The growing demand for waste utilization has attracted much attention in society as well as from the researchers. This chapter targets converting the discarded foundry sand as solid waste into a building product to utilize in the construction industry. Disposal of waste (spent) foundry sand through landfill affects the environmental quality, agricultural land, and groundwater due to the presence of toxic elements. In consideration of the above factors, utilize the waste foundry sand as a filler material to the polymeric binder. The polymeric binder selected is Diglycidylether of Bisphenol-A resin with phenalkamine hardener used in the ratio of 2:1. The varied weight percentages of binders viz., 5wt%, 10wt%, 15wt% and 30wt% were reinforced with spent foundry sand and their characteristics were studied. In data obtained from different studies with varied weight percentage of epoxy polymer binder, the optimal polymeric dosage was determined based on the physio-chemical properties, mechanical, thermal and durability aspects to achieve the better performance of product and was found to be 15%. The present study paves an avenue for safe and useful utilization of spent foundry sand and a novel method of solid waste management to mitigate environmental problems associated with disposal of spent foundry sand.