Abdessalam Guedri, Kawthar Yahya, Noureddine Hamdi, Oscar Baeza Urrea, Jean Frank Wagner, Mohamed Faouzi Zagrarni

• Estimating the amount of material without significant losses at the end of hybrid casting is a problem addressed in this study. To minimize manufacturing costs and improve the accuracy of results, a correction factor (CF) was used in the formula to estimate the volume percent of the material in order to reduce material losses during the sample manufacturing stage, allowing for greater confidence between the approved blending plan and the results obtained. In this context, three material mixing schemes of different sizes and shapes (gypsum plaster, sand (0/2), gravel (2/4), and Posidonia oceanica fibers (PO)) were created to verify the efficiency of CF and more precisely study the physico-mechanical effects on the samples. The results show that the use of a CF can reduce mixing loss to almost 0%. The optimal compressive strength of the sample (S1B) with the lowest mixing loss was 7.50 MPa. Under optimal conditions, the addition of PO improves mix volume percent correction (negligible), flexural strength (5.45%), density (18%), and porosity (3.70%) compared with S1B. On the other hand, the addition of PO thermo-chemical treatment by NaOH increases the compressive strength (3.97%) compared with PO due to the removal of impurities on the fiber surface, as shown by scanning electron microscopy. We then determined the optimal mixture ratio (PO divided by a mixture of plaster, sand, and gravel), which equals 0.0321 because Tunisian gypsum contains small amounts of bassanite and calcite, as shown by the X-ray diffraction results.