Development and Analysis of Artificial Ornamental Stone with Industrial Wastes and Epoxy Resin

Abstract

The mining and steelmaking industries, while vital for economic and social development, produce and dispose of waste that contributes to environmental instability and discomfort. In this context, this study aimed to develop novel polymer composites intended for Artificial Ornamental Stone (AOS) application by incorporating iron ore tailings (IOTs), quartzite waste (QTZ), and steel slag (SS) into an epoxy (EP) matrix. The chemical, mineralogical, physical, mechanical, morphological, and thermal properties of the materials were assessed. Three waste mixtures were proposed using the Modified Andreassen Curve method, each with 35, 45, and 55 v/v% of EP. The composite properties were evaluated, showing that the composite with QTZ, SS, and 55 v/v% EP exhibited the lowest porosity (0.3%), water absorption (0.1%), and highest flexural strength (41 MPa). The composite containing the three wastes with 55 v/v% EP presented 1.0% porosity, 0.4% water absorption, and 34 MPa flexural strength. Lastly, the composite with IOTs, QTZ, and 55 v/v% EP exhibited 1.1% apparent porosity, 0.5% water absorption, and 23 MPa flexural strength. Therefore, the polymer composites developed with IOTs, QTZ, SS, and EP demonstrated suitable properties for wall cladding and countertops, presenting a potentially sustainable alternative to reduce environmental impacts from the mining and steelmaking industries.