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<p>This study evaluates the potential of Kota Stone Powder (KSP) and Fly Ash (FA) as sustainable partial replacements for cement in M30 grade concrete. Six concrete mixes were developed, including a control mix (CC) and five binary blends with equal proportions of FA and KSP, varying from 2.5% to 12.5% each (total replacement: 5%–25%). The experimental program assessed fresh properties, mechanical strengths (compressive, split tensile, and flexural), durability (acid resistance, sulfate resistance, water absorption), and microstructural features using Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD). A cost-performance analysis and a Multi-Objective Optimization (MOO) approach were employed to identify the most efficient mix based on compressive strength, durability, and cost-efficiency. Results revealed that a 15% total replacement (KF-3: 7.5% FA + 7.5% KSP) offered optimal performance—enhancing workability, mechanical strength, and durability while significantly reducing cement consumption and cost. SEM and XRD analyses confirmed a denser matrix with reduced porosity and increased formation of C–S–H and ettringite phases. The MOO results validated KF-3 as the Pareto-optimal solution with the highest overall fitness score, highlighting the synergy between experimental findings and optimization modeling. This study demonstrates that FA and KSP can serve as effective supplementary cementitious materials, enabling eco-efficient, cost-effective concrete production aligned with circular economy and sustainability objectives.</p>

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Multi-objective optimization and experimental evaluation of fly ash and Kota Stone Powder as sustainable cement replacements in M30 grade concrete

  • 期刊论文

  • 发表日期：

    2025年10月1日

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  • Krishna Mohan Donderiya,
  • Hemant Shrivastava,
  • Abhilash Shukla,
  • Ashish Gupta

摘要

This study evaluates the potential of Kota Stone Powder (KSP) and Fly Ash (FA) as sustainable partial replacements for cement in M30 grade concrete. Six concrete mixes were developed, including a control mix (CC) and five binary blends with equal proportions of FA and KSP, varying from 2.5% to 12.5% each (total replacement: 5%–25%). The experimental program assessed fresh properties, mechanical strengths (compressive, split tensile, and flexural), durability (acid resistance, sulfate resistance, water absorption), and microstructural features using Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD). A cost-performance analysis and a Multi-Objective Optimization (MOO) approach were employed to identify the most efficient mix based on compressive strength, durability, and cost-efficiency. Results revealed that a 15% total replacement (KF-3: 7.5% FA + 7.5% KSP) offered optimal performance—enhancing workability, mechanical strength, and durability while significantly reducing cement consumption and cost. SEM and XRD analyses confirmed a denser matrix with reduced porosity and increased formation of C–S–H and ettringite phases. The MOO results validated KF-3 as the Pareto-optimal solution with the highest overall fitness score, highlighting the synergy between experimental findings and optimization modeling. This study demonstrates that FA and KSP can serve as effective supplementary cementitious materials, enabling eco-efficient, cost-effective concrete production aligned with circular economy and sustainability objectives.