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<p>In recent years, the need for sustainable alternatives to hazardous synthetic fibers has driven significant research in the field of polymer composites. This study presents the development and characterization of epoxy-based hybrid composites reinforced with sawdust and fly ash, aimed at enhancing structural insulating applications. The sawdust was alkali-treated to improve interfacial bonding, and various particle sizes of fly ash were incorporated. Composites were fabricated using the hand lay-up method with a fixed epoxy content of 95%, combined with 5% reinforcement of sawdust and varying fly ash contents (0.5, 1, 1.5, 2 wt.%). Mechanical tests revealed improvements in tensile strength, impact resistance, hardness, and compressive strength compared to neat epoxy. FTIR research revealed physical interactions between the components of the composite without the creation of new chemical bonds. Thermogravimetric analysis (TGA) showed that the addition of sawdust and fly ash improved the composites' thermal resilience by delaying the onset of thermal degradation and raising the amount of residual char at higher temperatures. This behavior implies that the fillers function as thermal barriers, decreasing heat transfer and delaying the epoxy matrix's breakdown. Additional evidence for changes in thermal behavior brought on by filler addition came from differential scanning calorimetry (DSC). Thermal conductivity test revealed a reduction by 50% W/m·K as filler content increased, confirming the composites’ potential as effective thermal insulators. These findings demonstrate the potential of utilizing agricultural and industrial waste to produce lightweight, cost-effective, and mechanically robust insulating panels.</p>

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Characterization and potential use of epoxy-based sawdust/fly ash hybrid composites for sustainable building applications

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月14日

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  • Huda M. Khdier,
  • Wafaa M. Salih

摘要

In recent years, the need for sustainable alternatives to hazardous synthetic fibers has driven significant research in the field of polymer composites. This study presents the development and characterization of epoxy-based hybrid composites reinforced with sawdust and fly ash, aimed at enhancing structural insulating applications. The sawdust was alkali-treated to improve interfacial bonding, and various particle sizes of fly ash were incorporated. Composites were fabricated using the hand lay-up method with a fixed epoxy content of 95%, combined with 5% reinforcement of sawdust and varying fly ash contents (0.5, 1, 1.5, 2 wt.%). Mechanical tests revealed improvements in tensile strength, impact resistance, hardness, and compressive strength compared to neat epoxy. FTIR research revealed physical interactions between the components of the composite without the creation of new chemical bonds. Thermogravimetric analysis (TGA) showed that the addition of sawdust and fly ash improved the composites' thermal resilience by delaying the onset of thermal degradation and raising the amount of residual char at higher temperatures. This behavior implies that the fillers function as thermal barriers, decreasing heat transfer and delaying the epoxy matrix's breakdown. Additional evidence for changes in thermal behavior brought on by filler addition came from differential scanning calorimetry (DSC). Thermal conductivity test revealed a reduction by 50% W/m·K as filler content increased, confirming the composites’ potential as effective thermal insulators. These findings demonstrate the potential of utilizing agricultural and industrial waste to produce lightweight, cost-effective, and mechanically robust insulating panels.