Affordable Solid Block (SB) Using Industrial Waste Fly Ash Binder and Ferrochrome Slag Fine Aggregate

Cement is a strong bonding material produced in all countries. Carbon dioxide (CO2) is emitted as a by-product during the chemical conversion stage of the clinker process in cement production. It ranges from 7 to 10% globally in the initial clinker production. To minimize this emission, the Portland product is replaced by fly ash. As a result, 55% of fly ash and 45% of OPC53 are utilized as a binder. In addition, industrial slag sand is supplanted to diminish the consumption of virgin sand (< 4.75 mm) and 100% of industrial waste ferrochrome slag sand (FS). The slag as fine aggregate replacement enhances the sustainability of the natural resource. The crushed gravel sand (CGS) and FS have a density of 1590 and 1898 kg/m3. The semi-log sieve curve of CGS and FS tends under the zone II sand. The SEM images of materials described the morphological shape and structure under micro-scale. The mixing methodology of solid block (SB) illustrates the precise procedure for hammering and hydraulic vibrating of the machine. The complete FS (100%) replacement mix shows 14% superior compressive strength than the referral block. The water absorption of SB with complete FS has 3.95% on 28 days. The cost of optimum SB is affordable by 9 Indian rupees (INR) per block, and 900 INR is saved by producing 100 blocks. The embodied energy (EE) of FS100 is 52.23% effective than conventional SB. This investigation recommends the SB with FS is innocuous to nature and an effective supplant of CGS.