Mechanical and Microstructural Performance of Gypsum Composites Incorporating Treated Rice Husk and Recycled Gypsum

The growing demand for more sustainable construction materials has driven the development of composites incorporating industrial and agricultural residues, contributing to the reduction in virgin raw material consumption and the valorisation of by-products. In this context, the present study investigated the influence of incorporating rice husk subjected to different chemical treatments and the partial replacement of commercial gypsum with recycled gypsum on the flexural strength, compressive strength and microstructural characteristics of gypsum-based composites. Initially, formulations containing 5 wt.% and 10 wt.% rice husk in three different conditions, untreated, treated with calcium hydroxide, and treated with acetic acid, were produced and evaluated in terms of compressive strength and flexural strength. The formulation containing 5 wt.% rice husk treated with acetic acid exhibited the best overall performance and was therefore selected for the subsequent stage of the study. In the second phase, mixtures incorporating 20 wt.%, 30 wt.% and 40 wt.% recycled gypsum, with and without the addition of 5 wt.% treated rice husk, were investigated. Furthermore, particle size distribution, X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) analyses were performed. The results demonstrated that the acetic acid treatment resulted in higher flexural and compressive strength compared with the other treatment conditions evaluated. Partial replacement with recycled gypsum also yielded promising results, with the formulation containing 70 wt.% commercial gypsum and 30 wt.% recycled gypsum exhibiting the highest mechanical strength among the composites without lignocellulosic reinforcement. Microstructural characterisation revealed the preservation of the principal mineralogical phases following the recycling process, and SEM micrographs showed the incorporation of rice husk within the gypsum matrix. Overall, the combination of 30 wt.% recycled gypsum and 5 wt.% rice husk treated with acetic acid represents a technically viable alternative for the development of gypsum composites intended for non-structural applications in the construction industry, while promoting the beneficial utilisation of waste materials.