Published Paper Details:

Concrete is one of the most widely used materials in construction, primarily composed of cement, water, and natural aggregates. However, the excessive extraction of natural sand has raised serious environmental concerns, including ecosystem disruption and depletion of riverbeds. As a result, the focus has shifted towards sustainable alternatives that incorporate industrial waste materials into concrete mixes. In this context, the present study investigates the use of mill scale, a steel manufacturing byproduct composed primarily of iron oxides, as a replacement for natural fine aggregates. A controlled mix of M20 grade concrete was designed, where sand was partially and fully replaced with mill scale at varying percentages 0%, 20%, 40%, 60%, 80%, and 100% by weight. The performance of each mix was assessed through tests on workability (slump test), compressive strength, split tensile strength, flexural strength, and density. Among these, the 40% replacement level showed significant improvement in strength properties, particularly in compressive, tensile, and flexural strength, indicating that mill scale can effectively enhance the mechanical performance of concrete. Additionally, the optimal mix was used to manufacture interlocking tiles, and their performance was evaluated in terms of load-bearing capacity, dimensional accuracy, and surface finish. This research demonstrates that mill scale not only improves concrete strength but also offers a sustainable solution for waste management and conservation of natural resources in the construction industry.