Thermally insulating gypsum composites incorporating aerosil for sustainable energy-saving buildings

This study aimed to investigate the possibility of including aerosils in plaster to develop a highly insulating product. Several plaster samples were prepared by adding different Aerosil percentages (5%, 10%, and 15%). Composite materials were characterized experimentally. The thermo-physical and microstructural characteristics of these samples were determined experimentally. Also, the flexural strength of the samples was systematically evaluated. The results show a clear improvement of the samples' thermal conductivity with a decrease of about 83%. Moreover, the thermal diffusivity is reduced by up to 77%. Furthermore, Aerosil lightens the plaster by reducing its density by up to 45.8%. The materials studied’ exceptional thermal performance and low density confirmed good products for the thermal insulation market, leading to an increase in the energy-saving capabilities of these materials and widening their scope of application to new construction and rehabilitation. The composites containing 10% Aerosil have an excellent property compared to 15% Aerosil based on water absorbency, making them competitive with building materials used in the construction sector. •Aerosil-enhanced plasters are investigated.•The influence of the Aerosil content in plaster on the thermophysical and mechanical properties is studied.•The results confirm that Aerosil-enhanced materials are promising insulating materials.