The adoption of sustainable building policies and the society’s increasing emphasis on sustainability underscore the urgent need to evaluate the environmental and economic impact of construction materials. This study examines the effects of incorporating polyurethane foam waste into gypsum-based ceiling tiles. It compares its economic performance and eco-efficiency with conventional alternatives. Methodologically, Life Cycle Cost Analysis (LCCA) quantifies total life cycle costs, followed by Eco-Efficiency Assessment (EE), considering results from both Life Cycle Assessment (LCA) and LCCA. Our findings reveal a compelling 5.91% cost advantage for the novel precast, driven by enhanced production capacity resulting from shorter drying times. The economic benefits of this approach are underscored by a detailed breakdown of cost savings in production phases. Furthermore, the EE remarks a substantial 7.5% boost, emphasizing the positive environmental impact achieved through reduced resource consumption and lower emissions combined with lower life-cycle costs. These results highlight the economic viability and eco-efficiency of polymeric waste-integrated gypsum ceiling tiles for environmental sustainability. The specific percentage improvements in cost and eco-efficiency provide a quantitative basis for understanding the advantages of adopting these innovative materials.
