Performance assessment and life cycle analysis of concrete containing ferrochrome slag and fly ash as replacement materials – A circular approach

•Circular pathway through use of FCS aggregate and fly ash in concrete was explored.•An eco-efficient mix design method based on PPOT was adopted.•Ten types of concrete mixes were prepared using PPOT and conventional mix design.•The techno-environmental performance of all mixes were studied.•FCSAC with 30% fly ash designed by PPOT was ranked as the most sustainable mix. Climate change mitigation and resource efficiency have emerged as crucial challenges for long-term sustainability of concrete. Implementing circular approach through waste valorisation in concrete production with eco-efficient mix design is an efficient mitigation pathway to combat natural resources depletion and environmental issues. This paper investigates techno-environmental sustainability of concrete utilizing 100% ferrochrome slag as alternate coarse aggregate and fly ash as partial cement substitute (0–40%) adopting particle packing optimization technique (PPOT) as a sustainable mix design method. Total of ten types of concrete mixtures were prepared using the alternate materials and mix design methods (PPOT and IS:10262(2009)). Natural aggregate concrete prepared by IS:10262(2009) mix design was considered as the reference mixture. Technical assessment of concrete was performed experimentally in terms of compressive strength and tensile strength. Environmental performance was investigated through life cycle assessment (LCA) as per ISO 14040-44 guidelines using cradle-to-gate system boundary and two functional units: 1 m3 concrete and 1 MPa compressive strength. Results revealed that ferrochrome slag aggregate concrete (FCSAC) containing fly ash up to 30% prepared by PPOT has enhanced strength than reference concrete. Regardless of the functional units used, FCSAC with 30% fly ash designed by PPOT was ranked as the most sustainable mix with significant environmental savings (around 50–70%) without compromising desired requirements. Sensitivity analysis was performed by varying transportation distance, mode of transport and energy mix. Results showed that FCSAC with 30% fly ash is not sensitive to the scenarios investigated. The outcomes will be helpful for decision-makers to develop policy directives and frameworks on synergistic use of ferrochrome slag and fly ash towards concrete sustainability.