Upcycled Polypropylene and Polytrimethylene Terephthalate Carpet Waste in Reinforcing Cementitious Composites.

In this study, carpet waste fibers--namely, polypropylene (PP) and polytrimethylene terephthalate (PTT) in the form of mono microfibers and hybrid combinations--were studied. The optimization of mono fiber parameters for fiber content (0.1, 0.3, and 0.5%) and length (6, 12, and 24 mm [0.236, 0.742, and 0.945 in.]) were conducted to achieve the optimum strength properties and minimize drying shrinkage. The microstructure, pore structure, and fiber-matrix interfacial properties of the optimized samples were characterized at 7, 28, and 90 days by means of scanning electron microscopy (SEM), X-ray micro-computed tomography (CT), and nanoindentation. The research data revealed that the inclusion of either the optimized mono PP fiber (υf = 0.5% and l = 12 mm [0.472 in.]) or PTT fiber (υf = 0.1% and l = 12 mm [0.472 in.]) improved the compressive strength of 4.3% and 16.1%, and the flexural strength by 11.5% and 9.2% at 28 days, respectively. Hybrid carpet fibers (0.4% PP + 0.1% PTT) provided a greater enhancement in compressive strength of 6.6%, and flexural strength by 13% at 28 days. Drying shrinkage mitigation of mortar over 120 days was recorded as 18.4, 22.3, and 25.8%, corresponding to the addition of 0.5% PP fibers, 0.1% PTT fibers, and hybrid PP/PTT carpet fibers. A pore-refining effect was also observed for mortars with 0.5% PP and hybrid PP/PTT carpet microfibers. The SEM images indicated that the trilobal cross-sectional shape of PTT carpet fibers had a stronger anchoring effect with cement hydrates than the rounded shape of PP carpet fibers. Nanoindentation identified the thickness of the fiber-matrix interfacial transition zone (ITZ) as approximately 15 µm (5.9 × 10-4 in.) for both mono PP and PTT fibers. Approximately 50% of the phases in the vicinity of the fiber-matrix interface comprised a porous structure at 7 days. However, the hydration of clinker over the 90-day period promoted the formation of calcium-silicate-hydrate (C-S-H) and portlandite to form a dense microstructure. [ABSTRACT FROM AUTHOR]