Potential of waste woven polypropylene fiber and textile mesh for production of gypsum-based composite

The huge production of woven polypropylene bags has led to an increase generation of plastic waste. The recycling of waste woven polypropylene bags and textiles in construction applications can be a viable option. Therefore, an attempt has been made to utilize the woven polypropylene fibers and textiles in the production of gypsum-based composite false ceiling tile for an economical and sustainable construction product. In the current research work, different water-to-powder ratios (0.6 %, 0.7 %, 0.8 %, 0.9 %) and fiber contents (0.25 %, 0.35 %, 0.45 %, 0.55 %) in the gypsum-based composite were prepared. Flexural plates with different thicknesses (18, 15, 12, and 9 mm) incorporating different recycling fibers and reinforced with different types of meshes were manufactured to produce sustainable gypsum-based plates. The physical properties, compressive and flexural strength properties of the fiber-reinforced gypsum-based composite were also evaluated. The textile and woven polypropylene fiber mesh reinforced gypsum false ceiling plates were compared with the control specimen. The results revealed that the density of gypsum-based composite decreased up to 26 % with the increase in the proportion of waste fiber contents. The compressive and flexural strength of gypsum-based composites exhibited a decrease with an increase in fiber contents and water-to-powder ratio. However, all the specimens satisfied the acceptable limit of 1 MPa and 2 MPa, respectively, according to BS EN 14246. The bending strength of all the plates incorporating different fiber content and thicknesses satisfied the minimum specified flexural strength criteria according to BS EN 14246. Moreover, the plates with different thicknesses and fiber contents also satisfied the minimum specified flexural criteria except for the plate with a thickness of 9 mm. However, all the plates with varying thicknesses and reinforced mesh have also satisfied the minimum load criteria specified by BS EN 14246. Thus, it can be envisioned that the woven polypropylene fibers and textiles can be effectively utilized to produce sustainable gypsum-based composite leading to reduce waste generation.