The incorporation of calcite marble waste in epoxy resin for the production of artificial stone can represent a technical-economical method and environmentally viable, reducing the amount of discarded residue in the environment, and adding economic value to marble waste and enabling the generation of jobs. The production of natural stone in Brazil recorded an exorbitant amount of waste generated in marble processing. Only 75% of marble taken from the deposits it becomes the finished product the rest is discarded. This study aimed to evaluate the mechanical and physical properties of produced artificial marble based in calcite marble waste and epoxy resin. The vacuum vibro compression was used for production as artificial marble and the specimens were cut according to standart NBR 15845. The results indicated that the artificial stones exhibit physical and mechanical results within the expected range for these kinds of materials. Artificial marble with a maximum flexural strength of 31,8 MPa, maximum compressive strength of 85,2 MPa, water absorption below 0.05% and a satisfactory adhesion between load and resin were obtained for the materials produced with 80% wt marble particles and 20% wt epoxy resin, enabling the development of an alternative material for civil construction applications.

Compact artificial stones are widely used in buildings around the world, and the expected demand to the next years is increasing. In this study, stone fragments from marble processing are recycled as raw materials for produce compact artificial stones using compaction in a vacuum environment (100 mm Hg). Crushed marble waste (80 and 85%wt) are mixed with unsaturated polyester resin as binder. Materials were processed under compaction pressures of 1 and 10 MPa, for 20 minutes at 90 °C. Artificial marble with flexural ultimate strength of 25 MPa, water absorption below 0.2% and homogeneous particles distribution were obtained to materials produced with 80%wt of marble particles. To artificial marbles with 85%wt of particles, lower flexural ultimate strength and higher water absorption were observed (18 MPa and 0.4% respectively). In addition, the greater compaction pressure used improves slightly values obtained in 3 points bending test. Furthermore, tangent delta peaks at 115 °C were observed to evaluated artificial marbles.

The present work is part of an innovation research project aiming to develop artificial stone from industrial wastes. In principle, the project goal is to fabricate artificial stones with improved characteristics to be used as plates for housing and road construction. In this work, the specific industrial residue was an electrostatically precipitated powder obtained from the initial sintering stage of an integrated steelmaking plant. Plates were produce by vacuum vibro-compression of epoxy resin mixed with 80 and 85 wt% of this specific residue. After curing, the plates were characterized for physical parameters and mechanical properties. The microstructural aspect of the finishing surface was analyzed for both novel artificial stones by scanning electron microscopy. The results indicated that the 80% residue incorporated artificial stone is superior to the 85% residue incorporated and markedly stronger than a commercial artificial stone, incorporated with granite residue, with comparable density and water absorption. These characteristics favor the technical substitution of the presently investigated artificial for the commercial stone. In particular, based on wear tests, the residue incorporated artificial stone would be restricted to application as pavement in medium traffic roads.