A new sustainable and environmentally friendly composite material has been developed from coconut fibre particles and recycled polystyrene dissolved in chloroform. Three particle sizes and four reinforcement ratios were used. The composite was moulded by cold pressing without measuring the pressure but by fixing the thickness. The density (592.53 – 723.03) kg.m-3 shows the lightness of the material. The moisture content (6.63 – 8.35%), water absorption rate (54.06 – 109.42) % and thickness swelling rate (2.86 – 16.09) % are within the acceptable range of ≤16% for use in dry and wet areas, except for formulations with a 55% reinforcement rate. The absorption kinetics of the composites produced show hydrophilicity and correlate with Page’s model. Microscopic examination shows better interfacial cohesion with low visible porosity for composites with the lowest particle content and reinforcement rate. Young’s modulus (129.29 – 530.95) MPa and mechanical stress at break (1.26 – 6.508) MPa are relatively low compared to structural materials. Thermal conductivity (0.22 – 0.347) W.m-1.k-1 and thermal effusivity (571.9 – 856.7) J.m-2.K-1.S-1/2 are within the range of thermally insulating materials. Smaller particles show better cohesion with the matrix. These materials are intended for use in furniture, false ceilings, house partitions, computer stands and telephone booth doors.
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