Vitrification is widely applied to transform hazardous materials into inert slags. Raising the value of the recycled slag is an important issue from an economic point of view. In this study, an alternative approach for mixing a plasma slag with unsaturated polyester resin for making the dough-like molding composites is proposed. Physical properties, including ultimate tensile strength, Rockwell hardness, and the elongation at break, were measured to evaluate the characteristics of the composites. A scanning electron microscope and an X-ray diffractometer were used to examine the micro characteristics of the specimens. The chemical stability of the composites was estimated using the toxicity characteristic leaching procedure and a hot water bathing process. In an optimal slag loading (mass ratio of slag to unsaturated polyester resin) ranged from 0.1 to 0.2, the slag powder improved the physical properties of the composites. With an increased slag loading, excess slag powder weakened the structure of the resin, reducing the ultimate tensile strength and Rockwell hardness. The acid and water bathing tests indicated that the resin is decomposed in a hot environment. However, the slag was not destructed nor were the hazardous metals leached out. The results show that the molding method is an effective technology to recycle the slag.
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