Optimizing Gypsum, Fly-ash, and Glass Fiber Composites for High-Performance Sustainable Bricks: Durability and Environmental Insights

There is growing demand on the building sector to implement sustainable materials that mitigate environmental impacts while maintaining structural integrity. This study investigates the synergistic integration of industrial by-products-gypsum, fly ash, and glass fiber-to develop high-performance compressed stabilized bricks with enhanced mechanical and durability properties. The present study hypothesizes that optimizing these materials can reduce reliance on conventional resources, lower carbon emissions, and address waste management challenges. The present experimental design was employed to systematically vary fly-ash (50-65%), gypsum (3-12%), and glass fiber (0.5-2%) content, with compressive strength and water absorption evaluated per IS 3495, IS 1077 and EN 772-13 standards. Microstructural analysis via SEM/XRD elucidated hydration mechanisms, while life cycle assessment quantified environmental benefits. Results indicate that fly-ash geopolymer systems achieved compressive strengths up to 59.53 MPa, with gypsum (3-6%) facilitating early strength through ettringite formation. Glass fiber reinforcement improved crack resistance, though its effects require further standardization. Water absorption remained within 8-12%, and fiber-reinforced composites exhibited 15% reduced mass loss after 25 freeze-thaw cycles. Envi0ronmental analysis revealed a 40% reduction in CO₂ emissions compared to Portland cement-based bricks. Industry feasibility assessments highlighted stable gypsum production but noted regional disparities in fly-ash availability. The present study's optimised composites can balance mechanical performance, durability, and sustainability, offering a viable alternative to traditional bricks. However, challenges such as fiber dispersion uniformity and material supply consistency necessitate further investigation. This work contributes to advancing circular economy principles in construction by transforming waste streams into value-added building materials, thereby reducing both environmental footprints and production costs. The findings provide actionable insights for policymakers and industry stakeholders seeking scalable solutions for sustainable infrastructure development in upcoming days.