Experimental Modelling and Multi-Objective Optimisation of Carbon Black, Clay-Carbon Black, and Clay-Fly Ash-Carbon Black Bricks for Sustainable Construction Applications.

The present invention proposes a systematic experimental modelling and optimisation method for developing sustainable clay-based masonry units, including Carbon Black Bricks (CBB), Clay–Carbon Black Bricks (CCB), and Clay–Fly Ash–Carbon Black Bricks (CFCB). A Taguchi orthogonal array design is employed to efficiently investigate the influence of material composition on compressive strength, water absorption, and bulk density. Response Surface Methodology (RSM) is proposed to establish predictive relationships and confirm model robustness. The integrated Taguchi–RSM framework reduces experimental trials while enabling reliable process–property optimisation. The resulting composite bricks demonstrate improved mechanical performance and reduced water absorption through the utilisation of industrial by-products, providing a scalable and eco-efficient solution for sustainable brick manufacturing.