Investigation of the medium calcium based non-burnt brick made by red mud and fly ash: durability and hydration characteristics

Abstract

Red mud is a type of highly alkaline waste residue produced in the process of alumina smelting by the Bayer process. Based on the idea of medium calcium content, solid wastes such as red mud and fly ash were used to prepare non-burnt bricks; and the mass ratio of CaO/SiO2 was selected in the range of 0.88–1.42. Mechanical properties and durability were investigated with a compressive strength test. X-ray diffractometry (XRD), scanning electron microscope (SEM), and Fourier transform infrared spectroscopy (FTIR) techniques were used to characterize the hydration characteristic. The environmental performance was analyzed by Inductively Coupled Plasma Mass Spectrometry (ICP). The results indicated that the mechanical properties and the durability were optimal when the mass ratio of CaO/SiO2 was 1.23. The hydration products were mostly C-S-H gel, ettringite, Na4Ca(Si10Al16)O32·12H2O and Ca3Al2(SiO4)(OH)8. They were responsible for the strength development, and the CaO/SiO2 mass ratio of 1.23 had the best polymerized structure. The results of an environmental performance test showed that the heavy metals in the raw materials were well-solidified in the brick. Therefore, this paper provides an effective solution for use of solid wastes in building material.