Abstract Geopolymer concrete (GPC) has gained significant awareness in recent years as an eco-friendly alternative to conventional concrete due to its lower CO2 emissions and utilization of industrial waste materials. The cementitious material fly ash (FA), GGBS, silica fume (SF) with incorporation of polypropylene fiber (PF), recycled aggregates (RA) further promote the strength properties of geopolymer concrete, particularly in terms of ductility and crack resistance. Exploratory tests been conducted to assess the effects of various parameters including activator type, curing conditions, fiber content, and aggregate characteristics on the mechanical behaviour and CO2 emissions of geopolymer concrete (GPC). The mechanical performance aspects like as compressive strength(45.7Mpa), flexural strength(4.78Mpa), and split tensile strength(4.12Mpa) were attain by optimum mix design GPC-FG where cement substituted with ratio of FA:GGBS:SF - 40:50:10 and compressive strength(50.4Mpa), flexural strength(5.51Mpa) and split tensile strength(4.99Mpa) were attain by optimum mix design of Polypropylene based GPC-FGP where cement substituted with ratio of FA:GGBS:SF:PF - 40:49:10:1. The optimal mix design GPC-FG and GPC-FGP are compared there is raise in compressive strength of 9.325%, flexural strength of 13.241%,split tensile strength 17.434% of GPC-FGP, along with CO2 of polypropylene fiber-based geopolymer concrete with recycled aggregates as shown 60.01% reduction of CO2 when compared with traditional concrete. The results demonstrate the potential of geopolymer concrete to achieve comparable or superior mechanical performance while significantly reducing CO2 emissions compared to conventional concrete. This research adds to sustainable construction knowledge by showcasing geopolymer concrete’s environmental benefits, mechanical strength, and potential applications in the industry and infrastructure development.
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