Performance of Sustainable Concrete Containing Bottom Ash as a Partial Replacement of Fine Aggregate along with Glass Fibers

Abstract

Concrete is one of the most widely used construction materials in the world; however, its extensive use results in the depletion of natural resources and increased environmental concerns. The growing demand for sustainable construction materials has encouraged the utilization of industrial by-products and innovative additives in concrete production. This study investigates the influence of bottom ash as a partial fine aggregate replacement along with glass fiber addition on the performance of sustainable concrete. Bottom ash obtained from the Koradi Super Thermal Power Station, Nagpur, was used to replace natural sand at varying proportions up to 30%, while short glass fibers were incorporated to enhance the mechanical properties of concrete. The experimental program evaluated the workability, strength and durability parameter of the modified concrete mixes. The results were compared with conventional concrete to assess the combined effect of bottom ash and glass fibers. The findings indicate that the incorporation of bottom ash and glass fibers can improve certain mechanical and durability properties Concrete is the most widely used construction material, but its growing demand has led to excessive extraction of natural river sand, causing environmental degradation such as riverbank erosion and ecological imbalance. To address this issue, the study explores the use of Coal Bottom Ash (CBA), an industrial by-product from thermal power plants, as a partial replacement for fine aggregate. Utilizing CBA helps reduce industrial waste, conserve natural resources, and promote sustainable construction. Since concrete has low tensile strength and is prone to cracking, glass fibers are also incorporated to improve tensile strength, flexural performance, toughness, and crack resistance. Previous studies have shown that CBA can replace 20–30% of natural sand without significantly affecting concrete strength or durability. Researchers also found that while CBA reduces workability due to its porous texture and higher water absorption, moderate replacement levels improve particle packing, long-term strength, and environmental sustainability. Glass fibers compensate for some drawbacks of CBA by enhancing crack resistance, tensile strength, and durability. However, limited research has examined the combined use of CBA and glass fibers, making this study important for developing eco-friendly, high-performance concrete. The experimental program investigated the mechanical and durability properties of M40 grade concrete containing varying percentages of CBA and a fixed dosage of glass fibers. Concrete cubes and cylinders were cast, cured for 7, 14, and 28 days, and tested for compressive strength, split tensile strength, flexural strength, density, water absorption, and crack resistance. The objective was to determine the optimum combination that provides improved structural performance while reducing the consumption of natural sand. Coal Bottom Ash used in the study was collected from the Koradi Thermal Power Station (KTPS), Nagpur, processed by drying and sieving, and then used as a partial replacement for natural sand. Particle size analysis showed that CBA has grading characteristics similar to river sand, making it suitable as a fine aggregate. The fineness modulus of CBA was 2.93, almost identical to river sand (2.94), and both satisfied ASTM C33 requirements, confirming the technical feasibility of using CBA in concrete. Compared with previous studies, the relatively higher fineness modulus of the CBA used in this research may improve workability and compressive strength. The study also evaluated the specific gravity of CBA, which was found to be 2.32, lower than that of river sand (2.63) due to the porous structure of bottom ash. Although this lower density can influence concrete properties, previous research indicates that properly processed CBA can still produce durable structural concrete. reducing dependence on natural fine aggregates and promoting the beneficial utilization of industrial by-product. The study demonstrates the potential of developing sustainable, economical, and environmentally friendly concrete suitable for modern construction applications through the combined use of bottom ash and glass fibers.

Introduction

Concrete is the most widely used construction material, but its growing demand has led to excessive extraction of natural river sand, causing environmental degradation such as riverbank erosion and ecological imbalance. To address this issue, the study explores the use of Coal Bottom Ash (CBA), an industrial by-product from thermal power plants, as a partial replacement for fine aggregate. Utilizing CBA helps reduce industrial waste, conserve natural resources, and promote sustainable construction. Since concrete has low tensile strength and is prone to cracking, glass fibers are also incorporated to improve tensile strength, flexural performance, toughness, and crack resistance.

Previous studies have shown that CBA can replace 20–30% of natural sand without significantly affecting concrete strength or durability. Researchers also found that while CBA reduces workability due to its porous texture and higher water absorption, moderate replacement levels improve particle packing, long-term strength, and environmental sustainability. Glass fibers compensate for some drawbacks of CBA by enhancing crack resistance, tensile strength, and durability. However, limited research has examined the combined use of CBA and glass fibers, making this study important for developing eco-friendly, high-performance concrete.

The experimental program investigated the mechanical and durability properties of M40 grade concrete containing varying percentages of CBA and a fixed dosage of glass fibers. Concrete cubes and cylinders were cast, cured for 7, 14, and 28 days, and tested for compressive strength, split tensile strength, flexural strength, density, water absorption, and crack resistance. The objective was to determine the optimum combination that provides improved structural performance while reducing the consumption of natural sand.

Coal Bottom Ash used in the study was collected from the Koradi Thermal Power Station (KTPS), Nagpur, processed by drying and sieving, and then used as a partial replacement for natural sand. Particle size analysis showed that CBA has grading characteristics similar to river sand, making it suitable as a fine aggregate. The fineness modulus of CBA was 2.93, almost identical to river sand (2.94), and both satisfied ASTM C33 requirements, confirming the technical feasibility of using CBA in concrete. Compared with previous studies, the relatively higher fineness modulus of the CBA used in this research may improve workability and compressive strength.

The study also evaluated the specific gravity of CBA, which was found to be 2.32, lower than that of river sand (2.63) due to the porous structure of bottom ash. Although this lower density can influence concrete properties, previous research indicates that properly processed CBA can still produce durable structural concrete.

Conclusion

The present investigation demonstrates that coal bottom ash can be successfully utilized as a partial replacement for natural fine aggregate in concrete, contributing to both sustainable construction and effective waste management. The experimental results revealed that the inclusion of bottom ash influences the fresh and hardened properties of concrete due to its porous texture, lower density, and higher water absorption characteristics. A gradual reduction in concrete density and workability was observed with increasing bottom ash content. This behavior is mainly associated with the lightweight and porous nature of bottom ash particles. Although the reduction in workability was noticeable, satisfactory consistency can be achieved through proper mix proportioning and the use of suitable admixtures. The mechanical performance of the concrete indicated that mixes containing moderate levels of bottom ash achieved strength values close to those of conventional concrete. Among the replacement levels investigated, the mix containing 20% bottom ash exhibited the most balanced performance in terms of strength, durability, and overall concrete quality. Non-destructive testing results also confirmed the acceptable integrity and uniformity of the modified concrete. The study further highlights that the physical characteristics of coal bottom ash, such as its particle grading and surface texture, make it suitable for use as a fine aggregate substitute. While its porous structure increases water demand, it can also contribute to improved particle interlocking and bonding within the concrete matrix when used at appropriate replacement levels. Based on the findings, it can be concluded that coal bottom ash is a viable alternative material for partial replacement of natural sand, particularly up to a replacement level of 20%. Its utilization not only conserves natural resources but also reduces the environmental impacts associated with the disposal of thermal power plant waste. Therefore, the adoption of coal bottom ash in concrete production offers a practical approach toward sustainable and eco-friendly construction. Further studies may focus on long-term durability behavior, the combined effect of bottom ash and fiber reinforcement, and the development of optimized mix design procedures for wider field applications.

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Copyright © 2026 Mr. Rutik K. Kale, Dr. Mahesh Raut. 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.