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<p>This study explores the development of sustainable polymer mortar composites using cashew nut shell oil (CNSL)-based polyurethane resin as a binder and kyanite powder as a filler. The objective was to assess the mechanical strength, durability, and chemical resistance of these composites to determine their feasibility as an alternative to traditional cementitious materials. Polymer mortars were prepared with varying resin (14–20%) and kyanite powder (16–20%) contents, combined with standard sand, and evaluated through mechanical, acid resistance, and microstructural analyses. Experimental results showed that polymer mortar with 18% polyurethane resin and 18% kyanite powder exhibited superior compressive (59.5&#xa0;MPa) and tensile (5.9&#xa0;MPa) strengths compared to conventional mixes. Acid resistance tests demonstrated that these composites retained their mechanical integrity, showing less than 2% weight loss after 28 days of exposure to 30% HCl acid, highlighting their chemical stability. FTIR analysis confirmed the presence of functional groups responsible for polymer-filler bonding, while XRD analysis indicated improved crystallinity and thermal stability. SEM imaging revealed a well-packed microstructure with reduced porosity, contributing to enhanced mechanical performance. Statistical ANOVA analysis confirmed the significant role of kyanite powder in improving mechanical properties, reinforcing the importance of optimized formulations. These findings establish CNSL-polyurethane-based polymer mortar as a high-performance, eco-friendly alternative to cement-based materials. Its potential for reducing dependency on petrochemical-based binders and utilizing industrial waste materials makes it a promising candidate for sustainable construction.</p>

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Utilization of CNSL resin in polymer mortar composites for enhanced durability and rehabilitation of building materials

  • 期刊论文

  • 发表日期：

    2025年4月28日

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  • Pritesh Dattatraya Aher,
  • Yogesh D. Patil,
  • Satish M. Waysal,
  • Bharatkumar Z. Dholakiya

摘要

This study explores the development of sustainable polymer mortar composites using cashew nut shell oil (CNSL)-based polyurethane resin as a binder and kyanite powder as a filler. The objective was to assess the mechanical strength, durability, and chemical resistance of these composites to determine their feasibility as an alternative to traditional cementitious materials. Polymer mortars were prepared with varying resin (14–20%) and kyanite powder (16–20%) contents, combined with standard sand, and evaluated through mechanical, acid resistance, and microstructural analyses. Experimental results showed that polymer mortar with 18% polyurethane resin and 18% kyanite powder exhibited superior compressive (59.5 MPa) and tensile (5.9 MPa) strengths compared to conventional mixes. Acid resistance tests demonstrated that these composites retained their mechanical integrity, showing less than 2% weight loss after 28 days of exposure to 30% HCl acid, highlighting their chemical stability. FTIR analysis confirmed the presence of functional groups responsible for polymer-filler bonding, while XRD analysis indicated improved crystallinity and thermal stability. SEM imaging revealed a well-packed microstructure with reduced porosity, contributing to enhanced mechanical performance. Statistical ANOVA analysis confirmed the significant role of kyanite powder in improving mechanical properties, reinforcing the importance of optimized formulations. These findings establish CNSL-polyurethane-based polymer mortar as a high-performance, eco-friendly alternative to cement-based materials. Its potential for reducing dependency on petrochemical-based binders and utilizing industrial waste materials makes it a promising candidate for sustainable construction.