Given the amount of industrial waste produced and collected in the world today, a recycling and recovery process is needed. The study carried out on this subject focuses on the valorization of one of these industrial wastes, namely the fly ash produced by an ultra-supercritical coal power plant. This paper describes the use and recovery of fly ash as a high percentage reinforcement for the development of a new high-performance composite material for use in various fields. The raw material, fly ash, comes from the staged combustion of coal, which occurs in the furnace of an ultra-supercritical boiler of a coal-fired power plant. Mechanical compression, thermal conductivity, and erosion tests are used to study the mechanical, thermal, and erosion behavior of this new composite material. The mineralogical and textural analyses of samples were characterized using Scanning Electron Microscopy (SEM). SEM confirmed the formation of a new composite by a polymerization reaction. The results obtained are very remarkable, with a high Young’s modulus and a criterion of insulation, which approves the presence of a potential to be exploited in the different fields of materials. In conclusion, the composite material presented in this study has great potential for building material and could represent interesting candidates for the smart city.

Composite materials are commonly employed because of their superior mechanical and electrical properties, as well as their lower density compared to metals. In this research, ceramic waste from the Casablanca region (Morocco) was incorporated into a composite material by combining it with finely ground ceramic fragments (CB) in an unsaturated polymer (UP) resin. The study objectives include the characterization of ceramic waste, evaluation of the mechanical stiffness, influenced by CB content and specimen thickness, and the assessment of its hydric behavior and erosion resistance in aggressive chemical environments. This valorization approach includes a baseline assessment of unmodified ceramic waste and UP’s compatibility and systematic documentation of geometry-dependent stiffness in short-cylinder compression tests. Several methods were used to characterize the material, including XRD, optical microscopy, FTIR-ATR, erosion testing, hydric behavior analysis, surface area measurement, and Young’s modulus. The results showed increased tensile strength and stiffness compared to the starting materials through the evolution of Young’s modulus, demonstrating the enhanced mechanical quality of the composite. Additionally, the material properties changed with the CB content and thickness of the sample, which indicated the potential for optimization. These findings advocate for the reuse of Moroccan industrial ceramic waste as a viable mineral filler for semi-structural polymer composites, supporting the circular economy, environmental sustainability, and public health.