International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 13 Issue: 04 | Apr 2026
p-ISSN: 2395-0072
www.irjet.net
DEVELOPMENT OF SUSTAINABLE FLY ASH BRICKS USING CRAB SHELL POWDER, MARBLE POWDER AND KADAPPA STONE POWDER AS PARTIAL CEMENT REPLACEMENT A.K. Nantha Kumar¹, K. Niraikula Sekaran², Dr. P. Sathees Kumar³, S.A. Shri Harini⁴, M. Sakthi Ruban⁵, S. Mohamed Asimkhan⁶, H.R. Jinob Khan⁷ ¹ Assistant Professor, Department of Civil Engineering, Mohamed Sathak Engineering College, Kilakarai – 623806, Tamil Nadu, India ² Professor, Department of Civil Engineering, Mohamed Sathak Engineering College, Kilakarai – 623806, Tamil Nadu, India ³ Professor & HOD, Department of Civil Engineering, Mohamed Sathak Engineering College, Kilakarai – 623806, Tamil Nadu, India ⁴,⁵,⁶,⁷ UG Student, Department of Civil Engineering, Mohamed Sathak Engineering College, Kilakarai – 623806, Tamil Nadu, India ---------------------------------------------------------------------***-------------------------------------------------------------------Abstract - Cement production accounts for approximately 8% of global CO₂ emissions and is increasingly costly. The rising cost of cement and its environmental impact necessitate the exploration of alternative binders in construction materials. This groundbreaking study investigates the partial replacement of cement in fly ash bricks using a novel combination of three waste materials: crab shell powder (rich in calcium carbonate for enhanced binding), marble powder (ultra-fine filler for superior density), and kadappa stone powder (micro-pore filler for reduced absorption). Bricks of standard size 19×9×9 cm were cast with four mix proportions: conventional control (17% cement), crab shell modified (15% cement + 2% crab shell), marble modified (15% cement + 2% marble), and the innovative hybrid mix (12% cement + 2% crab shell + 3% marble). All mixes contained 20% fly ash, 28.6% bottom ash, 2.86% kadappa powder, 18.6% Msand, 5% granite, and 8% baby chips. A total of 15 bricks were cast and rigorously tested for compressive strength and water absorption as per IS 1077 standards. The hybrid bricks achieved an outstanding average compressive strength of 4.2 N/mm² and remarkably low water absorption of 13.5%, significantly exceeding the IS 1077 requirements (3.5 N/mm² and 20% respectively). Efflorescence was rated as slight, well within acceptable limits as per IS 3495. The novelty of this research lies in the synergistic combination of three distinct waste materials to achieve an unprecedented 5% cement reduction – the highest reported in literature for fly ash bricks. The utilization of kadappa stone powder as a pore filler is a novel addition not explored in previous studies. This research successfully demonstrates a cost-effective, eco-friendly, and sustainable alternative for modern construction practices. Key Words: Fly ash bricks, crab shell powder, marble powder, kadappa stone powder, cement replacement, sustainable construction, waste utilization, pozzolanic materials, green building materials.
1. INTRODUCTION Cement is undeniably the backbone of modern construction, yet its production remains both economically burdensome and environmentally catastrophic. The cement industry alone accounts for approximately 8% of global anthropogenic carbon dioxide emissions, contributing significantly to climate change. According to the International Energy Agency, cement production is the thirdlargest industrial source of CO₂ emissions worldwide. Fly ash bricks, while widely recognized as an eco-friendly alternative to
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