<p>Red mud (RM), an industrial by-product of alumina production, poses significant environmental disposal challenges, while cement production contributes substantially to global CO₂ emissions. This study aims to develop sustainable high-strength geopolymer concrete (GPC) using RM in combination with ground granulated blast furnace slag (GGBFS) under ambient curing, optimizing precursor ratios and alkaline activator molarity to achieve workable, durable concrete without the application of superplasticizers. Six RM–GGBFS mixes with RM contents 0 to 80% were prepared using sodium hydroxide (SH)and sodium silicate (SS) solutions, maintaining an SS/SH ratio of 1.5 and an alkaline solution-to-binder ratio of 0.45. Results revealed that compressive strengths reached up to 52&#xa0;MPa and 63&#xa0;MPa at 7 and 28 days, with 40–50% RM mixes outperforming GPC made with only GGBFS. Flexural and split tensile strengths improved substantially, by 27–71% and 31–81%, respectively, while 60% RM content achieved strengths comparable to conventional high-strength concrete. Results demonstrated excellent performance under aggressive environments: sulfuric acid immersion caused 4.39% mass gain at 28 days and a minor 1.66% mass loss at 180 days, with compressive strength reductions limited to 2.2–3.14%. Exposure to 5% magnesium sulfate resulted in minimal mass loss (2.06–2.83%) and negligible compressive strength reductions (1–2.43%) over the same period. Additional analyses confirmed low water absorption, reduced embodied energy, a favorable carbon-strength ratio, and competitive costs. These results explain the potential of RM-GGBFS-based GPC as a sustainable alternative to conventional concrete, contributing to resource efficiency, waste utilization, and reduced environmental impact.</p>

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Red mud-ground granulated blast furnace slag-based geopolymer concrete: a comprehensive study on mechanical performance, durability and environmental impact

  • Mohibullah,
  • Prasanna Kumar Acharya

摘要

Red mud (RM), an industrial by-product of alumina production, poses significant environmental disposal challenges, while cement production contributes substantially to global CO₂ emissions. This study aims to develop sustainable high-strength geopolymer concrete (GPC) using RM in combination with ground granulated blast furnace slag (GGBFS) under ambient curing, optimizing precursor ratios and alkaline activator molarity to achieve workable, durable concrete without the application of superplasticizers. Six RM–GGBFS mixes with RM contents 0 to 80% were prepared using sodium hydroxide (SH)and sodium silicate (SS) solutions, maintaining an SS/SH ratio of 1.5 and an alkaline solution-to-binder ratio of 0.45. Results revealed that compressive strengths reached up to 52 MPa and 63 MPa at 7 and 28 days, with 40–50% RM mixes outperforming GPC made with only GGBFS. Flexural and split tensile strengths improved substantially, by 27–71% and 31–81%, respectively, while 60% RM content achieved strengths comparable to conventional high-strength concrete. Results demonstrated excellent performance under aggressive environments: sulfuric acid immersion caused 4.39% mass gain at 28 days and a minor 1.66% mass loss at 180 days, with compressive strength reductions limited to 2.2–3.14%. Exposure to 5% magnesium sulfate resulted in minimal mass loss (2.06–2.83%) and negligible compressive strength reductions (1–2.43%) over the same period. Additional analyses confirmed low water absorption, reduced embodied energy, a favorable carbon-strength ratio, and competitive costs. These results explain the potential of RM-GGBFS-based GPC as a sustainable alternative to conventional concrete, contributing to resource efficiency, waste utilization, and reduced environmental impact.