Advancements in sustainable construction: Transitioning from cement power plant beds to aerated concrete thermal blocks

Cement industry power plant bed material waste was introduced as a replacement for sand in non-autoclaved aerated concrete (NAAC) blocks for general building use. Aerated concretes are among the best materials for enclosing buildings for various purposes. This study explores the replacement of sand with power plant bed material waste from the cement industry in non-autoclaved aerated concrete blocks. The research hypothesizes that bed materials can enhance the physical and mechanical properties of NAAC blocks. The methodology involves producing NAAC blocks using cement bed materials, fly ash, gypsum, water, and a constant quantity of 0.65 grams of aluminum powder. Bed materials obtained from the cement industry range from 4.75 mm to 150 microns used for NAAC slurry. In this research, the particle size distribution analysis is considered as a bed materials sample in different periods. The blocks were created according to the guidelines of IS 2185 (Part III): 1984, with a size specification of 22 cm × 10.5 cm × 7 cm. The study measured the compressive strength and water absorption of these NAAC blocks and compared them with traditional clay and fly ash bricks. Experimental result shows that the NAAC blocks met the Indian Standard code strength requirement of 6 MPa, achieving 7.28 MPa at 28 days for Sample T5. These findings suggest that NAAC blocks using bed materials are both lighter and stronger than traditional bricks, indicating their potential for large-scale production.