Abdessalam Guedri, Noureddine Hamdi, Oscar Baeza-Urrea, Jean-Frank Wagner, Mohamed Faouzi Zagrarni, Fatma Abdallah, Nourhen Mefteh

• Gypsum (GPS) has great potential for structural fire protection and is increasingly used in construction due to its high-water retention and purity. However, many researchers aim to improve its physical and mechanical properties by adding other organic or inorganic materials such as fibers, recycled GPS, and waste residues. This study used a novel method to add non-natural GPS from factory waste (phosphogypsum (PG)) as a secondary material for GPS. This paper proposes to mix these two materials to properly study the effect of PG on the physico-mechanical properties and fire performance of two Tunisian GPSs (GPS1 and GPS2). PG initially replaced GPS at 10, 20, 30, 40, and 50% weight percentage (mixing plan A). The PGs were then washed with distilled water several times. Two more mixing plans were run when the pH of the PG was equal to 2.4 (mixing plan B), and the pH was equal to 5 (mixing plan C). Finally, a comparative study was conducted on the compressive strength, flexural strength, density, water retention, and mass loss levels after 90 days of drying, before/after incineration of samples at 15, 30, 45, and 60 min. The results show that the mixture of GPS1 and 30% PG (mixing plan B) obtained the highest compressive strength (41.31%) and flexural strength (35.03%) compared to the reference sample. The addition of 10% PG to GPS1 (mixing plan A) improved fire resistance (33.33%) and the mass loss (17.10%) of the samples exposed to flame for 60 min compared to GPS2. Therefore, PG can be considered an excellent insulating material, which can increase physico-mechanical properties and fire resistance time of plaster under certain conditions.