Life Cycle Optimization of Agro-Industrial Waste-Based Pervious Concrete for Sustainable Infrastructure Systems

Cement manufacturing releases nearly 900 kilograms of CO₂ for every ton of clinker produced, making it one of the main reasons concrete has such a large environmental footprint. This study explores the possibility of using two common agro-industrial by-products, iron slag and rice husk activated carbon (RHAC), in pervious concrete as partial substitutes for regular Portland cement (OPC). In accordance with ISO 14040/44 guidelines, a cradle-to-grave Life Cycle Assessment (LCA) was carried out to assess environmental effects, such as energy consumption, water depletion, and global warming potential (GWP). In comparison to control mixes, experimental results showed that optimal replacement levels of 30–35% (IS30-3 and IS35-3 mixes) resulted in up to 18% less water depletion, 17.5% less energy usage, and 21% less GWP. Beyond their positive effects on the environment, the blends demonstrated better pore refinement and durability from RHAC and higher mechanical performance from iron slag, which qualified them for use in urban infrastructure like sidewalks, pavements, and stormwater systems. Furthermore, mix designs can be fine-tuned to combine sustainability, mechanical integrity, and cost effectiveness through the incorporation of optimization approaches like Response Surface Methodology (RSM), Artificial Neural Networks (ANN), and hybrid AI-driven frameworks. The results demonstrate that RHAC-iron slag pervious concrete supports the circular economy by repurposing waste resources and is in line with international sustainability objectives. To develop resilient, carbon-efficient infrastructure solutions, future research should concentrate on long-term durability studies, AI-integrated optimization, and large-scale industrial applications.