High Calcium Wood Ash (HCWA) and Pulverised Fuel Ash (PFA) are by-products from the wood biomass and coal energy production which are produced in large quantity with combined annual production of 500 million tonnes. This poses a serious problem for disposal of the waste material especially at places where land is scarce. The prescribed study was aimed to examine the mineralogical phases and their respective amount present in the industrial wastes which governs the hydration mechanism towards self-sustained solidification of the ashes when used in combination. Besides, the influence of various forming pressure and hydrothermal treatment temperature on mechanical strength performance of HCWA-PFA cementless mortar blocks was also examined. In the study, the mechanical strength of the HCWA-PFA cementless mortar block produced using various forming pressure and hydrothermal treatment temperature was assessed in terms of compressive strength and dynamic modulus. The results of the study are indicative that HCWA is rich in calcium oxide and potassium oxide content. This enables the hybridization of HCWA with the amorphous silica and alumina rich PFA to form a solid geopolymer binder matrix for fabrication of cementless mortar block. Throughout the study, dimensionally and mechanically stable HCWA-PFA geopolymer mortar blocks were successfully produced by press forming and hydrothermal treatment method. Based on statistical analysis, the hydrothermal treatment temperature has a statistically insignificant effect on the mechanical strength of the HCWA-PFA cementless mortar blocks. The dominant factor which governs the mechanical strength of the HCWA-PFA cementless mortar blocks was found to be the hydraulic forming pressure. Moreover, it was found that hybridized HCWA-PFA can be recycled as the sole binder for fabrication of cementless concrete block which is a useful construction material.

Problem statement: Production of concrete is always deal with inconsistency. Sources of variation like materials from different geographical basis, mix design method, fineness of aggregates and so on will attribute to different level of achievement of the concrete. Even though researcher had verified that higher fineness modulus of sand would yield better performance for the concrete, but so far there have been scarce amount of paper reported on the mix design method adopting high fineness modulus of sand. Approach: This study discussed the revolution of design mix proportion towards achieving high strength with considerably cement content using local availably constituent materials. A total of 15 mixes was casted till to the high strength at more than 65 MPa was achieved. The compressive strength and workability of each mixes were presented. The method of mixture proportioning was begun with British Department Of Environment (DOE) method. Then, rational design method of achieving high strength concrete was developed. Results: At the end of experimental program, it was found that DOE method was not suitable to apply in designing high strength concrete. 12% was the optimum level of replacement of the total binder content by silica fume. Further increase of total binder content without adjustment to the amount of aggregate content has decreased the strength achievement of the concrete. Very coarse fine aggregate with fineness modulus 3.98 increased the compressive strength of the concrete in large extent. The increased of superplasticiser from 2.0% to 2.5% has decreased the compressive strength of the concrete. Conclusion: The rational mix design approach was developed. A Grade 70 concrete can be produced with moderate level of cement content by this approach.