Sustainable Design and Development of ceiling board from waste garment fabric reinforced composites with sisal fiber

Abstract

This study focuses on converting textile waste into a useful resource by utilizing it in to new product which is ceiling boards. The textile waste materials were collected from a local textile factory, MAA Garment. And it combined with sisal fibers as reinforcement with unsaturated polyester matrix. These recycled materials can be used to successfully develop composite materials that exhibit high strength, rigidity and ideal weight ceiling board applications. Different structural configurations were prepared with a 30/70% fiber-to-polyester resin ratio using randomly oriented cut waste fabrics: SSS (S1), SFS (S2), FSF (S3), and SSS (S4). The materials were mixed manually in the fabrication process. Demonstrating waste fabric and sisal fiber hybrid polyester composite laminates can effectively replace gypsum ceiling boards which offering notable environmental benefits and promoting the recycling of waste into functional construction materials are the two key goals of this research. Samples were prepared via the hand lay-up method, with fiber-to- polyester resin weight ratio 30/70%. And the sisal fiber were treated by alkali to enhance interfacial adhesion and remove impurities. Those treatment of fiber leads to enhance mechanical and physical properties of the laminate. This laminate pass through a series of experimental tests to evaluate the compressive strength, tensile strength, flexural strength, impact strengths, density, and water absorption rate. Finally the laminate shows good mechanical properties especially in flexural, tensile strength and water absorption. The optimized laminate achieved a 29% reduction in weight compared to gypsum boards, reducing from 12 kg to 8.49 kg. According to literature-based optimization, the water absorption of the laminate was only 5%, which represents a 54.5% reduction compared to lightweight cement boards, 50% compared to gypsum ceiling boards, and 44% compared to fiber cement boards (DORCK brand). To determine the optimal laminate configuration, the TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) method was employed. The analysis revealed that the F-S-F (S3) layup was the most effective. This optimal laminate, arranged in a 90°–45°–90° orientation, was further optimized using a Genetic Algorithm (GA) in MATLAB and its performance validated through re-analysis in ABAQUS software.