Energy Generating Solar Paver Blocks Incorporating Waste Materials for Smart Walkways in Coimbatore, India

Abstract

The rapid expansion of urban infrastructure and the increasing demand for decentralized renewable energy systems necessitate the development of multifunctional pavement solutions with integrated energy-harvesting capabilities. This study investigates the design, fabrication, and performance evaluation of photovoltaic-integrated sustainable concrete paver blocks for smart walkway applications in Coimbatore (CBE), India. M20 grade concrete paver blocks were prepared using 53-grade Ordinary Portland Cement, natural river sand, and 12 mm nominal size coarse aggregate, following IS mix design guidelines. To enhance sustainability, eggshell powder (ESP), primarily composed of calcium carbonate (CaCO?), was used as a 10 % partial replacement for cement, while recycled coarse aggregate (RCA) was incorporated at a 30 % replacement level. Specimens were cast, cured under standard conditions, and tested at 7, 14, 21, and 28 days. Mechanical properties were evaluated through compressive and flexural strength tests, while durability characteristics were assessed using water absorption, acid resistance, and skid resistance tests. The ESP–RCA modified paver blocks exhibited compressive strength comparable to conventional concrete with marginal variation within permissible limits, along with adequate flexural strength for pedestrian loading. Water absorption remained within acceptable limits, indicating a dense microstructure, while satisfactory acid resistance and enhanced skid resistance confirmed improved durability and surface performance. A polycrystalline photovoltaic module (6 V, 99 × 69 mm) was embedded within the paver block and protected by a 2 mm thick polycarbonate layer to ensure mechanical integrity and effective light transmission. The system demonstrated efficient conversion of solar energy for low-power applications such as pathway lighting. The results confirm that the proposed system offers a structurally sound, energy-efficient, and environmentally sustainable solution for smart walkway infrastructure.

Introduction

This study reviews and experimentally investigates sustainable paver blocks and solar-integrated pavement systems using waste materials such as eggshell powder, recycled concrete aggregates, and other industrial by-products to improve environmental performance and reduce dependence on natural resources.

Literature Overview

Previous research shows that:

• Eggshell powder can partially replace cement (around 10% optimal) to improve strength and sustainability.
• Recycled aggregates from construction waste can replace up to 40–60% of natural aggregates without major performance loss.
• Industrial by-products like rice husk ash, sawdust, and quarry waste further enhance eco-friendly concrete production.
• Solar-integrated pavements can generate energy while maintaining structural performance.
• Overuse of eggshell powder (>10%) may reduce mechanical strength.

Materials Used

• OPC 53 cement, M-sand, and 12 mm coarse aggregates as primary materials.
• Eggshell powder (rich in CaCO?) prepared from waste eggs.
• Recycled aggregates from construction and demolition waste.
• Potable water for mixing.
• Embedded mini solar panel system (with battery, LED, MOSFET circuit, and protective components) for energy-harvesting paver blocks.

Methodology

• Eggshells were cleaned, dried, ground, and sieved into fine powder.
• Mix design followed IS standards with:
  • 10% cement replaced by eggshell powder
  • 30% coarse aggregate replaced by recycled aggregates
• Concrete was cast into paver blocks, compacted, cured, and tested.
• A solar module was embedded for automatic day–night LED lighting.

Testing Procedures

Tests conducted included:

• Compressive strength
• Acid resistance
• Water absorption
• Flexural strength
• Skid resistance

Key Results

Compared to conventional blocks, sustainable paver blocks showed:

• Higher compressive strength (up to ~20 MPa at 28 days)
• Improved flexural strength
• Lower water absorption, indicating reduced porosity
• Slightly better or comparable acid resistance
• Good skid resistance, suitable for pedestrian use

Solar System Function

• Solar panel charges battery during daytime.
• LED automatically turns ON at night using MOSFET switching.
• Ensures energy-efficient, low-maintenance lighting for pavements.

Conclusion

The experimental results demonstrate that both conventional and sustainable paver blocks exhibited an increase in strength with curing age (7, 14, 21, and 28 days), with the sustainable blocks—prepared by replacing 30% cement with eggshell powder and 10% coarse aggregate with recycled aggregate—showing slightly lower early strength but achieving acceptable compressive and flexural strength by 28 days; although water absorption was marginally higher due to the porous nature of the replacement materials, it remained within permissible limits, while acid resistance and skid resistance were found to be comparable to conventional blocks, indicating no significant compromise in durability or surface performance; moreover, the successful embedding of solar panels within the sustainable paver blocks demonstrated effective electricity generation without affecting structural integrity, leading to the conclusion that such sustainable solar paver blocks provide a viable, eco-friendly alternative for construction by reducing material consumption, utilizing waste resources, and supporting renewable energy integration in infrastructure.

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Copyright

Copyright © 2026 Arthi V, Madhumitha S, Mahalakshmi D, Jaiakash M, Vishnu A. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.