Physical and mechanical properties of epoxy/Kota stone dust/fly ash hybrid composites for light duty structural applications

Abstract Kota stone dust (KSD) and fly ash (FA) are the wastes generated from the construction industry and thermal power plant, respectively. In the present work, a novel hybrid composite is developed to utilize KSD and FA as reinforcing phases in the epoxy matrix. The hand lay‐up method is adopted for the fabrication of 12 sets of samples. Four sets are prepared with single filler KSD and eight samples are prepared with a hybrid combination of KSD and FA. The prepared samples are undergone physical and mechanical tests. To understand the compatibility between filler‐matrix and visualize the dispersion of fillers in epoxy, micrographs are taken using the scanning electron microscope. The density and void contents of the material increases with an increase in filler content. The maximum water absorption measured is 0.96% for the combination of epoxy with 40 wt% KSD and 10 wt% FA. From mechanical testing, maximum tensile strength and flexural strength obtained is 34.4 MPa and 65.4 MPa, respectively, for a combination of epoxy with 20 wt% KSD and 5 wt% FA. Compressive strength and hardness increase with either of the content of the filler and reaches 116.28 MPa and 104 Shore D number, respectively, with 40 wt% KSD and 10 wt% FA. From experimentation, it was found that mechanical properties of the hybrid composites are better as compared to that of single filler composites though physical properties are slightly compromised by hybridization of fillers.