Potential Application of Epoxy Powder Coating Waste in Concrete: Strength Properties and Durability of Concrete

This paper presents the results of tests on concrete modified with waste powder from the production of epoxy powder coating, planned using design of experiment’s (DOE) experimental design methods. The scope of the investigation included detailed identification of the waste itself (TG/DTA, FTIR, SEM + EDS, laser diffraction), as well as evaluation of selected properties of concretes containing this waste, including compressive strength, density, and durability parameters such as frost resistance and chemical resistance. The scope of the experiment was defined by varying modifier content in the range of 4 to 11% of the cement mass and a water-cement ratio between 0.44 and 0.56. The concrete mixes obtained were characterized by good workability, fluidity, and consistency stability over time, despite the use of the modifier as an additional component in the concrete mix. No adverse effect of the waste used on the durability of the concrete was observed. Concretes modified with waste from the production of epoxy powder coating achieved a frost resistance class of F150 and showed good resistance to chemically aggressive environments (sulfates and chlorides). No products indicating adverse reactions between waste powder and reagents were found. The use of the DOE approach made it possible to determine, in the form of functional relationships, the influence of the modifier content depending on the water-cement ratio (w/c) of the concrete on its compressive strength and density. In general, a decrease in the compressive strength of concrete containing a waste powder modifier was observed, ranging from approximately 11% to 26% compared to unmodified concrete. However, the trend of decreasing compressive strength was reduced as the water-cement ratio of concrete decreased. At a water-cement ratio (w/c) of 0.443, no further decrease in compressive strength was observed. Concrete with 11% waste powder and a w/c ratio of 0.443 achieved 4.7% higher compressive strength than unmodified concrete with the same water-cement ratio. A beneficial interaction was found between a carboxylate-based plasticizer and the waste powder from the production of epoxy powder coatings. The proposed method of using waste as a concrete component is promising and may contribute to reducing the problem of waste management, as well as greenhouse gas emissions.