Modelling and Optimization for Mortar Compressive Strength Incorporating Heat-Treated Fly Oil Shale Ash as an Effective Supplementary Cementitious Material Using Response Surface Methodology

Fly oil shale ash (FOSA) is a waste material known for its pozzolanic activity. This study intends to investigate the optimum thermal treatment conditions to use FOSA efficiently as a cement replacement material. FOSA samples were burned in an electric oven for 2, 4, and 6 h at temperatures ranging from 550 °C to 1000 °C with 150 °C intervals. A total of 333 specimens out of 37 different mixes were prepared and tested with cement replacement ratios between 10% and 30%. The investigated properties included the mineralogical characteristics, chemical elemental analysis, compressive strength, and strength activity index for mortar samples. The findings show that the content of SiO₂ + Al₂O₃ + Fe₂O₃ was less than 70% in all samples. The strength activity index of the raw FOSA at 56 days exceeded 75%. Among all specimens, the calcined samples for 2 h demonstrated the highest pozzolanic activity and compressive strength with a 75% strength activity index. The model developed by RSM is suitable for the interpretation of FOSA in the cementitious matrix with high degrees of correlation above 85%. The optimal compressive strength was achieved at a 30% replacement level, a temperature of 700 °C for 2 h, and after 56 days of curing.