Manufacturing and properties of epoxy-basalt fiber laminates filled with waste rigid polyurethane foam for structural and damping applications

Global economic development and efforts to enhance overall quality of life yielded growth in the construction and building sector, increasing not only the demand for materials but also waste generation. Its efficient management should take full advantage of the exceptional properties of building materials. The presented work is the first reported study on possibly using waste rigid polyurethane (PUR) foam, commonly applied as thermal insulation, as particle-shaped low-density filler for manufacturing hybrid epoxy-basalt composites. It investigated the potential management of waste PUR foam by applying it as a functional filler to hybridize epoxy-basalt composites. Herein, 1, 2, 5, and 10 wt% PUR powder were introduced into the thermoset-based composites prepared using the vacuum bag method. A comprehensive analysis of mechanical and thermomechanical properties correlated with changes in the composite structure revealed the beneficial aspects of the waste filler addition associated with increased heat deflection temperature and mechanical damping ability. Introducing micrometric domains of the waste filler changed the composites' fracture character. It enabled maintaining the impact strength of composites containing up to 5 wt% of PUR powder at the level of unfilled epoxy resin. However, despite that, the incorporation of PUR powder unfavorably affected tensile and flexural performance, yielding a significant drop in moduli and strength. Graphical abstract