Mechanical and microstructural characterization of one-part binder incorporated with alkali-thermal activated red mud

The traditional production of silicate cement is associated with substantial carbon emissions and environmental degradation. In contrast, cementless alkali-activated binders, derived from solid waste and industrial byproducts, have garnered significant interest for their reduced material costs, energy efficiency, and environmental benefits. This research investigates the application potential of an advanced mixture of anhydrous sodium silicate and red mud in one-part alkali-activated binders. It is assessed through various analytical techniques, including compressive strength, X-ray diffraction, fourier transform infrared, thermogravimetric analysis, digital image correlation, and scanning electron microscopy with energy dispersive spectroscopy. Findings demonstrate that the synergy between red mud and anhydrous sodium silicate markedly enhances the early strength of one-part alkali-activated binders incorporated with alkali-thermal activation. The increment in sodium silicate content is pivotal for bolstering binder performance. A 40% red mud admixture results in a compressive strength of 40 MPa, achieving an optimal carbon-to-strength ratio. The inclusion of polypropylene fiber significantly influences the mode of compression failure in alkali-activated binders. Alkali-thermal activation of red mud elevates the levels of active silicon and aluminum, markedly augmenting the reactive silica and aluminum content. This modification fosters the disintegration and reorganization of Si-O and Al-O bonds in silica-aluminum materials, culminating in a denser structure. This structure is characterized by the generation of amorphous ((N, C)-A-S-H) gels, contributing to the material's enhanced properties.