Coal based power plants produce huge quantity of fly ash, for safe disposal of this, require huge amount of revenue. Same practice is conducted in SEPCO coal power plant situated in Karachi, this study was conducted to solve disposal issue in productive manner and also determine potential of coal fly ash for development of sustainable efficient construction material. In this study worked was conducted on investigation of alkali activator concentration on fly ash based geopolymer, morphological properties of geopolymer material at micro level using X-ray diffraction, scanning electron microscopy, Fourier-transform infrared spectroscopy and Brunner- Emit- Teller analysis to make it durable and environment friendly material for construction industry. The resulting material formed was porous, amorphous structured material with regular micro and macro pores resulting in reduced density and potentially enhanced properties. EDX analysis revealed lower incorporation of sodium (Na), silicon (Si), and aluminum (Al), indicating a limited dissolution of fly ash and poor formation of the geopolymeric gel and higher levels of unreacted oxides such as calcium (Ca), iron (Fe), and residual quartz reflects an underdeveloped geopolymer matrix due to less concentration of alkaline activator solution. In contrast, the 8 M geopolymer shows significantly higher concentrations of Na, Si, and Al, which are key elements in the formation of N-A-S-H gel networks. The improved Na/Al and Si/Al ratios in the 8 M sample point to more complete dissolution of the raw material and better integration into the geopolymer framework. FTIR analysis indicated the chemical environment of GP, with broad peaks in the 3336 cm-1 range suggestive of hydroxyl groups and new peaks for carbonate and bicarbonate groups. These changes indicate improved surface properties and reactivity, making GP more suitable for various applications. BET isotherm analysis confirmed the presence of meso porous in GP average pore size of 60 µm, porosity of 30.8% and BET surface area of 25 m2/g respectively. This research underscores the potential of CFA derived Geopolymers as a sustainable and high-performance alternative for construction materials. By optimizing the geopolymerization process, it is possible to produce cost-effective, durable, and environmentally friendly bricks and blocks, providing a valuable solution to both waste management and sustainable construction practices.