Graphical Abstract
Metrics
Eco-mechanical performance of fly ash-modified concrete blocks: strength development and CO2 emission assessment
Corresponding Author(s) : Basirul Alam Sarker Ovy
Journal of Applied Materials and Technology, Vol. 8 No. 2 (2027): March 2027
License
Copyright (c) 2026 Basirul Alam Sarker Ovy, Md. Abul Bashar, Md. Al Imran Hossan

This work is licensed under a Creative Commons Attribution 4.0 International License.
Abstract
Fly ash is a waste product from coal combustion and can be used as a partial substitute for cement, thereby aiding in the production of lower-carbon-footprint concrete. Most studies have focused only on mechanical or environmental performance, and fewer studies are available that integrate properties of fly ash concrete in terms of mechanical performance, water absorption and CO2 emissions at low replacement rates (£20%). Accordingly, this study aims to meet this need by developing an integrated eco-mechanical evaluation to identify a practical replacement criterion based on three indicators. Five mixtures with varying amounts of fly ash (0%, 5%, 10%, 15% and 20%) were developed. The compressive strength, splitting tensile strength and water absorption after 28 days were tested in the laboratory, while the cradle-to-gate CO2 emission was calculated by calculating the CO2 emission from every constituent of the concrete. These results indicate that the 5% fly ash was able to achieve about 94.3% compressive strength of the control mixture, while also reducing CO2 emissions by 4.71%, yielding the best strength–carbon balance of the mixtures. Increased replacement levels resulted in higher emission reduction, up to 18.85% at 20% fly ash, while producing more significant strength reductions. The findings serve as the basis for policy and specific specifications that would be associated with appropriate utilization of locally available fly ash in accordance with strength and durability requirements. It could be encouraged through material availability, transport, processing, quality control and the possibility of cement savings at the project level, through financial incentives or procurement preferences and performance-based standards.
Keywords
Download Citation
Endnote/Zotero/Mendeley (RIS)BibTeX
References
V. V. Nguyen et al., “Low-Density Geopolymer Composites for the Construction Industry,” Polymers, vol. 14, no. 2, p. 304, Jan. 2022, doi: 10.3390/polym14020304.
G. Habert et al., “Environmental impacts and decarbonization strategies in the cement and concrete industries,” Nat Rev Earth Environ, vol. 1, no. 11, pp. 559–573, Sep. 2020, doi: 10.1038/s43017-020-0093-3.
P. Friedlingstein et al., “Global Carbon Budget 2020,” Earth Syst. Sci. Data, vol. 12, no. 4, pp. 3269–3340, Dec. 2020, doi: 10.5194/essd-12-3269-2020.
M. Antunes, R. L. Santos, J. Pereira, P. Rocha, R. B. Horta, and R. Colaço, “Alternative Clinker Technologies for Reducing Carbon Emissions in Cement Industry: A Critical Review,” Materials, vol. 15, no. 1, p. 209, Dec. 2021, doi: 10.3390/ma15010209.
S. O. Bonney, J. Song, M. Liphadzi, and K. O. Adjei, “Modelling and Forecasting Concrete Demand for Sustainable Infrastructure Development in Developing Economies: Evidence from Ghana,” Buildings, vol. 16, no. 4, p. 850, Feb. 2026, doi: 10.3390/buildings16040850.
J. He, S. Kawasaki, and V. Achal, “The Utilization of Agricultural Waste as Agro-Cement in Concrete: A Review,” Sustainability, vol. 12, no. 17, p. 6971, Aug. 2020, doi: 10.3390/su12176971.
S. Von Greve-Dierfeld et al., “Understanding the carbonation of concrete with supplementary cementitious materials: a critical review by RILEM TC 281-CCC,” Mater Struct, vol. 53, no. 6, p. 136, Dec. 2020, doi: 10.1617/s11527-020-01558-w.
M. Firdous and B. Singh, “Supplementary cementitious materials in concrete and associated structural and environmental benefits: A review,” IOP Conf. Ser.: Earth Environ. Sci., vol. 889, no. 1, p. 012077, Nov. 2021, doi: 10.1088/1755-1315/889/1/012077.
D. Runganga, F. Okonta, and I. Musonda, “Strength and Durability Properties of High-Volume Fly Ash (HVFA) Binders: A Systematic Review,” CivilEng, vol. 5, no. 2, pp. 435–460, May 2024, doi: 10.3390/civileng5020022.
T. A. Fode, Y. A. Chande Jande, and T. Kivevele, “Effects of different supplementary cementitious materials on durability and mechanical properties of cement composite – Comprehensive review,” Heliyon, vol. 9, no. 7, p. e17924, Jul. 2023, doi: 10.1016/j.heliyon.2023.e17924.
C. Karakosta and J. Papathanasiou, “Decarbonizing the Construction Sector: Strategies and Pathways for Greenhouse Gas Emissions Reduction,” Energies, vol. 18, no. 5, p. 1285, Mar. 2025, doi: 10.3390/en18051285.
I. H. Shah, S. A. Miller, D. Jiang, and R. J. Myers, “Cement substitution with secondary materials can reduce annual global CO2 emissions by up to 1.3 gigatons,” Nat Commun, vol. 13, no. 1, p. 5758, Sep. 2022, doi: 10.1038/s41467-022-33289-7.
N. Yaseen, S. Alcivar-Bastidas, M. Irfan-ul-Hassan, D. M. Petroche, A. U. Qazi, and A. D. Ramirez, “Concrete incorporating supplementary cementitious materials: Temporal evolution of compressive strength and environmental life cycle assessment,” Heliyon, vol. 10, no. 3, p. e25056, Feb. 2024, doi: 10.1016/j.heliyon.2024.e25056.
S. Sakir, S. N. Raman, Md. Safiuddin, A. B. M. A. Kaish, and A. A. Mutalib, “Utilization of By-Products and Wastes as Supplementary Cementitious Materials in Structural Mortar for Sustainable Construction,” Sustainability, vol. 12, no. 9, p. 3888, May 2020, doi: 10.3390/su12093888.
V. K. Yadav et al., “Status of Coal-Based Thermal Power Plants, Coal Fly Ash Production, Utilization in India and Their Emerging Applications,” Minerals, vol. 12, no. 12, p. 1503, Nov. 2022, doi: 10.3390/min12121503.
J. S. Volz, “High-Volume Fly Ash Concrete for Sustainable Construction,” AMR, vol. 512–515, pp. 2976–2981, May 2012, doi: 10.4028/www.scientific.net/AMR.512-515.2976.
D. Das and P. K. Rout, “A Review of Coal Fly Ash Utilization to Save the Environment,” Water Air Soil Pollut, vol. 234, no. 2, p. 128, Feb. 2023, doi: 10.1007/s11270-023-06143-9.
Y. Miao et al., “The Effect of Industrial Byproducts Fly Ash and Quartz Powder on Cement Properties and Environmental Benefits Analysis,” Applied Sciences, vol. 15, no. 9, p. 5093, May 2025, doi: 10.3390/app15095093.
G. L. Golewski, “The Role of Pozzolanic Activity of Siliceous Fly Ash in the Formation of the Structure of Sustainable Cementitious Composites,” Sustainable Chemistry, vol. 3, no. 4, pp. 520–534, Dec. 2022, doi: 10.3390/suschem3040032.
F. U. A. Shaikh and S. W. M. Supit, “Compressive strength and durability properties of high volume fly ash (HVFA) concretes containing ultrafine fly ash (UFFA),” Construction and Building Materials, vol. 82, pp. 192–205, May 2015, doi: 10.1016/j.conbuildmat.2015.02.068.
Y.-C. Choi, “Hydration and Mechanical Properties of High-Volume Fly Ash Cement under Different Curing Temperatures,” Materials, vol. 17, no. 19, p. 4716, Sep. 2024, doi: 10.3390/ma17194716.
Z. F. Akbulut, D. Yavuz, T. A. Tawfik, P. Smarzewski, and S. Guler, “Enhancing Concrete Performance through Sustainable Utilization of Class-C and Class-F Fly Ash: A Comprehensive Review,” Sustainability, vol. 16, no. 12, p. 4905, Jun. 2024, doi: 10.3390/su16124905.
B.-J. Kim, G.-W. Lee, and Y.-C. Choi, “Hydration and Mechanical Properties of High-Volume Fly Ash Concrete with Nano-Silica and Silica Fume,” Materials, vol. 15, no. 19, p. 6599, Sep. 2022, doi: 10.3390/ma15196599.
S. K. Sahu, S. Kamalakkannan, and P. K. Pati, “Fly ash utilization in concrete tiles and paver blocks,” in New Materials in Civil Engineering, Elsevier, 2020, pp. 897–917. doi: 10.1016/B978-0-12-818961-0.00030-2.
K. C. Onyelowe et al., “Global warming potential-based life cycle assessment and optimization of the compressive strength of fly ash-silica fume concrete; environmental impact consideration,” Front. Built Environ., vol. 8, p. 992552, Oct. 2022, doi: 10.3389/fbuil.2022.992552.
R. Kurda, J. D. Silvestre, and J. De Brito, “Toxicity and environmental and economic performance of fly ash and recycled concrete aggregates use in concrete: A review,” Heliyon, vol. 4, no. 4, p. e00611, Apr. 2018, doi: 10.1016/j.heliyon.2018.e00611.
K. R. O’Brien, J. Ménaché, and L. M. O’Moore, “Impact of fly ash content and fly ash transportation distance on embodied greenhouse gas emissions and water consumption in concrete,” Int J Life Cycle Assess, vol. 14, no. 7, pp. 621–629, Nov. 2009, doi: 10.1007/s11367-009-0105-5.
G. Li et al., “Fly Ash Application as Supplementary Cementitious Material: A Review,” Materials, vol. 15, no. 7, p. 2664, Apr. 2022, doi: 10.3390/ma15072664.
D. Cheng et al., “Projecting future carbon emissions from cement production in developing countries,” Nat Commun, vol. 14, no. 1, p. 8213, Dec. 2023, doi: 10.1038/s41467-023-43660-x.
J. A. Olsson, S. A. Miller, and M. G. Alexander, “Near-term pathways for decarbonizing global concrete production,” Nat Commun, vol. 14, no. 1, p. 4574, Jul. 2023, doi: 10.1038/s41467-023-40302-0.
R. Liong, S. D. Puspitasari, F. S. Binhudayb, and S. Hesham, “Advancements in Green Materials for Concrete in South East Asia: A Mini Review,” Trop. Environ. Biol. Technol., vol. 2, no. 1, pp. 44–56, Jun. 2024, doi: 10.53623/tebt.v2i1.441.
B. K. Shukla et al., “Sustainable construction practices with recycled and waste materials for a circular economy,” Asian J Civ Eng, vol. 25, no. 7, pp. 5255–5276, Nov. 2024, doi: 10.1007/s42107-024-01111-y.
Y. Luo, Y. Wu, S. Ma, S. Zheng, Y. Zhang, and P. K. Chu, “Utilization of coal fly ash in China: a mini-review on challenges and future directions,” Environ Sci Pollut Res, vol. 28, no. 15, pp. 18727–18740, Apr. 2021, doi: 10.1007/s11356-020-08864-4.
V. K. Yadav et al., “Status of Coal-Based Thermal Power Plants, Coal Fly Ash Production, Utilization in India and Their Emerging Applications,” Minerals, vol. 12, no. 12, p. 1503, Nov. 2022, doi: 10.3390/min12121503.
F. M. Suryani, S. Rizal, A. Abdullah, and M. Isya, “Fly Ash Substitution in Lightweight Concrete for Rigid Pavement Construction on Low-Bearing-Capacity Soil,” Sustainability, vol. 15, no. 21, p. 15239, Oct. 2023, doi: 10.3390/su152115239.
T. Bilir, B. F. Aygun, J. Shi, O. Gencel, and T. Ozbakkaloglu, “Influence of Different Types of Wastes on Mechanical and Durability Properties of Interlocking Concrete Block Paving (ICBP): A Review,” Sustainability, vol. 14, no. 7, p. 3733, Mar. 2022, doi: 10.3390/su14073733.
S. Supit, K. Boonserm, and Priyono, “Mechanical properties and environmental impact assessment of eco-friendly pervious pavement blocks containing high-volume fly ash,” City Built Enviro, vol. 3, no. 1, p. 16, Aug. 2025, doi: 10.1007/s44213-025-00057-4.
D. N. Subramaniam and N. Sathiparan, “Comparative study of fly ash and rice husk ash as cement replacement in pervious concrete: mechanical characteristics and sustainability analysis,” International Journal of Pavement Engineering, vol. 24, no. 2, p. 2075867, Jan. 2023, doi: 10.1080/10298436.2022.2075867.
M. F. Asef, K. S. Ahmed, and M. Ahmed, “Physical and Strength Properties of Cements Manufactured in Bangladesh: A Case Study,” MIJST, vol. 10, pp. 49–59, Jun. 2022, doi: 10.47981/j.mijst.10(01)2022.319(49-59).
NSW Government, “How to calculate the embodied carbon of a concrete mix - factsheet,” 2025.