken.

Because of its brittle state, fibers and metal are easily separated out in a hammer mill. The granule then passes through a series of magnetic screens and sifting stations to remove the last vestiges of impurities. This process requires less energy than others and produces rubber crumb of much finer quality. The size of crumb granules can be varied between 0.6mm to 4mm. The average process time is around 40 minutes, from the start with a whole tyre to the finished product.

Both ambient and cryogenic processing can be repeated to produce finer particles. Increasingly, the two with their attendant technologies, are combined into one continuous system in order to benefit from the advantages and characteristics of each and to reduce overall costs. The ambient system is generally used for the initial size reduction phases. The cryogenic system is used to further reduce the material in size and then to remove the metals and textiles. The outputs from either or both systems can be used directly or as feedstock for further processing.

Figure 1: Typical cryogenic grinding system

Figure 2: The illustration of recycled tyres grinded into the crumb granules

Today, most tracks are constructed of rubber particles bound with latex or polyurethane. The latex or polyurethane surface is typically installed to a depth of 3/8 inch to 1/2 inch on top of an asphalt or concrete base. The rubber used may be black or coloured. Black rubber particles may granular or stranded and they may made from natural rubber, styrene-butadiene rubber (SBR) or ethylene-diene rubber (EPDM), virgin or recycle rubber (such as tyres in our example).

Colored rubber particles are almost always made of virgin EPDM rubber and they come in granular form only. In general, virgin rubber is more expensive than the recycled rubber and colored rubber is more expensive than the black rubber. When using recycled rubber, its quality and performance is depend on the care taken in separating different types of scrap before grinding. The performance of any type of rubber is also dependent on its chemical composition, the quality of its manufacture, its compatibility with the binder system and the care during its installation.

Latex-bound tracks provide good performance and durability. Latex systems can be installed in multiple layers or in a single layer, creating a permeable, resilient surface. In some systems, the rubber is spread over the track surfaces which are then sprayed with the latex binder. In other systems, the rubber particles and binder are premixed and then spread. Virtually, all latex systems are permeable to some degree. The advantage of a latex system is the initial cost it enables many schools with limited budgets to have a synthetic surface on their track. One disadvantage to latex is the fact that it is harder when the weather is cold and softer when it is hot, thus affecting comfort and performance for the athlete. Another drawback to latex is that the track may bubble when resurfaced.

Polyurethane systems have been around longer use than latex system and the full pour version are often used on world-class competitive tracks. Polyurethane track can be either permeable or impermeable. They are generally mixed and installed on building site, though pre-manufactured systems are available. There is few sub-divided polyurethane systems used to manufacture the running track:

I.

RSS 2000: The basic polyurethane-bound system consists of rubber particles bound with polyurethane to form base mat. The base mat may be used alone, or it may be enhance by the addition of a structural spray consisting of a mixture of polyurethane and rubber sprayed on top of the mat. This is a porous surface that will provide years of service and performance and is easily resurfaced with a new structural spray (usually in about 8 to 10 years). This creates a textured surface.

II.

RSS 3000: The base mat may be sealed and coated with a flood coat of polyurethane and rubber, creating an impermeable, textured surface. This means water, dirt, and sand will stay on the surface, resulting in less maintenance and longer life.

III.

RSS 5000: A full pour system may be used in which each layer is mixed and poured in place. Full pour systems are impermeable, textured surface.

With so many systems available, it is important that manufactures give a great deal of thoughts to choosing the best surfaces for a particular installation. Factor that impacting includes initial cost, maintenance cost over the expected life of the surface, life expectancy, surfaces wear and performances characteristics.

Figure 3: General steps in manufacturing the running track from recycled tyres

General steps in manufacturing running track

(1) Asphalt layer on sub-ballast

(2) Application of adhesive

(3) Coasting of the prefabricated base mat

(4) Closing of the pores of the base mat

(5)Application of liquid PUR coating

(6) Wearing Surface consisting of crumb granules

Figure 4: Anatomy of Recycled rubber running track- Sandwich type rubber running track 4. Testing of the recycled rubber products

A running track is a rubberized artificial running surface for track and field. It provides a consistent surface ability unencumbered by adverse weather conditions. Historically, various forms of dirt, grass, sand and crushed cinders were used. Many examples of these varieties of track still exist worldwide. Track system shall have documented independent test results from an accredited IAAF testing house to the requirements of the IAAF Performance Specifications for Synthetic Surface Athletics Tracks (Outdoor) dated January 1990. There is several testing need to be done before installing the running track.

Skin Sensitization Testing Delayed skin sensitization testing was carried out by a modified Buehler method for solid materials according to testing guidelines (US EPA, 1998) and in accordance with Good Laboratory Practices at Product Safety Laboratories (Dayton, NJ). Skin sensitization testing consisted of three 6 hr induction exposures, each exposure separated by one week from the preceding exposure. All test samples were applied to the animals skin. Then, after an additional two weeks, the animals were challenged with the test sample for 6 hrs and examined after 24 and 48 hours for signs of erythema (skin reddening).

Tires contain some natural rubber, and natural rubber contains latex allergens. Following dermal contact, latex allergens can induce skin sensitization in susceptible individuals. It is also possible that tire rubber contains allergens other than latex. People use surfaces made of recycled tires can be exposed to substances on those surfaces through dermal contact. Hands would probably be the most common points of contact. Thus, it is prudent to determine whether such dermal exposures lead to skin sensitization.

Surface Testing The surface testing is included: Imperfection Durability and dynamic performance of the surface may be compromised by imperfections such as bubbles, fissures, de-lamination, uncured areas etc. These will not be allowed and must be corrected.

Evenness The surface shall be installed so that on a localized level, there shall be no high spots or depressions beneath a 4m straightedge exceeding 6mm. Depressions beneath a 1m straightedge shall not exceed 3mm. There shall be no step-like irregularities greater than 1mm in height. Particular attention is to be paid to seams and joints in the surface. The intent is to ensure the safety of the athlete and provide an even running surface.

Thickness

The thickness of the surface shall be determined to meet force reduction and vertical deformation requirements hereunder. The high stress areas with a deliberately thickened surface shall not be taken into account.

Friction In order to identify the influence of the surface, a standard foot is utilised in the methods employed here for measuring friction. The coefficient of dynamic friction shall be not less than 0.5 under wet conditions. Since the coefficient of dynamic friction under dry

conditions is expected to be higher, only the performance under wet conditions is required.

Tensile Properties The tensile strength and elongation at break of a surface material will provide an indication of the durability of the surface. When determined the tensile properties using the method below, the minimum tensile strength shall be 0.5MPa for non-porous surfaces and 0.4MPa for porous surfaces. In applying these minima, sandwich systems shall be considered to be non-porous. For all surfaces, the elongation at break shall be a minimum of 40%. The test shall be conducted on a minimum of four samples and the result quoted is the average of the four results.

Colour The colour must be consistent within the design of the surface and when fading occurs, this must occur evenly. The colour shall be uniform to within one position on the recognised colour reference card or plate system used. For deliberately designed multicolour facilities each discrete colour shall be similarly uniform.

Drainage Water in excess of the height of the texture of the running track surface can affect the safety and performance of the athlete. When completely covered with water and allowed to drain for 20 minutes, there shall be no area of synthetic surface where the depth of residual water exceeds the depth of texture of the surface.

5. Cost compare with commercial available similar products The figure 5 and 6 below shows the cost comparison between the recycled rubber running track and commercial available similar product. Obviously, the price of recycled scrap rubber to manufacture the running track is lower than synthetic one- EPDM since the cost of compounding and processing is excluded for the recycled rubber running track.

Figure 5: The prices of recycled rubber running track

Figure 6: The prices of synthetic rubber running track

Common questions

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Recycled rubber is generally more cost-effective than synthetic alternatives for running track construction. The primary reason is the lower material cost since recycled rubber eliminates extensive compounding and processing required for synthetic rubbers. Savings on raw material costs allow for more budget-friendly installation, especially for institutions with limited finances. However, the comprehensive evaluation should factor in long-term durability, maintenance efforts, and possible replacements. Despite these savings, decision-makers must weigh these factors against the lifespan and performance of synthetic materials.

Combining cryogenic and ambient processing leverages the advantages of both methods. Ambient processing is used initially for size reduction of the tires, while cryogenic processing further refines the material. This combination allows for finer and more uniform crumb quality due to the brittle state achieved in cryogenic processing. Integrating both processes reduces overall costs by optimizing energy efficiency and enhancing the separation efficacy of different tire components. This approach ensures higher quality and consistency in the rubber products obtained.

Color and pigment choices in running track manufacturing play a crucial role in both usability and aesthetics. Uniform coloration is essential for visual appeal and differentiating lanes or event markers. Consistent color within the track ensures it meets design specifications, while uneven fading can degrade both functionality and appearance over time. Pigment stability and resistance to UV exposure are important for maintaining aesthetics. Stylistically, color can also influence user experience, making a track more inviting and visually engaging.

The cryogenic process involves freezing rubber at very low temperatures using liquid nitrogen, which makes it brittle. This allows for efficient separation of fibers and metals and produces finer quality crumb rubber with less energy than other processes. In contrast, ambient processing involves mechanically grinding the rubber at normal temperatures, often requiring more energy and producing crumbs with wider size distributions. The cryogenic process can be combined with ambient processing to benefit from the characteristics of both, ensuring high-quality output and cost efficiency.

Construction techniques significantly influence the quality and longevity of recycled tire-based running tracks. Proper layering and binding of rubber particles with the binder systems ensure a uniform, resilient surface that can endure wear and tear over time. Techniques such as ensuring evenness, avoiding imperfections, and controlling surface thickness are crucial. Adequate attention to seams, joints, and transitions secures a cohesive and even surface, minimizing potential hazards. Additionally, the choice of system—latex or polyurethane—and its configuration determine the track's ability to handle environmental stresses and maintain performance standards.

Manufacturers consider several factors when selecting a surface type for recycled rubber running tracks: initial and maintenance costs, expected lifespan, and performance characteristics of the surface. Certain systems like polyurethane offer superior durability and impermeability, which could lead to less maintenance and longer life. Manufacturers also weigh the impact of various systems on the safety and performance of athletes, ensuring the surface's elasticity, durability, and traction meet required standards. Additionally, environmental conditions and specific usage requirements influence the choice of surface type.

Latex-bound systems generally have a lower initial cost, providing a resilient, permeable surface that is softer in warm weather and harder in cold conditions, which can affect athlete performance. Over time, they may suffer from issues like bubbling when resurfaced. Polyurethane-bound systems, on the other hand, are more established and offer a denser, longer-lasting surface with options for both permeable and impermeable finishes. The durability, resilience, and uniformity of polyurethane systems often result in better long-term performance despite higher installation costs.

Latex-bound surfaces can face certain drawbacks: they are temperature-sensitive, leading to softer surfaces in warm weather and harder surfaces in cold weather, thus affecting athlete performance. As they age, these surfaces may experience bubbling during resurfacing due to adhesion issues. Also, while initially cost-effective, the long-term maintenance and varying durability can pose challenges compared to more durable polyurethane surfaces. These factors can affect the economic feasibility and surface quality in the long term.

Recycling scrap tires into rubber running tracks provides several environmental benefits. First, it reduces the number of tires in landfills, thus decreasing potential fire hazards that can result in pollution. Tires in landfills can emit methane gas, causing them to 'bubble up' through landfill liners. Recycling also prevents tires from becoming breeding grounds for mosquitoes. Furthermore, turning tires into running tracks allows for the reduction of reliance on fossil fuel-derived products. Finally, rubberized running tracks offer increased safety and performance through shock absorption, and they are environmentally friendly, given that they avoid the production of toxic compounds typically found when tires are improperly disposed of or burned.

Recycled rubber used in track manufacturing enhances athlete safety and performance by providing a cushion-like surface that absorbs impact, thus reducing strain on legs and knees. This shock-absorbent quality decreases the likelihood of injuries related to repetitive stress. The surface also offers consistent traction and reduces bare spots or areas where soil compaction might occur. Moreover, it helps in maintaining a playable surface in adverse weather conditions. These features contribute to a safer playing environment, enabling athletes to perform at their best.

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