Performance Optimization of Ceramic-Waste-Based Composite Materials for Structural Applications

Composite materials are commonly employed because of their superior mechanical and electrical properties, as well as their lower density compared to metals. In this research, ceramic waste from the Casablanca region (Morocco) was incorporated into a composite material by combining it with finely ground ceramic fragments (CB) in an unsaturated polymer (UP) resin. The study objectives include the characterization of ceramic waste, evaluation of the mechanical stiffness, influenced by CB content and specimen thickness, and the assessment of its hydric behavior and erosion resistance in aggressive chemical environments. This valorization approach includes a baseline assessment of unmodified ceramic waste and UP’s compatibility and systematic documentation of geometry-dependent stiffness in short-cylinder compression tests. Several methods were used to characterize the material, including XRD, optical microscopy, FTIR-ATR, erosion testing, hydric behavior analysis, surface area measurement, and Young’s modulus. The results showed increased tensile strength and stiffness compared to the starting materials through the evolution of Young’s modulus, demonstrating the enhanced mechanical quality of the composite. Additionally, the material properties changed with the CB content and thickness of the sample, which indicated the potential for optimization. These findings advocate for the reuse of Moroccan industrial ceramic waste as a viable mineral filler for semi-structural polymer composites, supporting the circular economy, environmental sustainability, and public health.