Development of sustainable construction materials from OSB and Aquapanel waste from industrialized façades

The increasing demand for sustainable construction solutions has led to growing interest in the reuse of industrial waste materials. This study explores the development of sustainable gypsum-based composites and mortars incorporating waste from industrialized façade systems, specifically oriented strand board (OSB) and Aquapanel® panels. A comprehensive experimental program was conducted to evaluate compressive and flexural strength, dynamic modulus of elasticity, capillary water absorption and thermal conductivity. The results show specific performance trends: compressive strength and surface hardness decreased slightly but remained above the regulatory 2 MPa threshold, confirming mechanical suitability. Flexural strength decreased by less than 4%, while all mixtures surpassed the 1 MPa minimum requirement. Conversely, modulus of youth increased progressively, reaching a 2.04% rise and 7000 MPa in the E0.6-25OA composite, indicating improved elasticity and reduced cracking potential. Capillary water absorption decreased by more than 15% compared with the reference mix, demonstrating enhanced water resistance. The fine particle size and good adhesion of OSB and Aquapanel® waste prevented the formation of micro-porosity that could reduce thermal conductivity at the expense of surface integrity. This research demonstrates, for the first time, the technical feasibility of incorporating OSB and Aquapanel waste into gypsum composites while meeting regulatory mechanical and hydrothermal performance criteria. The results highlight the potential of these materials to support circular-economy strategies by extending material life cycles and reducing natural resource consumption. • OSB and Aquapanel® waste enable viable gypsum mortars within regulatory limits • Flexural strength and elasticity correlate under increased waste incorporation • Waste addition reduces water absorption while maintaining thermal performance • Approach supports circular economy through reuse of industrial façade residues