Fire Safety Assessment of Insulation Boards Made from Recycled Cotton Fibers: Part I—Thermal Properties and Fire Behavior

Recycled cotton fibers offer a promising route for sustainable thermal insulation, but their flammability limits wider application. This study evaluated rigid recycled cotton insulation boards bonded with a polyvinyl acetate (PVAc)–starch system and modified with kraft lignin or aluminium trihydroxide (ATH) at dosages of 10 and 15 wt.%. Board density, thermal conductivity, volumetric heat capacity, thermal diffusivity, cone-calorimeter behavior, and ignitability under single-flame exposure were assessed. Thermal conductivity remained within a narrow range of 0.071–0.075 W·m−1·K−1, indicating that the basic insulation function was preserved despite formulation changes. Greater differences were observed in volumetric heat capacity and thermal diffusivity, particularly in lignin-modified boards at higher PVAc contents. Fire behavior was strongly formulation-dependent and showed no uniform dose-dependent response. The lowest peak heat release rate (pHRR) was obtained for the formulation containing 10 wt.% ATH and 20 wt.% PVAc, while the lowest total heat release (THR) was obtained for the formulation containing 10 wt.% ATH and 18 wt.% PVAc, reaching 170.31 kW·m−2 and 62.30 MJ·m−2, respectively. Lignin produced a less consistent effect on heat release. Under single-flame exposure, edge application was generally more critical than surface application, while ATH, particularly at 15 wt.%, provided the most consistent reduction in ignition and early flame spread. Overall, ATH was the more promising fire-modifying additive, although further formulation optimization and formal reaction-to-fire classification are required.