Tire powder-enhanced jute/epoxy composites: Performance improvement and design optimization for formwork sheathing panel

This study explores the development and optimization of a tire powder-enhanced jute/epoxy composite for formwork sheathing applications, addressing the limitations of conventional materials such as plywood, steel, timber, and plastic. The proposed hybrid composite aims to provide an economical, lightweight, and durable alternative while promoting sustainability through waste tire recycling. Experimental investigations assessed the mechanical and physical properties of eight composite laminates by modifying the epoxy matrix with varying tire powder content and incorporating recycled tire powder as a core sandwich in a jute/epoxy composite. The Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method identified L2 (20 % jute, 80 % epoxy, 4 % tire powder) as the optimal configuration, offering a superior balance of tensile, compressive, flexural, and impact strengths, along with reduced water absorption, improved density and cost efficiency. To further refine the sheathing panel, Genetic Algorithm (GA) optimization was applied, minimizing weight while ensuring structural integrity. The optimized panel features layer thicknesses of t1 = t2 = t3 = 2.5 mm and fiber orientations of 90°, 0°, and 90°, resulting in a minimal weight of 24.41 kg. Compared to conventional sheathing materials, the composite demonstrates significant weight reductions, including 37.73 % less than plastic (39.2 kg), 82.31 % less than steel (138 kg), 49.15 % less than plywood (48 kg), and 53.06 % less than timber (52 kg). Finite Element Analysis (FEA) validated the optimized design, confirming a high stiffness-to-weight ratio and a safety factor exceeding 2, ensuring reliability under applied loads. These results demonstrate that tire powder-enhanced jute/epoxy composites offer a sustainable, cost-effective, and high-performance alternative for formwork sheathing in construction. • Developed tire powder-enhanced jute/epoxy composite for formwork sheathing. • Promotes sustainability with recycled tire powder in composite. • TOPSIS optimized L2 configuration for balanced mechanical properties, water absorption, density and cost. • GA optimization reduced weight to 24.41 kg while ensuring integrity. • FEA validated design with high stiffness-to-weight ratio and safety factor over 2.