Valorization of Marble Waste through Resin-Based Composite Tile Development: Exploratory Assessment of Formulation-Dependent Fragmentation

Abstract

Marble processing generates substantial quantities of powder and stone residues that can potentially be recovered as secondary materials for construction-related applications. This study explores the valorization of marble-processing waste powder as a mineral filler in resin-based composite tiles and compares the fragmentation responses of three tested formulations. An exploratory experimental design was employed using 20 × 20 cm composite tiles fabricated from marble powder, resin, and catalyst. Three formulations were prepared: S1 (250 g marble powder and 250 g resin), S2 (200 g marble powder and 300 g resin), and S3 (150 g marble powder and 350 g resin). Three specimens were prepared for each formulation, resulting in nine specimens. Each specimen was subjected to an 8 kg load dropped from a height of 140 cm, and the resulting fragmentation was assessed qualitatively based on visible breakage and the presence of small fragments. S2 exhibited relatively limited fragmentation and fewer small fragments, whereas S1 and S3 showed more extensive breakage. The findings indicate that the tested formulations exhibited different fragmentation responses and that marble powder proportion did not show a simple monotonic relationship with fragmentation under the applied test conditions. However, because catalyst quantities also varied among the formulations, the observed differences cannot be attributed solely to marble powder content. The study provides preliminary evidence for converting marble-processing residue into resin-based composite tiles as a potential secondary-material utilization pathway. Further research should employ controlled formulation, standardized mechanical testing, material characterization, durability assessment, and environmental and economic evaluation