The global demand for cement and concrete is expected to rise by 2.4 to 3.0% annually, reaching around 4.8 billion metric tons. Current materials are insufficient to meet this demand, necessitating alternative aggregates that balance environmental impact, sustainability, economic benefits, and maintain strength and durability. Therefore, this paper is attempted to replace natural coarse aggregate (NCA) in M25 grade concrete with cinder coarse aggregate (CCA) in varying replacement proportions of 0% to 100%. The mechanical (compressive, split tensile and flexural strength) and durability (fire resistance, water absorption, and chloride ion penetration) characteristics are evaluated in order to determine the appropriate replacement percentage of cinder aggregate. Investigations have also been conducted to examine the microstructural characteristics of sustainable concrete specimens under electron scanning microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and X-ray diffractometry (XRD). The findings of these investigation shows that the strength properties continuously declines with the continuous replacement of CCA, but however the targeted mean strength of M25-grade concrete is still attained for all the replacement proportions. Durability characteristics improved with higher CCA content. The cost analysis for 1 m³ of sustainable concrete with CCA showed it to be quite feasible compared to conventional concrete.
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