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<p>To minimize environmental impact and guarantee structural efficiency, the construction industry increasingly adopts sustainable, high-performance materials. This study investigates the use of 20% gypsum (G) as a partial cement replacement and 100% copper slag (CS) as a fine-aggregate replacement in paver block manufacture. The optimal blend achieved compressive strengths of 45.6&#xa0;MPa at 7 days and 59.85&#xa0;MPa at 28 days, exceeding the IS 15658:2006 criteria for heavy-load applications. Water absorption remained within acceptable limits (4.65–5.43%), indicating low permeability and enhanced durability, while flexural strength ranged from 2.77&#xa0;MPa to 3.10&#xa0;MPa, providing adequate bending resistance. Regression models developed via response surface methodology (RSM) and validated by ANOVA produced R<sup>2</sup> values above 0.99, confirming the statistical significance of the material proportions. A cost analysis revealed a 12.59% reduction in overall material expenses, underscoring the economic viability of this combination. These findings demonstrate that Copper slag–Gypsum-based paver blocks offer a viable alternative to conventional materials for pavements, industrial flooring, and roadways. Future research should address long-term durability, field-scale performance, and feasibility of large-scale implementation to further sustainable infrastructure development.</p>

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Optimization of copper slag and gypsum in sustainable paver blocks: mechanical performance, durability, and cost analysis

  • 期刊论文

  • 发表日期：

    2025年8月30日

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  • Hrushikesh N. Kedar,
  • Amey Naik,
  • Aditya Jore,
  • Gaurav Shinde,
  • Ashwini Damale,
  • Satyajit Patel

摘要

To minimize environmental impact and guarantee structural efficiency, the construction industry increasingly adopts sustainable, high-performance materials. This study investigates the use of 20% gypsum (G) as a partial cement replacement and 100% copper slag (CS) as a fine-aggregate replacement in paver block manufacture. The optimal blend achieved compressive strengths of 45.6 MPa at 7 days and 59.85 MPa at 28 days, exceeding the IS 15658:2006 criteria for heavy-load applications. Water absorption remained within acceptable limits (4.65–5.43%), indicating low permeability and enhanced durability, while flexural strength ranged from 2.77 MPa to 3.10 MPa, providing adequate bending resistance. Regression models developed via response surface methodology (RSM) and validated by ANOVA produced R2 values above 0.99, confirming the statistical significance of the material proportions. A cost analysis revealed a 12.59% reduction in overall material expenses, underscoring the economic viability of this combination. These findings demonstrate that Copper slag–Gypsum-based paver blocks offer a viable alternative to conventional materials for pavements, industrial flooring, and roadways. Future research should address long-term durability, field-scale performance, and feasibility of large-scale implementation to further sustainable infrastructure development.