The growing demand for sustainable and energy-efficient construction materials has driven research on mineral-based composites that combine mechanical strength with superior thermal insulation. This study focuses on the development of thermal insulation panel boards through mechanochemical synthesis using red clay from Kauswagan, treated coal fly ash, and locally sourced diatomaceous earth from Kapatagan, Philippines. Process parameters—including milling time, rotation speed, and material ratios—were optimized to enhance particle refinement, surface reactivity, and interfacial bonding among mineral components.
X-ray diffraction (XRD) and chemical analyses confirmed the formation of aluminosilicate and quartz phases, improving the structural integrity and binding efficiency of the composites. The optimized panels exhibited low water absorption, high bulk density, and enhanced compressive strength, ensuring dimensional stability and durability. Thermal analysis showed a marked reduction in thermal conductivity, demonstrating excellent insulation performance, while SEM imaging revealed dense and well-dispersed microstructures resulting from mechanochemical activation.

The integration of industrial by-products such as treated coal fly ash with natural minerals not only minimizes environmental impact but also promotes the circular utilization of waste materials. Overall, this study demonstrates that mechanochemical synthesis offers an efficient and sustainable approach for developing high-performance thermal insulation panels suitable for green building applications and modern materials engineering.