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Four different composite mixtures with varying amounts of expanded vermiculite were exposed to high temperatures of 300, 600, 900 and 1100uC for 6 h. Physical and mechanical properties including unit weight, porosity, water absorption, residual compressive strength, residual splitting tensile strength and also ultrasonic pulse velocity were determined after air cooling. Microstructures were investigated by scanning electron microscopy. Lightweight concrete with vermiculite shows a good performance at elevated temperatures. Expanded vermiculite is a significant lightweight aggregate for cementitious materials which are used for fire resistance applications. Concrete with vermiculite can be used as cement based refractory.

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We have added expanded vermiculite and polypropylene fibers with low thermal conductivity to lightweight gypsum. Thermal conductivity of the composites decreases on addition of vermiculite as pore-maker. Physical and mechanical properties of the composites are improved by incorporating polypropylene fibers. A nonlinear finite element model of a three point bending model and a design of experiments analysis have been developed to evaluate and optimize the additive concentrations and also to understand the effects provided by the additives on the mechanical strength. Statistical response surface method with three-level factorial was employed to evaluate the effect of addition of vermiculite and polypropylene fibers on gypsum composites. Our methodology can be applied to other nonlinear materials for property optimization.

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