LEGACY replaces harmful bisphenols with biobased alternatives for the construction industry
In today’s construction sector, durability is key, but it shouldn’t come at the expense of human or environmental health. For decades, epoxy resins have played a critical role in high-performance coatings and protective layers, especially in heavy-duty construction. However, many of these widely used resins are still based on a bisphenol core, especially bisphenol A (BPA), a substance that is increasingly recognised for its harmful effects on both humans and the environment and for the challenges it poses at end of life. The LEGACY project tackled this issue by rethinking the formulation of epoxy resins.
The BPA problem: performance at a cost
Epoxy resins are praised for their strength, durability, and resistance to chemicals and moisture, qualities that make them ideal for use in floors, coatings, adhesives, and more. But their widespread use has a cost. When BPA-based resins degrade, they release toxic substances into the environment, contaminating soil and water and posing long-term risks to human health. This is a critical challenge for businesses striving to meet growing regulatory and consumer demands for safer, more sustainable materials.
A circular alternative: from waste to high-value material for construction
Within the LEGACY project VITO developed a promising solution by turning to lignin, a natural component found in wood and a byproduct of paper production. Usually treated as waste, lignin is both renewable and abundant, making it a valuable resource for companies looking to align with circular economy principles.
LEGACY’s research efforts transform lignin into a powerful building block for new epoxy resins. Using lignin as a renewable feedstock, VITO successfully converted industrial side streams into functional biobased epoxides through advanced depolymerisation and functionalisation processes. These resins were formulated, tested on relevant substrates under real-world conditions, and benchmarked against traditional BPA‑based systems, showing promising mechanical, chemical‑resistance, and application properties.
The LEGACY project demonstrated that biobased, BPA‑free epoxy resins can meet the performance needs of heavy‑duty construction coatings while significantly reducing environmental and health impacts. The product is both practical and effective, making the path to market adoption that much clearer.
Safe, sustainable, and ready for real-world use
LEGACY did not stop at technical development; it also prioritises safety and sustainability every step of the way. To ensure the new resins are truly safe for both people and the environment, LEGACY conducted in-depth eco-toxicological assessments, focusing on key toxicological endpoints and applying in vitro and ecotoxicity testing strategies aligned with the Safe and Sustainable by Design (SSbD) framework. These evaluations consider the potential risks across the entire product life cycle, providing businesses with confidence that the materials they use meet the highest standards and are ready for real-world use.
In parallel, the environmental, economic, and social sustainability of the innovations was assessed through an iterative approach, enabling continuous improvements along the innovation pathway. Both the environmental and socio-economic evaluations were carried out in accordance with the guidance provided by the SSbD framework.
Building with industry, not just for it
From the start, LEGACY has made a point of involving stakeholders throughout the innovation process. A dedicated survey was launched to understand how familiar businesses, particularly SMEs, are with the Safe and Sustainable by Design (SSbD) framework, and to assess their needs, priorities, and readiness to adopt new materials.
Stakeholder meetings have created space for open dialogue, allowing the project to gather insights and feedback on real-world demands. By doing so, LEGACY ensured its solutions are market-relevant and respond to real industrial needs.
Looking ahead: from demonstration to adoption
With the LEGACY project VITO developed and demonstrated fully BPA-free, bio-based epoxy resin coatings, tested and validated across relevant applications. More than just a proof of concept, it represents a viable, high-performing alternative that businesses can adopt with confidence. The project provides industry with actionable formulation guidelines, safety insights, and a clear techno‑economic perspective on future adoption, supporting companies in transitioning toward more sustainable and compliant coating technologies.
LEGACY’s success shows that sustainable bio-based chemistry isn’t just possible, it’s practical, progressive, and within reach for companies of all sizes. This way, the project contributed directly to the broader shift toward a more circular and responsible industrial system.
More information
Interested in exploring the potential of BPA-free, bio-based epoxy resin coatings for your company? Want to gain early access to innovations that will become widely commercially available in the coming years? Don’t hesitate to reach out.
The LEGACY project is supported by the European Union and NextGenerationEU through the Belgium Builds Back Circular (BBBC3) initiative, as part of the National Plan for Recovery and Resilience (NPRR).
