EFFECT OF PRE-HANDLING AND POST-TREATMENT CONDITIONS IN THE DEVELOPMENT OF GREEN POLYPROPYLENE COMPOSITE SLAB

Md Fauzan Kamal  Mohd Yapandi; Famiza  Abdul Latif; Mohammad  Noor Jalil; Nurul Dhabitah  Basri; Sharil Fadli  Mohamad Zamri; Nabilah Akemal  Muhd Zailani; Noor Najmi  Bonnia

Md Fauzan Kamal Mohd Yapandi Universiti Teknologi Mara
Famiza Abdul Latif University Teknologi MARA
Mohammad Noor Jalil University Teknologi MARA
Nurul Dhabitah Basri University Teknologi MARA
Sharil Fadli Mohamad Zamri University Teknologi MARA
Nabilah Akemal Muhd Zailani Universiti Teknologi MARA
Noor Najmi Bonnia Universiti Teknologi MARA

Keywords: Coal bottom ash, polymer composite, green composite, polypropylene composite

Abstract

Electricity generation in Malaysia produces large volumes of coal bottom ash (CBA), which often accumulates in ash ponds or landfills, posing environmental risks. This study examines the potential of using CBA as a reinforcing filler in polypropylene (PP) composites to develop a sustainable and environmentally friendly material. The impact of pre-treatment (sieving) and post-treatment (heat exposure) on the physical and mechanical attributes of PP-CBA composite slabs was thoroughly examined. Findings revealed that filtering the CBA to a uniform particle size (~250 µm) significantly enhanced composite consistency, resulting in improved polymer-filler interaction, better bonding, and overall structural stability. However, subjecting the slabs to heat at 50 °C and 100 °C created a more porous structure due to moisture loss, which negatively affected crystallinity, durability, and mechanical resilience. Fourier-transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD) results indicated a reduction in Silanol (Si-OH) groups and isotactic polypropylene (i-PP) peaks, confirming a decrease in crystallinity. The drop impact tests indicated that heated slabs exhibited reduced impact strength compared to untreated ones, with impact values decreasing from 3.4 J (sieved CBA) to 2.1 J (un-sieved CBA), further declining in heat-treated samples. The increase in impact strength observed with sieved CBA suggests that uniform particle distribution enhances mechanical integrity, making it a suitable candidate for applications in construction materials, lightweight structural panels, utility protection slabs, automotive components and furniture. However, moisture management and processing optimization are critical for maintaining mechanical performance and durability. Overall, this study supports the utilization of CBA into value-added materials, aligning with sustainable development and circular economy goals.