An Experimental Study on Strength of Concrete by Using Red Mud as Partial Replacement of Cement

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 08 | Aug 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 930
An Experimental Study on Strength of Concrete by Using Red Mud as
Partial Replacement of Cement
Somnath R. Mane, Prof. K.S. Upase
1M.TECH student, Civil Engineering Department,MS Bidve Engineering College, Latur, Affiliated to Dr. Babasaheb
Ambedkar Technological University, Lonere, Approved by AICTE, Accredited by NAAC, Maharashtra, India.
2Assistant Prof., Civil Engineering Department, MS Bidve Engineering College, Latur, Affiliated to Dr. Babasaheb
Ambedkar Technological University, Lonere, Approved by AICTE, Accredited by NAAC, Maharashtra, India.
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Red mud was used in the research as a cement
substitute in order to explore the qualities of concrete. The
Bayer Process, used to make alumina from bauxite ore, is
notable for its low energy efficiency and for producing large
volumes of red mud, or dust-like bauxite leftovers with high
levels of alkalinity.
Along with several other minor components, it is
made up of iron, titanium, aluminium, and silica oxides. Red
mud's presence of alumina and iron oxide makes up for
limestone's lack of those substances, which is the main raw
material used to make cement. Globally, significant efforts
have been made to address red mud management
challenges, including usage, storage, and disposal. These
efforts are motivated by economic as well asenvironmental-
related concerns.
Experiments havebeenconductedunderlaboratory
condition to assess the strength characteristics of the
aluminum red mud. The project work focuses on the
suitability of red mud obtained for construction. Four test
groups were constituted with the replacement percentages
0%, 5%, 10%, 15%, with cement in each series M35 grade
concrete. This paper points out another promising direction
for the proper utilization of red mud.
Key Words: Red Mud, Compressive Strength,
Workability
1. INTRODUCTION
Due to industrialization and urbanisation, cement
output has more than quadrupled globally during the
previous 15 years. In 2015,itisanticipatedthatproductionof
aluminium would increase to around 50 million tonnes. The
Bayer process uses bauxiteore to produce more than 95%of
the alumina that is producedworldwide.Red mud,whichisa
substantial volume of dust-like, highly alkaline bauxite
leftovers, is produced by Bayer's alumina manufacturing
process. One of the greatest industrial byproducts in
contemporarycivilization,itsestimatedworldwideinventory
reached 3000 million tonnes at the end of 2010, and it is
increasing by roughly 120 million tonnes annually. The
chemical and minerological makeup of bauxite residue is
determined by the source of the ore and the minerological
process parameters. Per tonne of alumina, 1–1.6 tonnes of
red mud are produced.
Red mud disposal expenses are between 1 and 2
percent of the cost of alumina. Red mud's cementatious
behaviour was taken into consideration whenanexperiment
was conducted to partiallysubstitutecementwithredmudin
concrete at varying percentages. Its effects on the
reinforcement of other concrete qualities were also
examined.
1.1 Advantages of Using Red Mud in Concrete
 Environmental improvement: Industrial waste may
replace 30% of the cement used in construction
operationsworldwide,reducingcarbondioxideemissions
by up to 320 million tonnes. The issue of not having
enough land to deposit the trash will be solved by
substituting industrial waste in concreting methods, and
ground water contamination can also be managed.
 Improvingsoil quality:Ascivilengineers,ourfirstconcern
should be employing environmentally friendly,
sustainable materials that have the necessary structural
strength. The problems with land storage will be
overcome, and the quality of the neighbouring soil will
significantly improve, if we employ red mud waste in the
production of concrete.
 Reduction in the Energy RequirementsfortheProduction
of Ordinary Portland Cement: One tonne of cement
requires between 1.6 and 1.9 tonnesofrawmaterials.The
majority of industrial waste is composed of pozzolanic,
limestone, and clay components. Red mud and fly ash are
examples of industrial wastethat maybeusedproperlyto
save natural resources and reduce resource use.
Additionally, it would save energy use and provide
concrete constructions the necessary strength.
 Benefits to the economy: Making cement demands a
significant amount of energy. Cement replacement can
result in substantial energysavings.Reusingsuchgarbage
does not need any energy.

1.2 Objectives of study:
 To identify various industrial wastes that can be
successfully used in the production of cement.
 To determine the barriers to the usage of industrial waste.
 To develop recommendations to promote the use of
industrial waste.
 To create some affordable, environmentally friendly
alternatives to traditional building materials.
 Characterization of industrial wastes using
physicochemical and mineralogical methods.
 To determine if industrial solid waste is suitable as a
source material, blending material, or admixture.
 To look at the restrictions on using industrial waste.
 To offer suggestions to encourage the use of industrial
waste.
Cement demand currently exceeds total output by a large
margin and is rising quickly.Our goal in this research project
is to investigate the appropriateness and use of dried red
mud as a partial substitute of Portland cement in building
concrete while keeping the aforementioned objectives in
mind.
1.3 Properties of Red Mud
1.3.1. Physical Properties of Red Mud:
 The typical range for red mud's fineness is 1000–3000
cm2/gm.
 Since the PH ranges from 10.5 to 12, itisalkalineinnature.
 Red mud has a specific gravity of 2.62.
1.3.2. Chemical Properties of Red Mud:
About 65% to 70% of the Red Mud is made up of
solids, with the remainder being moisture. Below is a list of
the Dry Red Mud's chemical components.
Table -1: Chemical composition of Red Mud
Components Percentage (by weight)
Fe2O3 30-60%
Al2O3 10-20%
SiO2 10-20%
Na2O 2-10%
CaO 2-8%
TiO2 1.8-2%
2. Materials and Methodology
2.1Cement
Table – 2: Physical Properties of OPC 53 Grade Cement.
Sr. No. Characteristics Values
1 Standard Consistency 53
2
Fineness of cementasretainedon90
micron sieve
3 %
3 Intitial setting time 30 minute
4 Specific gravity 315
5 7 days compressive strength 37 MPA
2.2 Fine Aggregate
The majority of the aggregate is able to pass a 4.75 mm IS
sieve.
The fine aggregate's specific gravity is measured to be 2.64.
2.3 Coarse aggregate
The nearby quarryprovidesthecoarseaggregate.In
this investigation, coarse aggregate with a specific gravity of
2.84 and a fineness modulus of 7.07 is employed. Its size
must be less than 20 mm and more than 12.5 mm.
2.4 Red Mud
Red mud, a byproduct of the Bayer process used to
manufacture aluminium from bauxite, is transported from
HINDALCO Belgaon to substitute cement.
2.5 Casting of Specimen
Test samples for utilizing the conventional moulds,
150mm x 150mm x 150mm cubes will be created. Cast
samples are used. After 24 hours of casting, the samples are
remoulded and maintained in a water tank for 7 and28days
of curing. 24 specimens in all were cast to evaluate various
qualities, including compressive strength and flexural
strength.
There will be 24 cube samples castwith dimensions
of 150mmx150mmx150mm for various Red Mud
replacement cement percentages. The percentages of Red
Mud in the concrete mixes—0%, 5%, 10%, and 15%—
replace some of the cement. Using tamping rods, all cubes
will be cast in a single lift and consolidated.Thecubemoulds
are removed once the cubes have reached their final setting,
and the cubes are then left in the water tank to cure for
between 7 and 28 days. The cube moulds are removed once
the cubes have reached their final setting, and the cubes are
then left in the water tank to cure for between 7and28days.

Table – 3: Number of Beams casted for 7 days and 28 days
% of Red Mud Number of Beam Cast
7 Days 28 Days
0 3 3
5 3 3
10 3 3
15 3 3
2.6 Testing of Specimen
The specimens were taken out of themouldafter24
hours and placed in water for 7 or 28 days to cure. The
specimens underwent a compression test after curing.Tests
were done on the specimen's strength after 7 and 28 days.
2.7 Workability
By using a compaction factor test witha w/cratioof
0.45 for the addition of various percentages of Red Mud, the
workability of concrete of the M35 grade is determined.
Table -4: Slump values for different percentage of mix
% of Red Mud
Slum Value
(mm)
0 92
5 89
10 78
15 71
2.8 Experimental Methodology
Compressive Strength Test
Compressive strength's output 28 days and 7 days
later are noted. The results show that the compressive
strength rises when the percentage of Red Mud is increased
from 0% to 10%; however, as the percentageofRedMud ash
is increased further, the compressive strength decreases.
This indicates that Red Mud can replace up to 10% of
cement.
2.9 Experimental Result
Table -5: Results of Flexural Strength
% of Red Mud
Compressive Strength
7 – Days 28 - Days
0 26.10 48.87
5 26.67 40.87
10 20.86 37.42
15 11.84 17.32
26.1 26.67
20.86
11.84
48.87
40.87
37.4
17.32
0
10
20
30
40
50
60
0% 5% 10% 15%
Compressive
Strength(N/mm2)
Graph 1:Compressive
Strengthat 7 and 28 days
7- Days 28-Days
3. CONCLUSIONS
 The following conclusions may be made from the
experimental research: Red mud absorbs more water
than cement, which is shown by a reduction in slump;
and an increase in red mud content lowers the concrete's
compressive and tensile strengths.
Fig 1. Compression Testing Machine

 Increasing the amount of red mud may make concrete
harder to work with, although superplastcizers can help.
 The constrictive by raising the replacement%ineachset,
strength is diminished. The cubes' compressive strength
can be replaced by up to 10% and still meet the approval
standards (as per IS 456 2000).
 M35 grade Red Mud Concrete costs around 4% cheaper
to make than regular concrete for a 10% replacement.
Thus, we may infer that red mud can be effectively used
as a cement substitute material, enabling large waste
product use.
 Cement and red mud are employed for non-structural
activities. Red mud concrete may one day be utilized
in structural applications. Finally, we may inferthat,with
quality control, red mud can be used as a long-term
alternative to cement in the construction industry.
4. References
1) Satapathy BK, Patnaik SC, Vidyasagar P (1991).
Utilisation of red mud for making red oxide paint.INCAL-
91, International Conference and Exhibition on
Aluminium at Bangalore, India 31st July-2ndAug. 1991
(1): 159-161.
2) Qi JZ. Experimental Research on Road Materials of Red
Mud; University of Huazhong Science and Technology:
Wuhan, China; 2005.
3) R. K. Paramguru, P. C. Rath, and V. N. Misra, ―Trends in
red mud utilization - a review,‖ Mineral Processing &
Extractive Metallurgy Review, vol. 26, no. 1, pp. 1–29,
2005.
4) U. V. Parlikar, P. K. Saka, and S. A. Khadilkar,
―Technological options for effective utilizationofbauxite
residue (Red mud) — a review,‖inInternational Seminar
on Bauxite Residue (RED MUD),Goa,India,October2011.

An Experimental Study on Strength of Concrete by Using Red Mud as Partial Replacement of Cement

More Related Content

Similar to An Experimental Study on Strength of Concrete by Using Red Mud as Partial Replacement of Cement (20)

More from IRJET Journal (20)

Recently uploaded (20)

An Experimental Study on Strength of Concrete by Using Red Mud as Partial Replacement of Cement