Gypsum plasterboard that incorporates various combinations of polyurethane foam waste and polypropylene fibers in its matrix is studied. The prefabricated material was characterized in a series of standardized tests: bulk density, maximum breaking load under flexion stress, total water absorption, surface hardness, thermal properties, and reaction to fire performance. Polypropylene fibers were added to the polyurethane gypsum composites to improve the mechanical behavior of the plasterboard under loading. The results indicate that increased quantities of polymer waste led to significant reductions in the weight/surface ratio, the mechanical strength and the surface hardness of the gypsum, as well as improving its thermal resistance. The polypropylene fibers showed good adhesion to the polymer and the gypsum matrix, which enhanced the mechanical performance and the absorption capacity of these compounds. The non-combustibility test demonstrated the potential of the new material for use in internal linings.
RESUMEN: Caracterización de placas de yeso con residuos de espuma de poliuretano reforzadas con fibras de polipropileno.Este artículo presenta un estudio experimental basado en la reutilización de residuos de poliuretano en una matriz de yeso para elaborar una placa de yeso laminado. Las placas fueron caracterizadas mediante los ensayos normalizados de densidad aparente, carga de rotura máxima a flexión, absorción total de agua, dureza superficial y reacción al fuego. Se han introducido fibras de polipropileno en la matriz con el objetivo de aumentar la resistencia mecánica del material. Los resultados muestran que el incremento de residuo polimérico en el material implica importantes reducciones de peso, resistencia mecánica y dureza superficial, a la par que se mejora su resistencia térmica consiguiéndose valores similares a los comerciales. Las fibras de polipropileno mostraron una buena adhesión con el polímero, mejorando el comportamiento mecánico y la capacidad de absorción. El ensayo de reacción al fuego confirmó que los residuos de poliuretano pueden ser empleados en la fabricación de placas de yeso laminado en cumplimiento con la normativa.
An ecological mortar is designed from industrial sub-products, with the objective of utilizing both the slag residues, generated during steel manufacturing processes, and the waste from Polyurethane Foam (PF) panels, generated during refrigerator chamber manufacturing processes. The ecological mortar design involves the dosing of Electric Arc Furnace (EAF) slag, together with finely ground Polyurethane Foam, cement, and additives. An energy efficient prefabricated block is designed with the mortar, for use in construction, and its energy performance is assessed as a material inserted within the envelope of a service sector (hospital) building, either as an exterior skin, or as an enclosing component within the façade interior. The main contribution of this research is the characterization of the thermo-physical and mechanical properties of a new prefabricated panel made with recycled materials. The full characterization of the properties of these new materials is presented and discussed. The new prefabricated panel demonstrates adequate thermo-mechanical characteristics as a substitute for traditional materials, while improving the sustainability of the building. As a secondary objective, the energy behaviour of the new panels when integrated in a real building is presented by means of a case study simulation. The use of computational thermal simulation confirmed that the properties of the prefabricated block influenced the annual thermal demand of the building for heating and cooling. Improvements to the thermal inertia of the building envelope were also confirmed with the inclusion of PF waste, giving the mortar an energy performance that was similar to conventional materials, in such a way that its use in façade construction may be validated, in addition to its environmental benefits, due to it having been manufactured with critical recycled industrial waste such as EAF slag and PF, thereby contributing to both the circular economy and sustainable development.
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