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This study investigated the potential of partially replacing cement with red mud (RM) in concrete and examined its effects on its mechanical properties and microstructure. This study aims to explore sustainable alternatives to traditional cement and evaluate the performance of concrete mixtures with varying percentages (%) of RM as cement replacement.

This research aims to comprehensively understand the impact of RM on concrete, aiming for both environmental sustainability and improved construction materials. Subsequently, concrete mixtures were prepared with varying RM contents, ranging from 0% to 21% in increments of 3%, replacing cement. The workability of these mixtures was evaluated using the Slump Cone Test, whereas their mechanical properties (compressive strength, flexural strength and split tensile strength) were assessed through standardized tests. The durability was further investigated via water absorption, acid attack, rapid chloride permeability tests, open porosity test and Sorptivity test. To gain deeper insights into the internal structure of concrete, microstructure analysis was conducted using X-ray diffraction and scanning electron microscopy. Finally, the results were analyzed and quantified.

The finding demonstrates that substituting 12% of cement with RM not only boosts the mechanical characteristics of concrete but also mitigates waste disposal. The microstructural analysis identified a denser cement matrix and improved bonding between the cement paste and the aggregates, suggesting potential improvements in strength and durability.

These results suggest that RM can be efficiently used to produce sustainable concrete with potential applications in construction projects with environmental considerations.