Integrated Material Selection Criteria for Ash-Based Cementitious Systems: Mechanical, Durability, and Environmental Perspectives

Abstract

The escalating environmental burden of ordinary Portland cement (OPC) Grade-53 production, accounting for 8-10% of global industrial CO2 emissions, has necessitated the exploration of sustainable alternatives through supplementary cementitious materials (SCMs). This comprehensive review synthesizes 52 peer-reviewed studies (2020-2025) to establish systematic material selection criteria for cement replacement using different types of ash, including coal bottom ash (CBA), fly ash (FA), rice husk ash (RHA), wood bottom ash (WBA), sugarcane bagasse ash (SCBA), coconut shell ash (CSA), and agricultural residue ashes. The research develops a multi-dimensional selection framework encompassing chemical composition analysis (SiO2, Al2O3, CaO content), physical properties (particle size, water absorption, bulk density), pozzolanic activity assessment, mechanical performance metrics (compressive, flexural, and tensile strength), durability characteristics, and environmental/sustainability parameters. Key findings reveal optimal replacement percentages: coal bottom ash (20-35%), fly ash (25-30%), rice husk ash (5-10%), wood bottom ash (5-15%), and sugarcane bagasse ash (10-15%), with coal bottom ash demonstrating 28.78% strength improvement at 35% replacement and 34% CO2 emission reduction. The framework incorporates application-specific selection algorithms, quality control protocols, durability testing methodologies, and practical implementation guidelines. Challenges identified include inconsistent properties in agricultural ashes, early strength loss, water demand increases, alkali-silica reaction (ASR) risks, and batch-to-batch variability, with corresponding mitigation strategies detailed. This study establishes a decision-support system enabling engineers and researchers to systematically select appropriate ash materials based on specific project requirements, environmental goals, and performance standards. Future research directions emphasize standardization of agricultural waste ashes, development of hybrid ash systems, integration of machine learning for property prediction, and long-term durability validation (>10 years), supporting the transition toward circular economy principles in sustainable construction.