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Acoustic underlay manufactured from carpet tile wastes. Part 2: Comparative study of optimised underlay with commercial products of similar calibre in accordance to universal standards

Miraftab M., Rushforth I., Horoshenkov K.

Autex Research Journal

2006

Vol. 6, no. 1

49--58

Carpet waste has successfully been converted into acoustic underlay materials that compete with commercial counterparts both in terms of performance and costs. This paper builds on an earlier paper [Miraftab et al, Autex Res.J.5(2), 96-105 (2005).] where granular/fibre mixing ratios, binder concentration and particle size distribution were shown to play a major role in maximising impact sound insulation capabilities of developed underlays. Product optimisation with respect to the particle size as governed by the aperture dimension and mean effective fibre length is further explored in this paper, and the developed underlay is compared with a selection of commercially available acoustic underlays. The results show that a 2mm-aperture screen at the granulating chamber output yields a waste stream with grains in the size range of 0.5-1.0mm and a mean effective fibre length of 2.75 mm which was most suitable to work with, and gave rise to samples with the best impact sound reduction performance. The optimised sample of 10mm recycled underlay (U2) appeared to perform better than most commercial systems tested. The manufactured underlay withstood, and in some instances, outperformed, during the standard tests as required within the BS 5808 protocol. The study concludes that recycling carpet waste to produce quality acoustic underlay with desirable impact sound insulation characteristics is technically feasible, and a viable alternative to landfill or incineration.

Acoustic underlay manufactured from carpet tile wastes. Part 1: Effect of variation in granular/fibre dry ratio, binder concentration, and waste particle size on impact sound insulation of the produced underlays

Miraftab M., Rushforth I., Horoshenkov K.

Autex Research Journal

2005

Vol. 5, no. 2

96--105

Carpet waste is of growing concern both to environmentalists and manufacturers pressured by increasing costs of landfill dumping. The challenge for carpet producers is to find ways of minimising their waste or find alternative uses for their unwanted by-products. This paper builds on an earlier study (Taylor, A.: 'Novel underlays from carpet waste', Ph.D. thesis, Bolton Institute, U.K., 2004) where carpet tile wastes have been successfully used to produce underlays for domestic as well as commercial markets. To add value, the acoustic behaviour of these underlays, where granular/fibre mixing ratios, binder concentration and particle size distribution play a major role, has been examined in this study. The results show that it is possible to maximise the impact sound insulation capabilities of these underlays by selective control and adjustment of the above variables. Manufacturing formulation consisting of 60:40 granular/fibre mixture ratio, 60% binder concentration and granule particle size dimensions of <2mm is shown to be most appropriate in achieving effective impact sound insulation.