Design and Manufacture of a Sustainable Lightweight Prefabricated Material Based on Gypsum Mortar with Semirigid Polyurethane Foam Waste

Abstract

The characterization of a new gypsum mortar-based composite material that incorporates various combinations of polyurethane waste in its matrix is reported in this paper. The new material, a lightweight plate for use in internal ceilings, is characterized in a series of standardized tests: bulk density, mechanical behavior, and the reaction to fire test. Moreover, the study details the industrial manufacturing process linked to the integration of waste from the plastics industry. Increased quantities of polymer waste caused significant reductions in bulk density and mechanical strength, although with reasonable behavior of the plates up to substitution levels of 50%. The non-combustibility test demonstrated the potential of the new material for interior use in buildings. The technology of the new gypsum mortar-based material and polyurethane waste could potentially maximize the reuse and the life-span of this type of waste that would otherwise be incinerated or dumped on landfill sites.