An Investigation of the Mechanical Properties and Thermal Insulation of Foamed Rubberised Polypropylene Fibre Concrete That Incorporates a High Quantity of Crumb Rubber Granules

Disposing of waste tyres in landfills poses significant environmental hazards, making recycling a crucial alternative. Rubberised concrete has been found to exhibit lower density and better thermal insulation performance than conventional concrete. In order to maximise the potential of thermal insulation of rubberised concrete, this study investigates the mechanical and thermal properties of foamed rubberised polypropylene fibre concrete (FRPFC). FRPFC was produced using a mix of crumb rubber (CR) granules, polypropylene fibres, and foam, targeting a density of 800 kg/m³, with CR substituting sand at varying levels. Compressive strength, flexural strength, splitting tensile strength, and thermal conductivity of FRPFC were evaluated. The results demonstrate that increasing CR granule content enhances compressive strength due to reduced porosity from lower foam usage. For instance, compressive strength improved by 55% (2.64 to 4.10 MPa) as CR granule content increased from 0% to 80%. Similarly, flexural strength and splitting tensile strength increased by 55% (1.61 MPa to 2.49 MPa) and 39% (0.41 MPa to 0.57 MPa), respectively, when CR content rose from 0% to 100% at a water-to-cement ratio of 0.50. Furthermore, thermal conductivity decreased by 34% (0.3608 W/mK to 0.2376 W/mK) when sand was fully replaced with CR granules, showcasing improved thermal insulation. Statistical analysis using ANOVA confirmed that the crumb rubber content significantly influences the mechanical and thermal properties of FRPFC, with higher CR content (80% and 100%) leading to superior performance. These findings highlight FRPFC's potential as an environmentally sustainable and thermally efficient construction material, contributing to enhanced mechanical properties compared to conventional foamed polypropylene fibre concrete.