Gypsum Binder Research Articles

Исследование возможности получения вяжущих материалов из отходов фосфорной промышленности

The research work is devoted to the possibility of recycling large-tonnage solid waste of phosphorus production – phosphogypsum in order to obtain binders for use in the construction industry to obtain various building materials. The main parameters of the process (the composition of the main raw material, the degree of grinding of the raw material, the temperature and time of dehydration of phosphogypsum) were investigated in the work. Physical and chemical studies of the properties and structure of wastes have been carried out, which make it possible to determine the fundamental possibility (or impossibility) of their use in a particular production. The use of the Rankin diagram as a technical model made it possible to determine the location of technogenic wastes of phosphorus production. The X-ray phase analysis of the gypsum binder samples showed that the X-ray patterns show lines of diffraction maxima corresponding to hemihydrate calcium sulfate, i.e., upon heat treatment of phosphogypsum up to 200°C, dihydrate gypsum in the composition of phosphogypsum mainly transforms into hemihydrate gypsum, which has good binding properties. The results of the conducted studies showed the feasibility of processing old phosphogypsum into gypsum binder.

A Newly Bio-Based Material for the Construction Industry Using Gypsum Binder and Rice Straw Waste (Oryza sativa)

Construction is one of the economic sectors with the greatest influence on climate change. In addition to working procedures, the primary carbon footprint is attributed to the choice of materials and the energy required for their manufacturing. The underlying idea of this study is to minimize the effects and offer new solutions to emerging problems in the quest for materials that can be deemed as natural, such as gypsum (calcium sulphate dihydrate) and rice straw (Oryza sativa). The acquisition of these materials involves a lower carbon footprint compared to the conventional materials. It is well known since ancient times that gypsum and cereal straw can be used in construction, with numerous examples still available. Cereal straw is one of the oldest construction materials, traditionally combined with earth and occasionally with certain binders, with it continuing to be employed in construction in many countries to this day. This work showcases the feasibility of producing stable prefabricated elements from straw waste with construction gypsum, addressing a significant environmental concern posed by the alternative of having to burn such materials. In this study, for the proposed bio-based material, specific tests, such as thermal conductivity, flexural and compressive strength, and fire resistance, were carried out to evaluate the principal physical and mechanical characteristics for different compositions of water, gypsum, and straw fiber samples. The results highlighted the good performance of the proposed materials in order to spread their use in the green building industry. The addition of straw fibers improved, in different ways, some important physical characteristics of these components so as to diminish environmental pollution and to obtain better material performance. The tests highlighted the different behaviors of the proposed material with respect to the different cuts of the straw and as well as the water/gypsum ratio; this is not very well understood and probably depends on the micro structure of the straw fibers. The blocks with raw straw showed a significant improvement in the breaking mechanism (1775.42 N) compared to the blocks with cut straw (712.26 N) when subjected to bending tests, and their performance in compression tests was also acceptable. Additionally, a very interesting reduction in thermal conductivity was achieved by incorporating rice straw (0.233 W/mK), and high fire exposure times were obtained, with gypsum preventing the spread of ignition in any type of fiber.

Gypsum Binder With Increased Water Resistance Derived From Membrane Water Desalination Waste

ABSTRACTA method has been developed for separating a mixture of calcium, magnesium and sodium sulfates obtained through the interaction of sulfuric acid and waste from the water purification process generated by using membrane filters. The primary goal of this method is to extract gypsum and produce gypsum‐based binders. Patterns were identified regarding how various types, ratio and quantities of additives: blast furnace slag, granite screenings, portland cement, electric steel smelting slag affect the water‐gypsum ratio, strength properties, and water resistance of high‐strength gypsum binders. It was found that adding a single‐component additive specifically to enhance water resistance does not significantly impact these properties. Complex additives have been developed based on Portland cement, granulated blast furnace slag, electric furnace slag, expanded clay dust, and granite screenings of various fractions. These additives are designed to maximize the water resistance of high‐strength gypsum binder based on synthetic calcium sulfate dihydrate. As a result, the water resistance coefficient increased from 0.45 to 0.52. Additionally, a technological block diagram of the process has been proposed.

Направления обеспечения качества гипсоизвестковых вяжущих при реставрации

Purpose: to consider issues related to the standard definition of the strength characteristics of an air binder and a cement binder. To show a technological solution to the problem of regulating the strength of an air binder stone by stabilizing care during setting and hardening. Methods: during the research, GOST 23789- 2018 “Gypsum binders. Test methods”. Results: a distinctive feature of restoration plaster solutions is that structure formation and strength gain occur only in an air-dry environment. As a result, the availability of approved and applied standards for the manufacture and use of restoration plaster solutions does not fully guarantee the creation of a reliable and safe environment for the life of an architectural heritage monument. It has been established that the mechanical characteristics (compressive and bending strength limits), as well as elastic parameters should be the same or lower in historical and restoration solutions in order to avoid changes in stress distribution. Practical significance: developed taking into account the comprehensive care of hardening stone, gypsum-lime binders can have a wide range of applications. They can be used as mortars for the preservation of architectural heritage and in the reconstruction of modern buildings, self-supporting partitions, fire protection elements or drywall (in places where a higher mechanical load is expected).

DEVELOPMENT OF DRY BUILDING MIXTURES BASED ON REDISPERSIBLE POWDER FOR REGULATING THE PROPERTIES OF PLASTER MIXTURES

The relevance of the work. The results is theoretically substantiated and experimentally confirmed the possibility of obtaining a dry additive-retarder of gypsum setting based on lime and polyvinyl acetate dispersions due to the formation of polyvinyl alcohol and salts of calcium acetate in the result of alkaline hydrolysis of polyvinyl acetate dispersion (PVAD) with the slaked lime in hydrated lime. The results of the work implemented in the production of dry gypsum mixes. Purpose. The development of dry building mixes based on gypsum and time increase of time of their conformance through adding of complex additives on the basis of burnt lime and polyvinyl acetate dispersions [PVAD]. Methodology. The study used standard research techniques to determine physical and mechanical properties of gypsum binders and quality of complex additives according to ДСТУ Б В.2.7-82:2010, ДСТУ Б В.2.7-23-95, ДСТУ Б В.2.7-171:2008. Study of phase composition of materials, micro – and macrostructure was carried out by x-ray diffraction, electron and light microscopy. The results. The influence of the main components of the additive (polyvinyl acetate dispersion and lime) on the properties of hemihydrate gypsum is investigated. The chemistry of the interaction of components of the complex additive, according to which the result of alkaline hydrolysis of polyvinyl acetate is formed: polyvinyl alcohol, a feature of its molecules structure is the presence of hydrophilic OH−groups and the hydrophobic component − a hydrocarbon radical. The hydrophilic part of the molecule being ion adsorbed on the surface of the particles of the binder, forms a monomolecular layer that is oriented with the hydrophobic part of the gypsum particles. It is also possible the formation of calcium acetate Ca(СН3СОО)2, which increases the concentration of calcium ions in solution. The combined effect of hydrolysis products significantly reduce the solubility of hemihydrate, the rate of formation of crystallization centers, due to the slowing effect of these supplements.

Synthesis of calcium sulfate whiskers via acidification exploiting FGD gypsum for improved binder properties

This research focuses on the synthesis of calcium sulfate whiskers using FGD (Flue Gas Desulfurization) gypsum as raw material through the acidification method and their utilization in gypsum binders. The acidification method using H2SO4 (1.5 mol/L) is distinguished by its sustainability and resource efficiency. The addition of Calcium Sulfate Whisker as an activator enhances the binder's properties by increasing its strength, durability, resistance to environmental factors, and overall structural integrity. The effects of different reaction parameters on the properties and microstructure of CSW have been studied. This research has the potential to bring about significant improvements in various applications, from construction materials to industrial products. Calcium Sulfate Whiskers act as pore fillers within the binder matrix which reduces the porosity and helps to decrease water absorption up to 12%. CSW is characterized by its needle-like structure, which provides an intricate network within the binder matrix. SEM images showed the strong interfacial bonding between the whiskers and the binder matrix, enhanced by the rough surface of the whiskers, which improves mechanical interlocking and adhesion. CSW demonstrates its potential as a highly active component in the binder. The whiskers facilitate efficient nucleation sites, accelerating the hydration reactions within the binder and enhancing the overall performance of the binder. CSW incorporation in the binder increases the compressive strength by up to 21.6% and flexural strength by 37%. The exceptional mechanical strength and efficient nucleation sites provided by CSW contribute to an increase in the workability of the binder and make it suitable for interior as well as exterior applications. These interconnected facets collectively position the project as a valuable and highly pertinent contribution, where sustainable innovation and improved material properties are of paramount importance. It potentially reduces the need for traditional additives with higher environmental impacts, making the binder formulation more eco-friendly.

Improving additive manufacturing for housing construction

The use of additive manufacturing in construction can significantly reduce the speed of construction of an object, labor costs, waste, reduce the risks of industrial injuries, etc. Despite a number of existing advantages of these technologies, their implementation in construction is associated with various problems, one of which is the need to ensure the required adhesion strength of printed layers. There are a number of studies devoted to solving this problem and creating effective materials for additive construction production, mainly based on cement binders; to a much lesser extent, these studies are available in the field of mixtures based on gypsum and mixed (gypsum-cement-pozzolanic) binders. The purpose of this work is to develop a scientifically based technological solution for improving additive technologies for low-rise housing construction using gypsum-cement-pozzolanic mixtures (GCPS) by regulating recipe-technological factors that provide increased adhesion strength of printed layers. Based on the results of the research, a technological solution has been developed to improve the technology of additive construction production of GCPM by regulating the kinetics of the increase in plastic strength of the mixture when it is modified with a multifunctional complex additive, which makes it possible to ensure the viability of the mixture required for 3D printing in the range of 0–50 minutes, significantly reduce the defectiveness of the extrudate during the 3D printing process, and increase the adhesion strength of the printed layers. It has been established that the adhesion strength of layers printed without a technological break from the GCP concrete mixture, modified with multifunctional complex additive, is 65% higher compared to the base composition, and when a technological break lasts 6 hours, it is 25% higher, which confirms its effectiveness in additive manufacturing.

Optimizing the Compositions of Plaster Mixtures Based on Gypsum Binder Using REOLIN RA 120

Optimizing the Compositions of Plaster Mixtures Based on Gypsum Binder Using REOLIN RA 120

Снижение экологической нагрузки на регион за счет рационального способа утилизации фторангидрита

The article considers the chemical industry technologies contaminating the environment with sulfate-calcium waste in three regions of the former Soviet Union, i.e., the Tomsk region (SHK LLC, Seversk), the Perm territory (Galopolimer JSC, Perm), and East Kazakhstan region (UMZ JSC, Ust-Kamenogorsk). The differences and similarities of technological processes of anhydrous calcium sulfate production in the above-mentioned regions have been considered. Some properties of sulfate calcium (acid fluoride) that until recently was the main environmental contaminator used in the technology of hydrogen fluoride production have been specified. The objective of the study is to provide generalized positive results obtained by the authors of the article in the field of optimization of sulfuric decomposition of fluorspar not changing the production conditions and the quality of the main product — hydrogen fluoride. As a result of the process, the solid waste of hydrogen fluoride production is transformed into a target product, i.e., a technogenic anhydrite binder that can be an alternative to Portland cement and gypsum binders in the construction industry. Therefore, acid fluoride waste is removed from the hydrogen fluoride technology, and the environmental contamination with sulfate-calcium waste is prevented. In addition, a new trend in the construction industry is set, which is the industry production of anhydrite materials and products. The list of pilot-industrial and semi-industrial tests of the production of various anhydrite products has been provided (as an image listing the fields of use of acid fluoride in the industry of construction materials). In conclusion, the amount of environmental damage caused by the acid fluoride waste has been specified. In the Ob basin of the West Siberian region, it was 270 million rubles for 2023.

New insight into the phase changes of gypsum

The phase changes of gypsum were considered to be sufficiently understood for a long time. However, due to the increasing importance of gypsum recalcination (connected with the planned closure of thermal power plants resulting in a lack of FGD gypsum) and new detailed research associated with it, gaps in the current knowledge have been discovered. This paper clarifies phenomena occurring during the production of gypsum binder, anhydrite, and potentially eco-friendly calcium sulfate-based ceramics at 22–1300 °C by in-situ XRD, thermal analysis, and SEM. It was found that undesirable insoluble anhydrite II arises even in the temperature range from 40 to 90 °C despite the current state-of-the-art. New knowledge about the existence of the individual phases, microstructure (cracking of crystals; fragmentation and sintering of anhydrite AII at temperatures above 700 °C when a ceramic-like material is formed), and their external consequences (changes in moisture and heat transport properties) has been gained.

ВЛИЯНИЕ СУПЕРПЛАСТИФИЦИРУЮЩИХ ДОБАВОК НА ОСНОВЕ ЭФИРА ПОЛИКАРБОКСИЛАТА НА ТЕХНОЛОГИЧЕСКИЕ И ФИЗИКО-ТЕХНИЧЕСКИЕ СВОЙСТВА ГИПСОЦЕМЕНТНО-ПУЦЦОЛАНОВОГО ВЯЖУЩЕГО

Effective modifiers of the structure and properties of concrete based on gypsum-cement-pozzolanic binder are chemical additives. Among a wide range of chemical additives, superplasticizing additives can be distinguished. The most effective in terms of water-reducing effect, increasing the mobility and strength of concrete based on gypsum-cement-pozzolanic binder are superplasticizers based on polycarboxylate ethers. The paper presents studies of the influence of superplasticizing additives on the physical and technical properties of gypsum-cement-pozzolanic binder based on low-grade gypsum and cement binders, and a binary active mineral additive consisting of zeolite-containing marl and microsilica. It has been shown that the introduction of the studied modifiers makes it possible to improve the performance properties of products based on gypsum-cement-pozzolanic binder, which is expressed in an increase in compressive strength and an increase in water resistance. Patterns of changes in water demand, setting time, and water-reducing effect of the gypsum-cement-pozzolanic binder mixture were obtained when it is modified with polycarboxylate additives of the following grades:“Melflux 2651 F”, “Polyplast type S”, “Polyplast type R”, “SPS-06”, “SPS-08”, “DK-100” and C-3 in comparison with unmodified HCPV, the change in strength with compression and softening coefficient of gypsum-cement-pozzolanic binder stone with these additives. It has been established that reducing the water requirement of the gypsum-cement-pozzolanic binder mixture by 60 % increases the compressive strength of gypsum-cement-pozzolanic binder stone samples by 33.5 MPa compared to the control composition. It has been shown that the most effective modifiers among those studied are “Polyplast type S” and “DK-100”.

The Use of Phosphogypsum as a Source of Raw Materials for Gypsum-Based Materials

Gypsum binders and the products based on them are widely in demand in the construction materials market, which is due to their easy production technology, lower energy consumption, and low environmental impact in relation to Portland cement. Not only natural gypsum (NG), but also phosphogypsum (PG), which is a by-product of the synthesis of orthophosphoric acid from phosphorite rock, can be used as a source of raw materials for the production of gypsum materials. PG is produced annually in large quantities throughout the world. In chemical composition, PG mainly consists of calcium sulfate dihydrate CaSO4·2H2O, so it is a good potential analogue of natural gypsum, which is used as the main component of gypsum building materials. Thus, the useful recycling of PG as a technogenic resource with valuable properties will expand the raw material base for the production of gypsum materials. This approach to handling technogenic resources fits well with the principles of a circular economy. However, like any technogenic resource, PGs from different enterprises normally differ in their deposits of the original phosphate rock and production technologies. Therefore, PG contains a large number of undesirable impurities, the proportion and composition of which vary over a wide range. This feature does not allow for predicting the properties of PG-based materials without a preliminary detailed study of PG. This research was aimed at carrying out a comprehensive study of the characteristics of PGs from three different industrial plants to evaluate their relationship with the properties of gypsum materials based on them. It was found that PGs have significant differences in their structural and morphological characteristics both in relation to each other and in relation to NG. Also, binders based on PG and NG have significant differences in their physical properties. The average density, compressive strength, and flexural strength for the PG binders with equal workability are lower than those of NG binders. At a water/solid ratio (W/S) < 0.7, all PG binders exhibit comparable compressive strength to NG binders. Thus, PG can act as an alternative to natural gypsum in gypsum binders.

Effective Method of Improving the Performance Properties of Wall Products On the Basis of the Gypsum Binder

The basis of the conducted research was the goal of modifying composite gypsum-containing binders for the manufacture of wall products with increased water resistance, strength, frost resistance, and durability by developing a hydrophobizing solution for processing products based on gypsum binder. The article presents the results of research on the modification of artificial gypsum stone with a developed hydrophobizing chemical solution based on calcium polysulfide and titanium dioxide. Comparative indicators of water absorption of original and solution-impregnated samples, which were exposed to the frontal influence of water, are given. The water absorption of the modified samples is within 9...21% and does not change after the frontal impact of rain. Indicators of chemical resistance of impregnated samples in solutions of magnesium sulfate, urea, acetic and oxalic acids, which are characteristic components for aggressive environments of livestock complexes, food and chemical industry, are presented. The test results of the samples showed that the developed chemical solution provides a chemical resistance factor of 0.7, that is, they are chemically stable in such environments. It is shown that, depending on the number of applied layers of the solution or the time of impregnation, hydrophobization gives high indicators of the softening coefficient of the products, which is in the range of 0.6...0.82. The research results showed that thanks to the developed hydrophobizing solution, the construction and technical characteristics of the artificial gypsum stone are significantly increased. Wall products made of this material have high operational characteristics, and it is advisable to use them both indoors and outdoors.

High-strength gypsum binder with improved water-resistance coefficient derived from industrial wastes.

The article presents the possibility of increasing the water resistance of gypsum binders (GBs) obtained based on synthetic gypsum by introducing additives derived from industrial wastes. Regularities were obtained for the influence of the type and amount of additives on the water/gypsum ratio (W/G), strength indicators and water resistance of high-strength GB. The introduction of a single-component additive to improve water resistance does not have a significant effect. Complex additives based on Portland cement, granulated blast-furnace slag, electric steel-smelting slag, expanded clay dust and granite screenings of various fractions have been developed that make the maximum contribution to improving the water resistance of a high-strength GB based on synthetic calcium sulphate dihydrate, which made it possible to increase the water-resistance coefficient from 0.39 to 0.82.

On the Mechanism of Destruction and Oxidation of Starch for the Production of Plasterboard Sheets (PBS)

The technological process of PBS production requires careful control of the phase composition of the gypsum binder used, as well as compliance with the drying modes of the sheets. This is necessary in order to ensure the adhesion of the gypsum core to the cardboard and, as a result, to give the sheets the required mechanical and physical properties. The use of various kinds of modified starches in the production technology of PBS makes it possible to achieve the required adhesion with fluctuations in the phase composition of the binder and deviations in the drying mode of products. Considering this, it becomes obvious that the characteristics of modified starches have a significant effect on the quality of PBS. The study of existing standards regulating the quality indicators of starch derivatives showed the absence of parameters reflecting the effectiveness of their use in the production technology of PBS. In this paper, the structural features of the most widely used types of modified starch are considered. The paper summarizes information about the mechanism of adhesion of the gypsum core to cardboard, the factors influencing this process, the mechanisms of starch destruction and oxidation, and also offers a list of quality indicators of starch derivatives and the requirements for them. It is shown that the effectiveness of the use of modified starches in the production of PBS is achieved by regulating the direction and depth of the processes of destruction and oxidation.

АНАЛІЗ ВПЛИВУ ПОЛІФУНКЦІОНАЛЬНОГО МОДИФІКАТОРА НА ВОДОСТІЙКІСТЬ КОМПОЗИЦІЙНОГО ГІПСОВОГО В'ЯЖУЧОГО

The article highlights the issue of increasing the water resistance of a composite gypsum binder based on the analysis of a full-scale experiment. To solve the problem, a 24-point plan in the form of "triangles on a cube" of the experimental and statistical model of the effect of additives of various types and purposes on the properties of a composite gypsum binder, taking into account the interactions between them, calculated in the COMPEX program, was used. A universal method of increasing the water resistance of gypsum materials is to reduce their porosity. For this purpose, small amounts of polymeric or plasticizing additives are introduced into the gypsum binder to increase their density. A way to increase water resistance is to add up to 10-40% of mineral components, which, due to their binding properties, harden into a water-resistant stone-like material. At the first stage of the experiment, we analyzed the change in water resistance by the value of the softening coefficient Kr under the influence of micro-puzzolan additives, a micro-reinforcing modifier additive, and Sika superplasticizer. The range of variation of all additives was established by the experiment plan. The next stage of the study analyzed the possibility of further improving water resistance by using bulk and surface water repellents. To evaluate the effect of hydrophobic primers on the surface properties of gypsum binder samples, the marginal wetting angle is measured using the sitting drop method. It is shown that the complex modification of the composite gypsum binder with micro-reinforcing, polymineral micro-puzzolanic filler additives and Sika superplasticizer in optimal proportions makes it possible to obtain a composite gypsum binder with a softening coefficient of 0.9. Volumetric hydrophobization provides an additional increase in compressive strength and water resistance.

Influence of glass-fiber epoxy coating on bond behavior of FRCM systems with different internal and external CMLs

FRCM composite systems display outstanding capabilities for the reinforcement of existing structures. Their modeling is challenging for the numerous damage scenarios and sources of non-linearity; also, test methods for mechanical characterization are still debated. In this study, six different FRCM systems were considered by combining the same glass-fiber textile, dry or epoxy-coated, and three different matrices based on cement, lime, and gypsum binders. The experimental results of the single shear tests highlighted the beneficial effect of the epoxy resin coating that greatly improves the fiber-matrix adhesion capacity in terms of stress, although nullifying the smooth softening behavior, resulting in brittle failure of the textile. Then, an analytical model aimed at calibrating the CMLs and predicting the corresponding global load slip diagram of the six systems is proposed. The assumptions considered are that the internal and external interfaces experience two different shear stress-slip laws and that the brick and both the matrix layers are rigid.

Dry mixes on gypsum and mixed bases in the construction of low-rise residential buildings using 3D printing technology

3D-printed building construction technology is developing in most countries, such as France, China, Russia and others, and the dry mixes and equipment used are being improved. The development of 3D-printing construction technology is dictated by its many advantages: architectural diversity, speed and automation of the technological process of construction of buildings and structures with a noticeable reduction in the cost of production. However, there are a number of problems of this technology that are waiting for optimal solutions. The paper proposes solutions to two such problems: firstly, the choice of mixture with gypsum and gypsum-cement binders, ensuring the continuity of the 3D printing process of the building and allowing the construction of buildings up to three floors with sufficient safety margin, high seismic stability, as well as with good heat and noise insulation; secondly, the design of buildings with a rational structural and technological solution of the roof and floor, allowing the interface of these structures with load-bearing printed walls. Different compositions of dry mixes were tested in a series of field tests of large-sized wall blocks made with the use of a construction 3D-printer and filled with especially light porous expanded claydite, expanded clay concrete or heat-insulating foam gypsum with subsequent testing on press equipment of increased load-carrying capacity (with determination of bearing capacity and deformability of the large-sized block). When designing low-rise buildings, erected by additive technology, as an optimal design of floors, it is proposed to use frame-monolithic beam structures made of metal thin-walled steel galvanized profiles, filled with foam gypsum mix, providing heat and noise insulation and covered with a thin layer of high-strength self-leveling gypsum mix, providing the necessary structural strength of the floor and, accordingly, the minimum load on the foundation.

Механические характеристики реставрационных растворов при использовании в их составах метакаолинов

Purpose: To analyze the possibility of using highly active metacaolines in the compositions of gypsum-lime binders for restoration work. To consider the compatibility of the components of restoration solutions based on the reproducibility of their main characteristics, such as mineralogical and chemical composition, physical and mechanical properties and durability. Methods: The work uses physico-chemical research methods, as well as methods of comparative analysis, in accordance with the guidelines of GOST 125-2018 “Gypsum binders. Technical conditions”. Results: It is shown that the introduction of metacaolin into the binder compositions provides an increase in the strength of the binder stone. The optimal amount of metacaolin is 20% in a gypsumlime mixture. It has been experimentally established that an increase in the content of Al2O3 in metacaolin from 39 to 44% leads to an increase in the early compressive strength of a stone made of modified gypsumlime binder. An increase in the content of Al2O3 leads to an increase in strength characteristics. Practical significance: The conducted studies demonstrate that such indicators as the average particle size, specific surface area, have an impact on the hydraulic activity of the pozzolan additive. The quality of highly active metakaolins is directly dependent on the degree of purity of kaolin. However, additives may differ in the mass content of oxides, in particular the content of the main oxides SiO2 and Al2O3. The use of highly active metacaolines in the compositions of gypsum-lime binders makes it possible to restore architectural monuments.

Characterisation of new sustainable gypsum composites with low-density polyethylene waste from single-use bags

The main objective of this research is to determine the feasibility of using Low-Density Polyethylene (LDPE) waste as secondary raw material in the production of new eco-friendly gypsum composites. For this purpose, LDPE waste in crumb form has been incorporated as a partial replacement by weight of the plaster material powder at percentages of 1%, 2% and 3%. Additionally, the gypsum binder in traditional gypsum composites has been replaced for LDPE waste in granulated form, at percentages of 2.5%, 5.0% and 7.5%. The experimental campaign has involved a detailed physical and mechanical characterisation of the gypsum compounds produced to study their potential applications in the construction sector. The results show that more efficient materials are obtained with the addition of these plastic wastes, significantly reducing bulk density and thermal conductivity coefficient compared to traditional gypsum-based materials. Additionally, a considerable reduction in capillary water absorption coefficient and open porosity has been observed. Moreover, the mechanical strengths in flexion and compression surpassed the limits established by current regulations for all the prepared mixtures. In this way, these innovative gypsum composite materials can be useful for application in the production of prefabricated elements, promoting the reincorporation of these plastic wastes, which currently present a challenge from the perspective of sustainability and circular economy.