Environmental risks and mechanical evaluation of recycling red mud in bricks

More and more by-products are being used in certain materials, especially in the construction industry. Natural construction materials contain amounts of heavy metals and radionuclides , but when by-products are used in these kinds of materials, this could lead to a growth in their concentrations and have a negative impact on public health.In this paper, red mud was used as a raw material (as a clay substitute) to manufacture fired bricks. Physical, mechanical, radiological and heavy metal leaching properties of fired bricks with a replacement ratio of up to 80 wt% of clay to red mud are discussed. In addition, the effect of different sintering temperatures (1173K and 1373K) was analyzed, and results showed that the higher the temperature produced, the higher the mechanical strength.To environmentally characterize materials, they were subjected to two different leaching tests: a batch test for raw materials and a monolithic test for the bricks, respectively. The results obtained were compared with the limits stated for several heavy metals by the European Landfill Directive. Results showed that red mud gives leachate concentration values for Cr higher than the limits stated for non-hazardous by-products. Bricks do not exhibit the same problem in the samples containing a high RM proportion and manufactured at a low sintering temperature (1173K), although in the case of V, a high concentration is observed.The contents of radionuclides such as Ra-220, Th-232 and K-40 of the final construction materials were analyzed and compared with different indexes. This paper indicates the maximum amounts of RM that can be used to replace clay for the manufacture of fired bricks without environmental risk. • Fired brick utilized red mud instead of traditional clay in a high ratio have been studied. • The temperatures and content of red mud on the properties of bricks were studied. • Bricks with 80%wt of RM and fired at 1100 °C present a compressive strength higher than 16 MPa. • No leaching and radiological problems according to different test and limits have been found with a high RM content.