Preparation and Properties of Environmentally Friendly Resin-Based Artificial Stones Fabricated from Ceramic Waste

Abstract

The rapid development of the traditional ceramic industry contributes considerably to economic advancements; however, the ecological hazards caused by the large amount of sintered ceramic wastes generated during ceramic production and discarded at landfill sites are becoming increasingly severe. To realize the large-scale resource utilization of ceramic waste, sintered ceramic waste was used in this study to partially replace natural quartz sand, and new environmentally friendly artificial stones were fabricated by using vacuum vibration molding and inorganic/organic composite curing technology. The effects of ceramic waste addition and particle size on the mechanical strength, surface hardness, wear resistance, stain resistance, and microstructure of artificial stone materials were investigated. The results showed that the replacement of quartz sand with 40–55% ceramic waste significantly improved the mechanical strength of artificial stone and maintained sufficient surface hardness and wear resistance. When 45% of ceramic waste powder (particle size ≥ 120 mesh) was added, the bending strength of the artificial stone was 64.4 MPa, whereas when 55% of ceramic waste particles with different particle sizes were added, the maximum compressive strength was 158.7 MPa. Good wear resistance and sufficient Moh’s hardness of 5.5–6.5 was obtained for all the samples. The prepared ceramic waste artificial stone also had a dense microstructure and low water absorption and porosity, which are helpful for improving stain resistance.