Effect of Fiber Loading on Mechanical and Flame-Retardant Properties of Poplar-Fiber-Reinforced Gypsum Composites

Abstract

Gypsum-based composites were prepared via a slurry casting process using construction gypsum as the binding material and poplar fibers as reinforcing material. The effects of different fiber content and curing time on the mechanical properties, water resistance, and flame retardancy of these composites were investigated, and the influence mechanism was characterized by infrared spectroscopy, scanning electron microscopy, and X-ray diffractometry. The results showed that the best composite mechanical strength was achieved with 10% poplar fiber- content, and the absolute dry flexural and compressive strengths reached 3.59 and 8.06 MPa, respectively. Compared with pure gypsum, the flexural strength and compressive strength increased by 10% and 19%, respectively. The inclusion of fibers somewhat prevented the migration of free water within the composites and enhanced their water resistance. At 10% fiber content, the composite’s 24 h water absorption rate was 34.3%, 8% lower than that of pure gypsum, with a softening coefficient of 0.55. However, fiber content increases the porosity of gypsum-based composites. When heated, this increased porosity accelerates’ heat conduction within the matrix, raising the peak and total exothermic rates, thereby weakening the composites’ inherently flame-retardant properties. Poplar-fiber-reinforced gypsum-based composites offered superior performance in commercial applications, compared to pure gypsum board, providing a sustainable and green alternative for ceilings, partitions, and other applications, while broadening the prospects for gypsum-based composites in the engineering field.