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<p>Concrete has dominated the construction sector as the most widely used building material since the early twentieth century. But because of the demolition of existing structures, millions of tons of concrete waste are dumped every year. This affects the environmental sustainability and fertility of the land. In order to limit the ruthless extraction of virgin gypsum resources and the effective utilization of concrete waste, this study explores a novel approach by using recycled concrete fine aggregates in gypsum mortar. The goal of this study was to investigate the mechanical and physical characteristics of the developed gypsum composites and the thermal insulation and flexural strength properties of composite false ceiling plates for their practical use as a product in the construction sector. The recycled concrete fine aggregate (RFA) of sizes, ≤ 2&#xa0;mm, ≤ 4&#xa0;mm and 2–4&#xa0;mm were replaced with gypsum at four different percentages i.e., 15%, 30%, 45%, and 60% (by weight). With the increase in the dosage of RFA, the density and water absorption values exhibited a direct correlation and saw an increase. However, a decrease was observed in the UPV values by increasing the RFA dosage from 15 to 60%. With the increase in the size of RFA from finer to coarser particles, both density and UPV demonstrated an incremental rise. In addition, water absorption decreased in each proportion by increasing the size of the aggregate. The bending and compression strengths of all composites dropped as the RFA dosage and size increased, but they fulfilled the minimum required strength limits of 1&#xa0;MPa and 2&#xa0;MPa respectively, as prescribed by standard BS EN 13279-1, making them all eligible for the production of plates. Additionally, all composite false ceiling plates satisfied the requirement of withstanding a linear mid-span load of 6&#xa0;kg, as per BS EN 14246. The thermal conductivity test proved the superior thermal insulation capabilities of the developed composites in comparison with the control mix, underscoring their considerable potential for application in energy-efficient construction projects. The cost comparison revealed that the composite product is cost-effective, offering an economical alternative that effectively reduces the environmental impact of concrete waste.</p>

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Valorization of recycled concrete fine aggregates in gypsum mortars for developing eco-friendly false ceiling plates

  • 期刊论文

  • 发表日期：

    2026年4月13日

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  • Rashid Latif,
  • Muhammad Rizwan Riaz,
  • Anam Fatima,
  • Rizwan Azam,
  • Muhammad Hassan Javed

摘要

Concrete has dominated the construction sector as the most widely used building material since the early twentieth century. But because of the demolition of existing structures, millions of tons of concrete waste are dumped every year. This affects the environmental sustainability and fertility of the land. In order to limit the ruthless extraction of virgin gypsum resources and the effective utilization of concrete waste, this study explores a novel approach by using recycled concrete fine aggregates in gypsum mortar. The goal of this study was to investigate the mechanical and physical characteristics of the developed gypsum composites and the thermal insulation and flexural strength properties of composite false ceiling plates for their practical use as a product in the construction sector. The recycled concrete fine aggregate (RFA) of sizes, ≤ 2 mm, ≤ 4 mm and 2–4 mm were replaced with gypsum at four different percentages i.e., 15%, 30%, 45%, and 60% (by weight). With the increase in the dosage of RFA, the density and water absorption values exhibited a direct correlation and saw an increase. However, a decrease was observed in the UPV values by increasing the RFA dosage from 15 to 60%. With the increase in the size of RFA from finer to coarser particles, both density and UPV demonstrated an incremental rise. In addition, water absorption decreased in each proportion by increasing the size of the aggregate. The bending and compression strengths of all composites dropped as the RFA dosage and size increased, but they fulfilled the minimum required strength limits of 1 MPa and 2 MPa respectively, as prescribed by standard BS EN 13279-1, making them all eligible for the production of plates. Additionally, all composite false ceiling plates satisfied the requirement of withstanding a linear mid-span load of 6 kg, as per BS EN 14246. The thermal conductivity test proved the superior thermal insulation capabilities of the developed composites in comparison with the control mix, underscoring their considerable potential for application in energy-efficient construction projects. The cost comparison revealed that the composite product is cost-effective, offering an economical alternative that effectively reduces the environmental impact of concrete waste.