Production of engineered stone from waste foundry sand using epoxy-phenalkamine binder

Discarded foundry sand from casting industries was directly disposed off through landfill resulting shortage of disposal land and environmental threats such as land and water pollution, heavy metals leaching, etc. Therefore, it is necessary to utilize industrial solid waste to develop a wealth material. Development of engineered stone using waste foundry sand (WFS) with suitable polymeric resin would be considered as the best alternative to the above and it is being the subject of research. Further to advance the study, bio-based phenalkamine hardener was used in the DGEBA epoxy resin system (EP) over synthetic hardeners. The EP was varied from 5 wt% to 15 wt% with respect to WFS to attain a desired performance of the stone. The desired property of the engineered stone was achieved at 12.5 wt% and 15 wt% of binder with bending strength of 19.87 MPa and 26.78 MPa, respectively. The outcome of the research paves an avenue for utilization of industrial solid waste and bio-based hardener over synthetic and thus leads to sustainability and technology development. [Display omitted] •Engineered stone possesses excellent bending strength of 26.78 MPa.•WFS-EP stone shows flame retardant with V0 rating.•Developed stone were thermally stable up to 320°C.•EP matrix encapsulated the stone capable to resist UV rays.