AbstractThe necessity of low-cost building and mortar-free wall construction (dry stack masonry) led to the development of a newly proposed block called a fly ash-lime-slag dry stack block (FaL-S DSB) with ingredients from industrial waste materials (fly ash, lime, and ground-granulated blast-furnace slag). The perforations in the proposed DSB accommodate the connecting element between the courses of masonry and headed to mortar-free construction. The scaled FaL-S DSB was produced with five different mix proportions (L10S20, L15S20, L15S25, L20S20, L20S25) by pressing method. The experimental studies were carried out to examine the physical, mechanical, and durability properties and also analyzed the embodied energy and carbon emissions of FaL-S DSB. The compressive strengths of a prism and wall panel made of FaL-S DSB were also studied. Out of five mixes, L20S25 resulted in higher dry and wet compressive strength values of 11.50 and 7.89 MPa, respectively. The values were compared with commercially available red brick (RB). The FaL-S DSB was also observed for loss in weight and loss in strength by immersing in acid (H2SO4) for 1, 3, 7, 28, 56, and 90 days. The L20S25 mix FaL-S DSB exhibited minimum loss in weight (5.69%) and loss in strength (11.50%) compared to other proportions.