moldedCAST™,our basic lumber formula, matches or exceeds the basic physical properties acceptable by the ASTM testing methods and is similar to other polyethylene products available on the market.
Our basic source of material is postindustrial and pre-consumer. Our products tend to be more dense than other manufacturers' (weighing more per cubic inch). As result of our R & D efforts, we have made the decision to use less foam and more stabilizers and compatabilizers.
The texture and color of our product is more natural, i.e., pleasantly inconsistent. On occasion, there will appear multiple color flecks on the surface. This is a result of our mix containing materials that have different viscosities when they melt. The chemical composition and physical properties of the material match and bond together but the colors of the regrind used in our blend sometimes appear on the surface. If it is important to your project to have a uniform “plastic” look, please tell us and we will try to compromise our artistic urges and create a more uniform colored product just for you.
fiberCAST™ is our basic reinforced lumber formula. Plastic lumber is an amorphous blend of olefin polymers that, by their nature, do not have a grain like wood. This being said, it is possible to strengthen the bonds between the polymer molecules and simulate a grained-strength product. This product also meets or exceeds the basic physical properties offered by other plastic lumber manufacturers. Again, our product tends to be heavier and occasionally has inconsistent texture and multiple-colored flecks on the surface. We add compatabilizers, bonding agents, fiberglass, stabilizers, and other ingredients that increase our product's ability to hold the molecules together and thus achieve a more structural application.
| BUILDERS take note: |
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| If you are considering using a product (like our CASTplastic™ , there are DISTINCT CHARACTERISTICS that you must plan for: |
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EXPANSION/CONTRACTION COEFFICIENT for any plastic is greater than wood. This material expands and contracts while the hardware does not. Leaving expansion room will guarantee that this project will be there for your great grandchildren. |
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this co-efficient can be minimized by increasing the percentage of “filler” in the formula selected for your product. |
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when using bolt and nut fastners:
drill slightly larger holes than usual. |
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when using deck or lag screws:
always drill a larger hole through the top board
and a smaller than usual pilot hole into the baseboard. |
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on larger timbers we advise placing your fasteners about 1/3 the distance from either edge so that you are drilling through solid plastic alongside the core and not directly into the core.
Our CASTplastic™ lumber's strength is not in a natural grain (as in wood) but in the box-beam-like element produced by our flow-molding process.
Looking at a cross-section of our material, you will see a porous core surrounded by solid plastic. This core helps to force the hot, fluid plastic into the shape of the mold and holds the outer planes parallel to each other after the cooling process. Technically, this core helps to “stress” the plastic as it is forming into the specified dimensions and adds strength to the product.
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DO NOT TRY TO RIP A PIECE OF CASTplastic ™ LENGTHWISE .
If you try to “rip” a 2” x 6” into two 2” x 3” s the strength of the piece will be destroyed. |
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If you have an application that calls for a milled shape over the length of the lumber, we highly recommend that the shape be molded into the part. |
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AVOID NOTCHING! It is common practice in deck building to notch the support post to fit in rafters, rails, etc. DO NOT USE THIS TECHNIQUE WHEN USING OUR MATERIAL. We are able to mold the shapes you need to build your deck project from structural reinforced posts and rafters to the deck, steps and newel post. If you notch into this core, you can loose up to 1/3 of the physical property of the product. |
Compounded/custom formulas
In our custom section, you can see a variety of products that not only have special shapes for a particular application but also have special formulas for that same application. We continue to be surprised with the new solutions our flow-mold process offers to our customers. Do not be shy, call and ask…
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