The production of Ordinary Portland Cement (OPC) is a significant source of global CO2 emissions, driving the need for sustainable alternatives in construction materials. This study investigates the optimization of sandcrete bricks incorporating laterite soil and sawdust ash (SDA) as partial replacements for cement and fine aggregate, specifically for road paving applications. A comprehensive experimental program was executed using a Scheffé’s mixture design with five components water, cement, SDA, fine aggregate, and laterite generating 35 distinct mixtures. The compressive strength of these mixtures was determined at 28 days, and the data were utilized to develop a highly accurate third-degree polynomial regression model (R² = 0.9954). The results demonstrate that optimal mixtures with moderate SDA (5-10%) and laterite (5-15%) content can achieve compressive strengths exceeding 51 MPa, comparable to conventional sandcrete. However, higher replacement levels induced a strength reduction of up to 28%, attributed to cement dilution and the deleterious effects of elevated alkali content in SDA. Computational optimization identified seven optimal mix proportions with predicted compressive strengths ranging from 32 MPa to 37 MPa, suitable for structural paving elements like kerbs and interlocking blocks. This research conclusively establishes that laterite and SDA are viable supplementary cementitious materials, but their successful application hinges on precise proportioning to leverage their pozzolanic benefits while mitigating their adverse effects, thereby offering a pathway for more eco-friendly construction in the roadway sector.

This study successfully demonstrates the viability and defines the optimal parameters for utilizing laterite soil and sawdust ash (SDA) as sustainable partial replacements in sandcrete bricks for road paving applications. Through a rigorous application of Scheffé’s mixture design and a third-degree polynomial optimization model, the complex interactions between water, cement, SDA, fine aggregate, and laterite were systematically characterized to develop predictive models with a high coefficient of determination (R² = 0.9954). The key findings of this investigation are threefold. 1.The mineralogical composition of the additives plays a critical role; the pozzolanic silica and alumina in laterite contribute to secondary strength-forming reactions, while the high alkali content (K₂O) in SDA presents a potential risk for durability issues at elevated replacement levels. 2.The experimental results delineate a clear threshold for substitution. While optimal mixtures with moderate SDA and laterite content (e.g., R12, R26, R27) achieved compressive strengths comparable to the conventional control mix (51.54 MPa), higher replacement levels led to significant strength reduction up to 28% in some cases primarily due to cement dilution and chemical interference. The derived computational model enabled the identification of seven optimal mixture compositions, with predicted compressive strengths ranging from approximately 32 MPa to 37 MPa, validating the efficacy of the optimization approach.

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