Experimental and AI-based modeling of C-25 concrete with partial cement replacement using fly ash and marble powder

Experimental and AI-based modeling of C-25 concrete with partial cement replacement using fly ash and marble powder | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Experimental and AI-based modeling of C-25 concrete with partial cement replacement using fly ash and marble powder Snehal U. Bobade, Shailendra P. Banne, Raviraj Sorate, Dhanashree A. Latthe, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7809648/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 9 You are reading this latest preprint version Abstract This study explores the combined use of fly ash (FA) and marble powder (MP) as a binary supplementary cementitious blend for C-25 concrete, aiming to reduce clinker content without sacrificing performance. The mixes used FA–MP (1:1 by mass) to replace 0–35% of OPC, with a constant water-to-binder ratio of 0.50. Material characterization using X-ray diffraction (XRD) and scanning electron microscopy (SEM) confirmed the presence of reactive quartz-mullite phases and spherical cenospheres in FA, and predominantly calcite with angular, fine particles in MP, supporting a pozzolanic-filler synergy. The fresh and hardened properties, including slump, setting time, compressive strength (7, 14, and 28 days), strength activity index (SAI), water absorption (WA), and dry density (DD), were measured and complemented with AI/ML predictions using DNN, ELM, RF, XGB, and SVR. The results indicate an optimal replacement at 25% (SUB25), achieving a 110 mm slump, 34 MPa 28-day strength, SAI = 109.9%, WA = 1.12% (≈ 66% lower than that of the control), and DD = 2420 kg/m³. SEM of hardened mixes revealed a dense, well-interlocked C–S–H matrix at SUB25, whereas 35% replacement reintroduced micro-voids. Among the models, Random Forest yielded the most accurate predictions (R² = 0.99, MAE = 0.20 MPa, RMSE = 0.28 MPa), followed by DNN, with SVR performing the poorest. The findings demonstrate that 25% FA–MP substitution delivers balanced workability, strength, and durability while reducing cement use. Coupling microstructural evidence with robust AI/ML modeling offers a practical, data-driven pathway for optimizing sustainable concrete mixes and reducing the environmental footprint of construction. Fly Ash Marble Powder C-25 Concrete Compressive Strength AI/ML DNN Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Under Review Version 1 posted Editorial decision: Revision requested 01 Nov, 2025 Reviews received at journal 01 Nov, 2025 Reviewers agreed at journal 21 Oct, 2025 Reviews received at journal 11 Oct, 2025 Reviewers agreed at journal 10 Oct, 2025 Reviewers invited by journal 10 Oct, 2025 Editor assigned by journal 09 Oct, 2025 Submission checks completed at journal 09 Oct, 2025 First submitted to journal 08 Oct, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7809648","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":532624850,"identity":"26f17152-ddd2-4996-9479-a2f5d78db6dd","order_by":0,"name":"Snehal U. 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powder","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"asian-journal-of-civil-engineering","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"","sideBox":"Learn more about [Asian Journal of Civil Engineering](https://www.springer.com/journal/42107)","snPcode":"42107","submissionUrl":"https://submission.nature.com/new-submission/42107/3","title":"Asian Journal of Civil Engineering","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Springer 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The mixes used FA\u0026ndash;MP (1:1 by mass) to replace 0\u0026ndash;35% of OPC, with a constant water-to-binder ratio of 0.50. Material characterization using X-ray diffraction (XRD) and scanning electron microscopy (SEM) confirmed the presence of reactive quartz-mullite phases and spherical cenospheres in FA, and predominantly calcite with angular, fine particles in MP, supporting a pozzolanic-filler synergy. The fresh and hardened properties, including slump, setting time, compressive strength (7, 14, and 28 days), strength activity index (SAI), water absorption (WA), and dry density (DD), were measured and complemented with AI/ML predictions using DNN, ELM, RF, XGB, and SVR. The results indicate an optimal replacement at 25% (SUB25), achieving a 110 mm slump, 34 MPa 28-day strength, SAI\u0026thinsp;=\u0026thinsp;109.9%, WA\u0026thinsp;=\u0026thinsp;1.12% (\u0026asymp;\u0026thinsp;66% lower than that of the control), and DD\u0026thinsp;=\u0026thinsp;2420 kg/m\u0026sup3;. SEM of hardened mixes revealed a dense, well-interlocked C\u0026ndash;S\u0026ndash;H matrix at SUB25, whereas 35% replacement reintroduced micro-voids. Among the models, Random Forest yielded the most accurate predictions (R\u0026sup2; = 0.99, MAE\u0026thinsp;=\u0026thinsp;0.20 MPa, RMSE\u0026thinsp;=\u0026thinsp;0.28 MPa), followed by DNN, with SVR performing the poorest. The findings demonstrate that 25% FA\u0026ndash;MP substitution delivers balanced workability, strength, and durability while reducing cement use. Coupling microstructural evidence with robust AI/ML modeling offers a practical, data-driven pathway for optimizing sustainable concrete mixes and reducing the environmental footprint of construction.\u003c/p\u003e","manuscriptTitle":"Experimental and AI-based modeling of C-25 concrete with partial cement replacement using fly ash and marble powder","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-23 08:14:13","doi":"10.21203/rs.3.rs-7809648/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Revision requested","date":"2025-11-01T06:10:24+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-11-01T04:20:55+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"205622222859356153863740399834851156293","date":"2025-10-21T05:09:11+00:00","index":"hide","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-10-11T12:35:48+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"238498787960550740689152314799874076730","date":"2025-10-10T07:38:51+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-10-10T06:32:24+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-10-09T16:07:30+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2025-10-09T14:34:36+00:00","index":"","fulltext":""},{"type":"submitted","content":"Asian Journal of Civil Engineering","date":"2025-10-08T15:43:10+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"asian-journal-of-civil-engineering","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"","sideBox":"Learn more about [Asian Journal of Civil Engineering](https://www.springer.com/journal/42107)","snPcode":"42107","submissionUrl":"https://submission.nature.com/new-submission/42107/3","title":"Asian Journal of Civil Engineering","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"db1e064b-964b-419a-86e6-c581bcf31adc","owner":[],"postedDate":"October 23rd, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2025-11-07T10:53:13+00:00","versionOfRecord":[],"versionCreatedAt":"2025-10-23 08:14:13","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7809648","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7809648","identity":"rs-7809648","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}