Mould sheets from both recycled and virgin HDPE and PP materials are compressed at a manufacturing facility in Carrum Downs. All coloured sheets are made from 97-98% recycled HDPE with the addition of UV resistant pigments and UV stabiliser that protects the polymer from UV degradation. Black sheets are made from 100% recycled HDPE or PP with the addition of carbon black for UV resistance. The recycled materials are sourced from a number of companies around Australia that specialize in recycling of plastics.
All recycled materials are derived only from industrial sources (not post-consumer) to ensure product quality and consistency. No filler or foaming agents are used in the raw materials to retain the original mechanical and chemical properties of the polymer. Each batch of material is tested for contamination before use. All scrap generated during trimming and machining of the sheets are recycled back into black material pellets and re-used. Scrap is collected from the sheets for recycling from a number of customers.
In the production process, the sheet thickness is controlled by accurately measuring the weight of raw material in each mould, which results in sheet thickness tolerance of +/-5% of nominal thickness. Each sheet is checked for thickness and defects after manufacture. Each sheet is trimmed to size or cut into parts on CNC routers. CNC cutting tolerance is +/-0.5mm.
PP is harder than HDPE and has better scratch resistance. PP is 20% more rigid than HDPE, but is also more brittle, easier to crack or break. PP has higher temperature resistance than HDPE (120 degrees Celsius vs 100 degrees Celsius). HDPE is about 20% more flexible than PP, but HDPE is almost unbreakable. HDPE is easier to machine and cut. HDPE has much better long term UV resistance.
PP sheets are made only from recycled black and virgin natural materials. HDPE sheets are made from recycled black, recycled coloured, virgin black and virgin natural materials. Black and coloured materials are UV stabilised for long term outdoor use. They are covered by a 15 year structural warranty. Natural materials are not UV stabilised and will break down outdoors over time. Recycled materials are not approved for food contact applications, but virgin materials are.
Any custom colour is subject to a minimum order of 1500kg of raw material. The price is the same as standard colours. Weight per sheet is on the price list, which you can use to work out the MOQ of sheets of a given thickness. Lead time for custom colours can be up to 6 weeks. Any combination of standard colours can be mixed.
You can screw fix into the sheet. We recommend using coarse threaded galvanised or stainless steel self-tappers (wood screws). Drill a pilot hole equal to the minor diameter of the thread or the screw shank. It is possible to use screws designed for chipboard without pilot holes in HDPE, but screws should not be less than 10mm from the edge of the sheet. Screws can be driven into the edge of the sheet if the sheet is at least 15mm thick and a correct size pilot hole is used.
If attaching sheets to a rigid structure, e.g. a frame or posts, the holes in the sheet must be oversized to allow for thermal expansion and contraction. As a guide, the holes must be 8mm larger than the screws or bolts used to attach a full 2.4×1.2m sheet. Countersunk screws cannot be used. Washers should be used to cover the oversized holes. The screw spacing will depend on the sheet thickness. For 7mm – 10mm we recommend every 300mm. For under 12mm-15mm we recommend every 400mm. For 19mm or thicker we recommend using a screw roughly every 600mm.