Oil palm shell (OPS) in concrete is well studied as an alternative material of fine aggregate in concrete, as a way to use agricultural waste, and helps to contribute to environmental sustainability and economical construction cost. However, OPS addition will lead to lower properties of the concrete, and much research focuses on treating the OPS to overcome it. Many previous works focused on replacement without examining the effect of different particle sizes of OPS. Hence, this study focuses on the performance of concrete with different particle sizes of OPS as sand replacers in concrete at 25% and 50%. The physical and permeability properties of concrete prepared with OPS particle sizes in the ranges between 600μm to 4.75mm (L), 300μm to 1.18mm (M), and of less than 600μm (S) and two different percentages of 25% and 50% by weight as sand replacement are examined. More than 200 cubes, cylinders, and prisms were tested to determine their physical, mechanical, and permeability properties. The workability was measured by the slump height, the mechanical properties by the compressive strength test, flexural strength test, splitting tensile test, ultrasonic pulse velocity (UPV) test, and rebound hammer test. While the permeability properties by the water penetration test, sorptivity test, and rapid chloride permeability test. The findings showed that increasing the particle sizes of OPS would reduce concrete’s physical and permeability properties. The optimum OPS particle size for structural concrete grade 30 is less than 600μm. With OPS particles of 600um, green concrete using OPS can be made for medium to low-strength applications in the construction industry.

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