Chloe Zhang
Corrugated plastic cardboard is a versatile material used for packaging, shipping, and even furniture construction. Its durability and weather resistance make it a popular choice for protecting items during transport. However, how well does corrugated plastic cardboard hold up against the elements? This type of cardboard is designed to withstand heat, humidity, cold, and moisture, which are common challenges faced in various climates. Unlike traditional cardboard, which can soften and disintegrate when wet, corrugated plastic cardboard offers enhanced protection against rainfall, humidity, and condensation. This article will delve into the weather resistance of corrugated plastic cardboard, exploring its unique properties and how it compares to other materials in protecting against the elements.
Characteristics and values of corrugated plastic cardboard
| Characteristics | Values |
|---|---|
| Weather resistance | Withstands heat, humidity, cold, and moisture |
| Durability | Repeated usage |
| Waterproofing | Contact paper, clear tape, shellac, glue, foam, fibreglass+ epoxy, polyurethane, paint, clear acrylic spray, plastic coatings |
| Strength | Depends on the flute (number of flutes) |
| Burst strength | Specified in kilopascals (kPa) |
| Piercing strength | Specified in joules (J) |
| Edge crush resistance | Specified in kilonewtons per meter (Kn/m) |
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What You'll Learn
Corrugated plastic can withstand moisture, unlike cardboard
Corrugated plastic is a highly durable and weather-resistant material. Unlike cardboard, it can withstand exposure to moisture, humidity, heat, and cold without compromising its structural integrity. Cardboard, on the other hand, is highly susceptible to moisture damage. Its fibres absorb moisture from the air, causing it to soften and break down, which can lead to tearing and loss of stiffness. This is a significant issue in humid environments, where cardboard retains more water and becomes more difficult to work with.
The hygroscopic properties of cardboard's chemical pulp mean that it absorbs and releases moisture until equilibrium is reached. This can result in denting or tearing of the cardboard when exposed to condensation or rain. In contrast, corrugated plastic is designed for repeated use and can withstand the extreme environmental conditions often faced during transport, such as rain and high humidity.
While cardboard can tolerate higher temperatures, deviations in humidity can cause it to stretch, curl, and warp. The stability and load capacity of corrugated cardboard are dependent on its flute, or the number of flutes present. The presence of multiple flutes creates a wave-like structure that contributes to its strength. However, when exposed to moisture, the glue holding these flutes together can be compromised, affecting the structural integrity of the cardboard.
To enhance the moisture resistance of cardboard, treatments such as water-resistant adhesives (WRAs) can be applied. Weather-resistant cardboard boxes are engineered to withstand challenging conditions, including rainfall, wind, and high humidity. These boxes are commonly used to protect sensitive items during shipping. Additionally, individual sheets of cardboard can be treated with coatings like shellac, polyurethane, or clear acrylic spray to provide a level of water resistance.
Corrugated plastic's inherent weather resistance makes it a superior choice for applications where moisture is a concern. Its ability to withstand repeated use without replacement further adds to its advantages over cardboard in terms of durability and cost-effectiveness. By choosing corrugated plastic, users can have peace of mind that their items will remain protected from the elements.
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Weather-resistant cardboard boxes can be engineered
Corrugated plastic can withstand heat, humidity, cold, and moisture, unlike cardboard, which can be compromised or fail if exposed to these elements. However, weather-resistant cardboard boxes can be engineered to offer reliable protection in challenging conditions.
The chemical pulp that forms the basic material of corrugated cardboard has hygroscopic properties, meaning the fibres absorb moisture from the ambient air. This can cause the paperboard to stretch, curl, and form warps, compromising the structural integrity of the box. However, treatments can be applied to prevent this. For example, glue or wheat paste can be applied to external surfaces to protect against damage.
One method to improve the weather resistance of cardboard is to glue multiple panels together so that the corrugation alternates by 90 degrees every other panel. This makes the cardboard more sturdy, and the wheat paste (a 1:5 mixture of flour and water) can be used as an adhesive. Other tricks to improve durability include folding over edges to protect against damage and integrating wood supports.
Another method to improve weather resistance is to apply a coating to the cardboard. Contact paper, clear tape, and clear acrylic spray can all be used to repel water. A biodegradable solution is a paste wax made from a mixture of IPA, shellac flakes, and beeswax. This can be brushed onto the cardboard to provide water resistance without turning it into chemical waste.
Weather-resistant cardboard boxes are designed to withstand rainfall, wind, and high humidity. They feature moisture-resistant construction and water-resistant adhesive (WRA), which enhances durability under high humidity and prolonged exposure to wet conditions. These boxes are ideal for shipping sensitive items or operating in humid environments, ensuring shipments remain safe and intact.
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Cardboard loses strength and compression in hot, humid weather
Cardboard is a highly sensitive material to its environment, especially moisture. Its structural integrity is compromised when exposed to high humidity, and its ability to dry paints and inks is decreased as it increases viscosity when in contact with moisture. Humidity is important when considering packaging due to concepts such as relative humidity (RH) and stacking strength. With 50% RH, the stacking strength of cardboard drops to 80% of its original strength.
In humid conditions, cardboard should be taken out of its original shipping carton and laid out flat to dry quicker. It can be placed under a fan or in an air-conditioned room. Cardboard should be ideally stored in a cool place. In cool and dry areas, lamination can be used as a finish to reduce the chance of moisture damage, as well as cracks and creases due to dryness.
Cardboard loses its strength and compression as the temperature rises. The stability and load capacity of corrugated cardboard depend on the number of flutes. The paperboard begins to stretch, curl, and form warps. The moment cardboard is exposed to moisture, it begins to fall apart, and it is easily damaged even when kept dry.
The effects of weather on cardboard are not exclusive to rain, but also heat and humidity. When cardboard comes in contact with any environment that allows for moisture and bacteria growth, there tends to be damage to both the physical structure and the glue holding the cardboard together. This naturally impacts how packaging materials can look, feel, and remain structurally strong.
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Cardboard becomes fragile and prone to tearing in cold weather
Cardboard is a versatile material with many applications, including packaging and insulation. However, its structural integrity can be compromised by exposure to moisture, humidity, heat, and cold. In cold weather, cardboard can become fragile and prone to tearing.
When exposed to cold, dry air, cardboard loses moisture and becomes brittle. This is because cardboard is made from wood fibres, which naturally absorb moisture. In dry conditions, cardboard acts like a sponge with all the water removed—it becomes rigid and brittle, making it difficult to fold without tearing. This is a particular concern in cold, dry climates, where cardboard is more susceptible to cracks and tears.
The impact of cold on cardboard is influenced by the humidity of the environment. In high humidity, cardboard absorbs moisture, affecting the strength of corrugated boxes. This is due to the hygroscopic properties of the chemical pulp used in corrugated board, which cause it to absorb moisture from the ambient air. As a result, cardboard in humid environments retains more water and loses stiffness, becoming easier to tear.
To mitigate the effects of cold on cardboard, some form of protection against moisture loss is necessary. Lamination, for example, acts as a seal, providing a protective barrier against dryness. Biodegradable shellac can also be applied as a coating to provide water resistance without compromising recyclability. Additionally, gluing multiple panels of cardboard together with the corrugation alternating by 90 degrees can increase sturdiness.
While cardboard can be insulated with bubble wrap or other materials to provide some protection in cold weather, it is essential to consider the limitations of cardboard in extreme conditions. Corrugated plastic is designed for repeated use in various weather conditions and can withstand heat, humidity, cold, and moisture better than cardboard.
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Coatings can be used to make cardboard water-resistant
Corrugated plastic cardboard is designed for repeated use and can withstand heat, humidity, cold, and moisture. On the other hand, cardboard is not inherently weather-resistant and can be compromised or fail if exposed to moisture, humidity, heat, and cold. However, coatings can be applied to cardboard to enhance its durability and water resistance.
One traditional and effective method to make cardboard water-resistant is wax coating. This can be done by dipping the cardboard in melted wax or applying the wax directly to its surface. Another option is PE lamination, which involves covering the cardboard with a thin film of polyethylene, a type of plastic, through heat and pressure. While effective for waterproofing, PE lamination impacts the recyclability of cardboard due to the mixed materials.
Varnish and lacquer coatings are also commonly used to provide water resistance and enhance the aesthetic appeal of packaging with a glossy or matte finish. Acrylic coatings are another popular choice as they offer a water-resistant layer that is more environmentally friendly and does not significantly alter the appearance of the cardboard. These coatings can be applied by spraying or rolling and can be formulated to provide varying degrees of water resistance.
For food packaging, Liquiguard is a popular waterproof cardboard coating that offers resistance to oil, grease, and moisture. It is FSA-approved for direct contact with food and is fully biodegradable and recyclable. Shellac, a biodegradable option, can also be used as a water-resistant coating. It can be mixed with IPA and beeswax to create a paste that can be brushed onto the cardboard.
Overall, while corrugated plastic cardboard inherently offers better weather resistance than its cardboard counterpart, coatings can be effectively used to enhance the water resistance and durability of cardboard, making it suitable for various applications.
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Frequently asked questions
Corrugated plastic cardboard is designed for repeated use and can withstand heat, humidity, cold, and moisture. However, standard corrugated cardboard softens and breaks down when exposed to moisture.
There are several ways to make corrugated plastic cardboard more weather resistant. One way is to glue multiple panels together so that the corrugation alternates by 90 degrees every other panel, with wheat paste or wood glue recommended as adhesives. You can also apply a waterproof coating, such as a mixture of shellac flakes, beeswax, and IPA, or a mixture of hot glue sticks, wax, and mineral oil.
Corrugated plastic cardboard is more durable and weather-resistant than regular cardboard, which needs to be replaced after a few uses. It can withstand extreme environmental conditions during transport, such as rain, high humidity, and condensation. Corrugated plastic cardboard is also easier to print on and recycle than regular cardboard.
