Optimization of Mix Design for Lightweight Boards Based on GGBFS–Waste Rock Wool Using Response Surface Methodology

This study aimed to establish the optimal mix proportions for eco-friendly lightweight boards based on Ground Granulated Blast-furnace Slag (GGBFS) and waste rock wool using Response Surface Methodology (RSM). The investigation focused on optimizing three key properties: flexural failure load (Y₁), moisture content (Y₂), and specific gravity (Y₃). ANOVA results identified Binder and Perlite as the most dominant and statistically significant factors, exhibiting critical conflicting effects necessary for balancing strength and lightweight goals. Wollastonite showed a non-linear effect on flexural strength, peaking at an intermediate level. A Response Optimization simulation, targeting a minimum flexural load of 400 N, moisture content of 2.0%, and specific gravity of 0.80, yielded an optimal mix proportion: Binder 52.12%, Perlite 48.45%, and Wollastonite 7.37%. This blend achieved a high Composite Desirability (D) of 0.8725. Experimental verification confirmed the model’s reliability. The measured flexural load (408.54 N) successfully exceeded the 400 N target, and all measured values exhibited a low error margin (under 7%) compared to the predicted values. This optimized mix proportion provides a reliable foundation for developing high-performance, sustainable lightweight construction materials.