Materials Research. 2012; 15(3): 333-340
© 2012
DOI: 10.1590/S1516-14392012005000033
Concretes with Red Mud Coarse Aggregates
Dênio Ramam Carvalho de Oliveira*, Carlos Rodrigo Costa Rossi
Faculty of Civil Engineering, Federal University of Pará – UFPA,
Rua Augusto Correa, 1, CEP 66075-970, Belém, PA, Brazil
Received: August 26, 2011; Revised: January 31, 2012
Red mud (RM) is a mineral waste, residue of the Bayer process used to obtain alumina from
bauxite. While the exploration of rolled pebble damages the environment and is much more controlled
by the government, the huge RM disposal areas do not stop increasing and polluting soil, rivers and
groundwater sources in Amazon. In this work, the material mixtures used to produce coarse aggregates
presented up to 80% of RM, 30% of metakaolin and 30% of active silica as recycled waste. Several
tests were carried out to determine the aggregates physical properties and to evaluate the mechanical
performance of the concretes with the new aggregates, including hydraulic abrasion strength, and the
results were compared to the reference ones, i.e. rolled pebble concretes. Additionally, the sintering
process neutralizes any toxic substance as occur in some RM products like tiles and bricks, and these
results have encouraged an industrial or semi-industrial production of RM aggregates for concretes.
Keywords: concrete, red mud, coarse aggregate, hydraulic abrasion
1. Introduction
The degradation of the natural resources causing a
shortage of raw materials supports the search for alternative
materials, clean sustainability and waste recycling
techniques. Thus, efforts must be done not only for recycling
but also for the development of large-scale production
materials in attempting to avoid large amounts of waste,
especially mineral waste. Currently, Brazil is the third largest
world producer of alumina, generating around 6.1 million t
of the industrial waste RM per year causing serious damage
to the nature. The waste red mud is a byproduct from the
aluminum industry, concentrated in the north region of that
country, mainly in the Para state, northeast of the Amazon
forest. Environmental problems from the inappropriate
disposal of waste varies from contamination of rivers,
groundwater, soil, flora and fauna damage, corrosion of
metal equipment and the bad aspect of the storage areas.
Thus, many researches for RM application in constructions
have been conducted for both the appropriate allocation of
the residue or its use in industrial scale, e.g. Yang & Xiao1
and Sglavo et al.2. Even for a correctly planned factory
costs with transport up to the disposal areas associated
to the annual huge amounts of RM, without considering
costs with installation and maintenance of geosynthetics
and contention walls, become its management extremely
necessary to enable a better control of the disposed volumes.
Therefore, this work presents an innovative alternative
application for RM, mixing it with fine sand, metakaolin or
active silica for further burning to obtain a ceramic aggregate
with mechanical strength and average apparent density
appropriate for the application in conventional concretes.
However, as it is a case of new material, it is necessary to
evaluate the aggregates with physical characterization tests.
*e-mail:
[email protected]
All samples were grouped to enable comparisons in terms
of density, unit mass, shape, texture and water absorption
in relation to the concretes with natural rolled pebble (SiO2)
once it is the main coarse aggregate applied in the north
region of Brazil, in the Amazon forest. This aggregate come
from the Amazon rivers bed and its exploration damages the
environment permanently, changes the rivers profile and
prejudices the subsistence (fishing) of the riverine people.
To prove the feasibility of high levels of RM in
the production of coarse aggregates for concretes, the
methodology recommended by Albuquerque3 was followed,
which achieved satisfactory results with the tested mixtures,
good enough to technically compete with the rolled pebble
aggregates. On the toxicity of the new aggregates, the
vitreous silica structure forms the basis of the compositions
for the trading glass, whose properties are modified by the
addition of other metal oxides. The wide use of silica in
the ceramic is due to its hardness, infusibility, low cost and
ability to form glasses. If in the manufacturing process,
during the formation of glassy phase, the gases escape, no
swelling of clay particles is possible, these defects can be
corrected by adding appropriate fusible materials, as the
burned oil, which lifts the period of gas releasing to higher
temperatures, or by faster heating with less introduction of
air or by adding substances that increase the viscosity of
the glassy phase. This vitreous structure becomes the RM
aggregates inert and secure to be handed4,5. The mechanical
properties of the concrete mixtures of Albuquerque3 were
also competitive, with an average compressive strength
of 20 MPa and an average elasticity modulus of 26 GPa,
equaling and surpassing in 26% the values found for the
reference concrete (with rolled pebble), respectively. Then,
trying to improve the performance of the new aggregates
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Oliveira & Rossi
mixtures with proportions of 1:1.5:2.5 or 1:1.5:3.0 in mass
were tested. The results overcame expectations for all
tests, corroborating the use of the new alternative materials
involved by hard concrete.
2. Experimental Program
2.1. Materials
2.1.1. Red mud
The residue used in this work came from a mining
company placed near to Belém city, in the north region of
Brazil. Generically, this RM has a typical composition and
is an insoluble residue generated during the clarification
stage of the Bayer process in the alumina production. The
chemical composition of RM can be variable and depends
on the nature of the bauxite. Normally, the RM retains all
iron, titanium and silica present in the bauxite, besides
the aluminum not extracted during the refining, combined
with sodium in the form of an aluminum silicate hydrated
and sodium of zeolitic nature. The most common mineral
phases are hematite (α-Fe 2O 3), goethite (α-FeOOH),
magnetite (Fe3O4), boehmite (γ-AlOOH), quartz (SiO2),
sodalite (Na4Al3Si3O12Cl) and gypsum (CaSO4.2H2O), with
small amounts of calcite (CaCO3) and gibbsite (Al(OH)3),
according to Barrand & Gadeau6 and Motta & Oliveira7.
Table 1 presents the chemical composition of the RM used
as raw material to produce coarse aggregates, and Figure 1
shows the X-ray diffraction8.
On the toxicity of the waste, the Environmental
Protection Agency (EPA) does not classify the RM as a
hazardous waste. However, there is a presence of high
levels of calcium and sodium hydroxide, leaving the
RM toxic and constituting a danger to people nearby.
One of the reasons for the environmental impacts caused
by the high alkalinity is due to the same elements that
make it toxic (Soda). The large world production of RM
is associated with a more rigorous implementation of
Materials Research
ecological monitoring. Several countries have adopted
appropriate procedures to dispose of this waste in a
correct way to avoid the contamination of the soil and
rivers, as shown on Figure 2. In China, around 10% of
RM produced is recycled for extraction of metal or used
as raw material for bricks production. The ceramic blocks
were used in constructions at the southeast of Australia.
A whole house with RM ceramic products was built
in Barcarena, a small city placed 200 km from Belém,
where tests are being carried out to verify the possibility
of incorporation of this waste in the Portland cement.
The amount of RM disposed in Amazon represents 80%
of the Brazilian annual production, 6.132 million t9, as
shown on Figure 3, and this volume could be totally used
to produce bricks and tiles.
2.1.2. Coarse aggregates
Aggregate is an inert component that when added
to concrete performs the function of filling and resistant
material consisting of particles jointed by the cement
paste, result from the hydration of the mixture. In this
work sand of quartz origin was added as fine aggregate
and the rolled pebble was used as reference natural coarse
aggregate. Such reference aggregates were sieved according
to NBR 721710 to present average diameter of 19.0 mm,
similar to the average diameter of the aggregates with RM,
except RMMC70.
After analyzing the costs generated to produce RM
bricks and tiles to build the house in Barcarena, it was
verified that the production of aggregates for concretes could
be feasible and would consume a large amount of RM as the
bricks manufacturing had done. Then, the RM was taken to
a drying oven at 100 °C for 24 hours and after was milled
in a mill balls until the large grains become powder, which
lasted 2 hours approximately. The mass percentages for
each material of the mixtures were 70 or 80% of RM, 30 or
20% of fine sand, 2% of burned oil and 30% of water, to
improve the workability of the composite. Table 2 shows the
Table 1. Chemical composition of the Amazon RM (Hildebrando et al.8).
Composition
Fe2O3
SiO2
Al2O3
Na2O
TiO2
CaO
K 2O
MgO
Fire loss
%
39.2
19.18
19.10
9.01
3.04
1.21
0.10
0.04
9.12
Figure 1. X-ray diffraction of the Amazon red mud (Hildebrando et al.8)
Figure 2. RM disposal area in Pará.
Concretes with Red Mud Coarse Aggregates
2012; 15(3)
335
Table 2. Mixture proportions to produce the RM coarse aggregates.
Mixture
RMAS70
RMMC70
RMFS70
RMTS70
RMFS80
Component (%)
Active
silica
Metakaolin
Fine
sand
Thick
sand
Red
mud
30
0
0
0
0
0
30
0
0
0
0
0
30
0
20
0
0
0
30
0
70
70
70
70
80
Figure 5. RM coarse aggregates sintering.
Figure 3. RM amount disposed in Amazon.
for concretes. This proposal is still under analysis. Figure 4
shows a comparison between the estimated consumption and
final cost of the RM aggregates, bricks and tiles, and only
the tiles annual production did not surpassed the RM annual
generation. These final costs are close to those practiced in
Brazil, and can be reduced along the manufacturing process
of the aggregates.
Cubic metal molds were used for initial conformation of
the aggregates, resulting in a well defined cubic geometry
with edges of 20 mm, aiming a low variation on the average
diameter of the aggregates. After the initial molding the
aggregates were still plastic to be rounded manually to
simulate the rolled pebble geometry. The next step was to
take the aggregates to a special oven (shown on Figure 5),
set on a refractory tray covered by alumina powder, and
the temperature was increased to 1,200 °C for sintering
for a period of 3 hours approximately. It was found that
around 40% of the final temperature there was a slight
shrinkage on the aggregates ranging from 4.8 to 15.0%.
Therefore, the maximum diameter was 19.0 mm, except
for RMMC70 with 9.5 mm. Figure 6 shows the coarse
aggregates ready to be used.
2.1.3. Concrete mixtures
Figure 4. Consumption of RM and final cost to manufacture
aggregates, bricks and tiles based on the Brazilian annual production
of these materials.
mixture proportions with fine sand (RMFS70 and RMFS80),
thick sand (RMTS70), metakaolin (RMMC70) and active
silica (RMA-S70). From these mixtures was possible
estimate the costs to produce the referred aggregates in a
rotary cylindrical oven taking account the stages applied
in the clinker production and its relative costs. It must be
remarked that a similar oven was proposed by the researchers
of the Federal University of Pará in 2010 to be built by an
aluminum producer aiming to produce coarse aggregates
The concrete preparation methodology was initially
to weight all materials according to the mix proportion
of 1:1.5:2.5 in mass. However, after the first tests and
aiming better mechanical performance, the ratio coarse
aggregate/cement was increased in 20%, ranging from 2.5
to 3.0 during the dosage of RP19b and RMFS80 samples.
The applied materials were the cement CP II-Z-32, washed
fine sand and coarse aggregates with RM for comparison
with the reference concretes, dosed with rolled pebble.
The predicted resistance for the reference concretes was
25 MPa, with water/cement (w/c) proportion constant of
0.45 for all mixtures3. There was a need of plasticizer
additive Glenium 51 in the dosage of the samples RMFS80
and RP19b, and the amount was in accordance with the
recommendation of the manufacturer. Figure 7 shows
the mixture procedure and the cylindrical specimen
preparation.
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Oliveira & Rossi
Materials Research
2.2. Testing methodology
2.2.1. Coarse aggregates
The RM aggregates physical characteristics as unit
mass, density and water absorption were experimentally
determined in accordance with the codes NBR 993711,
NBR 977612 and NBR 725113, respectively. Only one sample
of each aggregate was tested.
2.2.2. Concrete
Figure 6. Rolled pebble and RM coarse aggregates ready to be used.
Figure 7. Concrete specimens preparation.
Figure 8. Hydraulic abrasion test.
To establish the influence of aggregates (produced
with RM and a second raw material) in the physical
and mechanical properties of the concretes, several
tests were carried out to determine the density, axial
compressive resistance and the elasticity modulus. In all
cases cylindrical specimens (SPs) were used and grouped
as follows: 36 SPs for density tests, 30 SPs for elasticity
modulus tests and more 42 SPs for axial compression
tests, all proofs with 100 mm of diameter and 200 mm
of height, totalizing 108 SPs. The testing methodology
used to determine the mechanical properties followed the
prescriptions of NBR 573914, NBR 852215 and NBR 722216.
All specimens were kept under the same environmental
conditions in a humid chamber.
The abrasion resistance at 28 days is a very importance
parameter because it is the final resistance of the concrete
to be considered in the design of weirs, canals and wet
concrete pipes lines, which are constructions largely
applied in Amazon. Because of this, the resistance at this
age is a standard parameter for the performance of these
materials over their service life. The testing methodology
recommended by ASTM C1138M17 qualitatively intends to
simulate the behavior of water in spiral motion containing
suspended solids, i.e. small steel spheres to abrade the
concrete, enabling evaluation the relative resistance of the
Concretes with Red Mud Coarse Aggregates
2012; 15(3)
337
Table 3. Physical properties of the coarse aggregates.
Specimen
Density
(kg.m–³)
Unit mass
(kg.m–³)
Water absorption
(%)
Initial diameter
(mm)
Final diameter
(mm)
RP19
RP9.5
RMFS80
RMFS70
RMTS70
RMAS70
RMMC70
2,650
2,660
2,440
2,650
2,160
1,200
2,040
1,450
1,510
1,410
1,670
1,240
0,690
1,180
1,00
1,00
0.83
0.50
1.00
3.25
0.25
19.0
9.5
20.0
20.0
20.0
20.0
10.0
19.0
9.5
19.0
19.0
19.0
19.0
9.5
Table 4. Concretes’ density and mechanical properties.
Concrete sample
–
Density (kg.m ³)
NSP/SD
Elasticity modulus (GPa)
NSP/SD
Compression strength (MPa)
NSP/SD
RP19a
RP19b
RP9.5
RMFS80
RMFS70
RMTS70
2,300
2/1.0
2,310
9/74.5
2,270
3/13.2
2,350
9/64.3
2,330
3/29.3
2,040
3/3.8
2,050
3/7.1
1,780
3/30.7
23.6
20.6
24.3
38.9
30.2
25.8
29.9
19.4
3/1.5
6/1.7
3/0.8
6/3.5
3/1.7
3/1.6
3/0.5
3/1.0
23.4
5/2.5
25.9
6/1.8
28.2
5/2.8
40.3
6/2.1
20.0
5/4.1
18.2
5/4.3
24.1
5/2.2
5/2.9
concrete against hydraulic abrasion. Then, six concrete
disks with diameter of 300 mm and height of 100 mm
were prepared, three with RM aggregates and three with
rolled pebble. The equipment and testing details are shown
on Figure 8.
In this experiment the volumes (Vt) of the specimens
are determined and then they remain under test for 72 hours
and volume measurements are taken each 12 hours,
totaling seven measurements (including the zero hour
measurement). Thus, the volume is calculated according
to Equation 1. The specimen’s abrasion is measured in
relation to the lost material volume (VLt), taken as the
difference between the initial volume of each specimen (Vi)
and its volume at a given moment (Vt), as shown on
Equation 2. The results of the tests are the volumes of lost
or abraded material for each period of 12 hours. At this
time, to compare the samples, the final abrasion test results
were used, i.e. results of 72 hours of abrasion. Another way
to show the test results, according to ASTM C1138M17, is
to measure the average abraded height (HEt), considering
the area on the top of the specimen (A) always constant,
according to Equation 3.
Vt =
RMMC70 RMAS70
Wa − WW
GW
(1)
VLt = Vt − Vi
(2)
HEt = VLt / A
(3)
With,
• Wa: mass of the specimen in saturated air;
• Ww: apparent mass of the specimen;
• Gw: density of water.
17.2
3. Experimental Results
3.1. Aggregates physical characterization
The lowest value for density was found for RMAS70
which presented the highest water absorption of 3.5%. The
highest density was for RMFS70, but with water absorption
of 0.5%, as presented in Table 3. The classification according
to the density of aggregates was performed as follows:
lightweight aggregates (γ < 1,120 kg.m–3), normal weight
aggregates (1,120 kg.m–3 < γ < 2,080 kg.m–3) and heavy
aggregates (γ > 2,080 kg.m–3)18. From the experimental
results the RM aggregates were classified as heavy weight,
except RMAS70 and RMMC70, classified as normal weight
aggregates, with RMAS70 presenting just 1,200 kg.m–3. This
lower value for active silica had already been observed in
previous researches and new RM lightweight aggregates
are being developed in the Federal University of Pará using
additives to increase releasing of gases and become the
structure of these aggregates more porous.
3.2. Concrete physical and mechanical
characterization
All specimens were tested at the age of 28 days and the
average results are presented in Table 4. In this table, NSP
and SD mean number of tested specimens and standard
deviation, respectively. For all tests of axial compression
and elasticity modulus a servo-controlled machine was used.
The experimental results are discussed below.
3.2.1. Density
The concrete density was obtained through the
mass/volume relationship for all 36 SPs. The lowest value
was found for the RMAS70 concrete, 1,780 kg.m–3. It was
expected once the lightest aggregate was also RMAS70,
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Oliveira & Rossi
Materials Research
Figure 9. Elasticity modulus and axial compression tests.
this high percentage enables to suppose that their physical
and mechanical properties can influence the mechanical
properties of the concretes significantly18. In this work the
elasticity modulus of the aggregates were not determined,
but it was observed that this mechanical property for the
concretes with RM aggregates varied with the density of the
concretes, and the value found for RMFS80 was twice the
value for RMAS70, following the same proportion between
their coarse aggregate density, which resulted in a larger
amount of RMAS70 aggregate and porosity.
3.2.3. Axial compression strength
Figure 10. Abrasion evolution through height loss measures.
which reduces the overall hard concrete weight, and as the
mass proportion of cement plus fine aggregate to coarse
aggregate is 1.0, the final result should be close to an
average density. The highest value was found for RMFS80,
2,350 kg.m–3, just 2% higher than the reference concrete
RP19b.
3.2.2. Elasticity modulus
The elasticity modulus tests on the 30 SPs with RM
and rolled pebble aggregates at the age of 28 days were
conducted in accordance with NBR 852215. Except the
group RMAS70 all concretes with RM aggregates presented
values higher than the reference ones. The highest value
of 38.9 GPa was found for RMFS80 and was 90% higher
than that for RP19b, with same mixture proportion. The
elasticity modulus is directly related to the properties of
the cement paste, with the modulus of stiffness of the
aggregates and the method of its determination. In general,
coarse aggregates can represent up to 70% of the normal
concrete volume (compressive strength < 50 MPa), and
The average experimental values for axial compression
strength of all samples were found according to NBR 573914
prescriptions. The reference concrete strengths were close
to the expected for 28 days, 25 MPa and the concrete with
the aggregate sample RMFS80 presented resistance around
40 MPa, corroborating the elasticity modulus behavior and
being 67% higher than the sample RMMC70. Figure 9
shows the final aspect of the samples where the failure
cracks occurred in the paste, indicating the high strength
of the material used as aggregate.
3.2.4. Hydraulic abrasion strength
The average hydraulic abrasion experimental results
are presented in Table 5. Figure 10 shows the average
abraded height evolution versus the elapsed time considering
specimens RMFS19-80 and RP19b. The average abraded
height for RMFS80 was around 85% of the reference
concrete RP19b, but the larger difference found between
the disks was 30%, that can be explainable by the greater
mechanical resistance of the concrete.
Figure 11 shows the aspect of the disks surface between
second (12 hours) and seventh measurement (72 hours)
for both concretes. RMFS80 concrete abraded less and
presented a uniform aspect and only the RP concrete
began to abrade in the aggregate at the time of 12 hours.
The RM aggregate abrasion was just recorded in the third
measurement (24 hours). After the seventh measurements,
according to ASTM C1138M17, all specimens were dried
Concretes with Red Mud Coarse Aggregates
2012; 15(3)
339
Table 5. Abraded volume and height for RP19b and RMFS80 concrete disks.
Sample
Parameter
SR19b
VLt (liter)
NSP/SD
HEt (mm)
NSP/SD
VLt (liter)
NSP/SD
HEt (mm)
NSP/SD
RMFS80
Hours
0
12
24
36
48
60
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.173
3/0.046
2.448
3/0.649
0.103
3/0.058
1.146
3/0.818
0.308
3/0.100
4.357
3/1.412
0.223
3/0.072
3.155
3/1.013
0.372
3/0.070
5.267
3/0.992
0.288
3/0.069
4.070
3/0.978
0.457
3/0.093
6.465
3/1.318
0.343
3/0.045
4.852
3/0.633
0.495
3/0.107
7.008
3/1.515
0.385
3/0.010
5.451
3/0.134
72
0.517
3/0.122
7.314
3/1.728
0.442
3/0.037
6.253
3/0.526
Figure 11. Concrete disks after second and seventh (bottom) abrasion measurements.
up in an oven at 100 °C during 24 hours and weighed to
determine the dry abraded mass. The average lost mass
for RMFS19-80 samples was 8.5% against 9.2% of the
references RP19b.
4. Conclusion
The direct use of red mud in the production of different
types of new RM coarse aggregates leads to results quite
motivating. The average value for axial compression strength
of the sample RMFS80 was 55% higher than RP19b and
67% above of RMMC70. The result was more significant
for the modulus of elasticity, exceeding the value of RP19b
in 89%. Considering the abrasion resistance of the RMFS80
concrete, it was verified a lower abrasion degree. Due to the
rounder shape of the new aggregates, with a smaller contact
area, and to the stronger cement paste, the RMFS80 concrete
had an average abraded height 15% lower than the RP19b
concrete. It was an expected and reasonable result once
normal weight aggregates were used, but the application
Oliveira & Rossi
340
of RM as aggregates for concretes resistant to hydraulic
abrasion proved to be technically feasible and indicates
its durability under hard conditions. The rounded shape,
the highest concentration of waste (RM) in the mixture
and, especially, the higher proportion of coarse aggregates
contributed to the best mechanical performances. Therefore,
despite of the few tests carried out and discussed in this
work, and no information concerning the durability of these
alternative aggregates, their application in conventional
Materials Research
concretes seems to be possible and satisfactory, but others
properties must be investigated to enable an industrial or
semi-industrial scale production.
Acknowledgments
The authors thank to CAPES, CNPq and ITEGAM by
the financial support in developing this and other researches
in the Amazon forest.
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