Abstract:
Sri Lanka's vibrant textile and apparel industry generates a substantial amount of textile waste,
particularly discarded denim, from its manufacturing processes. Both large-scale production
facilities and small garment workshops contribute to this accumulation, making denim waste an
abundant, yet largely untapped, resource and a significant pollutant. Currently, most discarded
denim ends up in landfills, where synthetic dyes and chemical finishes contaminate ecosystems. To
mitigate this environmental impact, this research investigates the feasibility of designing and
fabricating sustainable flat washers using a denim fabric waste composite. The composite material
was prepared by embedding denim fabric waste into an epoxy resin matrix, which was then crosslinked using a methyl ethyl ketone peroxide catalyst. Different denim fiber-to-resin ratios (1:15,
1:20, 1:25, and 1:30) were prepared according to ASTM standards to investigate their mechanical
properties, including compressive strength, tensile strength, flexural strength, and hardness. The
1:20 denim fiber-to-resin ratio composite consistently exhibited superior mechanical properties
compared to the other composites. The 1:20 denim to resin ratio composite showed the flexural
strength of 356.67 MPa which suggests the material's capability to withstand bending loads
effectively. The tensile strength of 5.33 MPa was achieved by 1:20 fiber to resin composite
indicating sufficient durability for tension-based applications and also exhibited compressive
strength of 29.47 GPa highlights the material's ability to resist high compressive forces, making it
suitable for heavy-load applications. Although their hardness is lower compared to conventional
washers made from aluminum and mild steel, they still provide adequate hardness for many
applications. The findings underscore the potential of using recycled textile waste as a viable
alternative to traditional materials, offering environmental benefits without significantly
compromising mechanical performance. This makes the 1:20 ratio composite flat washers a
promising option for applications where sustainability is a key consideration, such as induction
motor holder, fan head screw, automobile engine holding place and bicycle rear wheel axle washers.
This work contributes to Sustainable Development Goals (SDGs) 9 and 12 in Sri Lanka.
