Production and characterization of a novel artificial stone using brick residue and quarry dust in epoxy matrix

Nowadays there is an increasing tendency to reuse industrial residues in order to reduce their environmental impact. A typical alternative for a residue is to be incorporate into a productive process that could be economically viable. In this work, 80wt% of residues, quarry dust and chamotte from brick industries, were incorporated into 20wt% of epoxy resin for the production of a novel artificial ornamental stone to be used in civil construction. For preparation of test specimens the granulometric composition associated with the best packaging of residues was determined by the Simplex method. Artificial stone plates were produced using vibration and vacuum processes. Specimens were tested for mechanical, physical and thermal properties as well as chemical resistance. The developed artificial stone presented mechanical properties within the standard expected range, with rupture stress of 30MPa. Density and thermal behavior were also found to comply with values of natural ornamental stones applied in civil construction. This artificial stone was resistant to chemical attack by HCl, one of the most aggressive acid, which caused a weight loss of only 0.08g. According to wear test, the thickness reduction indicated that the artificial stone could be used for high traffic pavement.