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A Geopolymeric Approach to Utilize the Bound Caustic of Bayer’s Red Mud and Waste Foundry Sand in Clay Brick

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Abstract

Disposal of red mud and waste foundry sand (WFS) is a serious issue because of its adverse effect on environment. On the other hand the availability of natural clay for brick manufacturing is scarce. The present study attempts to utilize red mud, waste foundry sand and fly ash as a replacement for natural clay in bricks. Geopolymeric approach was adopted to cast bricks in which the calcination of the bricks was avoided. Initially, the bricks were casted in two sets with varying concentration of caustic of 10 M and 12 M, respectively, along with waste foundry sand (WFS), fly ash, sodium silicate and caustic (precursors). Thus, casted bricks of 12 M gave compressive strength of 3.5 N/mm2 and water absorption of 3.93%. However, the bricks showed heavy efflorescence as time elapsed. Further to reduce the efflorescence, the fresh caustic concentration was reduced to 5 M by utilizing the red mud which had bound caustic associated with it. Eventually these bricks reduced the problem of efflorescence and gave strength of 3.27 N/mm2 comparable with conventional clay bricks (3.6 N/mm2). The bricks were investigated for its mineralogy using XRD which showed presence geopolymeric minerals. The study gives novel approach to utilize red mud in clay bricks by geopolymeric approach without any pretreatment and calcination.

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The research did not receive any specific grant from funding agencies in public, commercial or not for profit sector.

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Authors and Affiliations

  1. Department of Civil Engineering, KLE Dr. M. S. Sheshgiri College of Engineering and Technology, Belagavi, Karnataka, India

    Pratibha V. Gaonkar, Shristi Bevinakatti, Nayana P. Hoolikantimath, Basavaraj G. Katageri & Praveen A. Ghorpade

  2. Department of Civil and Environmental Engineering, KIT’S College of Engineering, Kolhapur, Maharashtra, India

    Smita S. Borchate

Authors
  1. Pratibha V. Gaonkar
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  2. Shristi Bevinakatti
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  5. Basavaraj G. Katageri
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  6. Praveen A. Ghorpade
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Correspondence to Praveen A. Ghorpade.

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Gaonkar, P.V., Bevinakatti, S., Hoolikantimath, N.P. et al. A Geopolymeric Approach to Utilize the Bound Caustic of Bayer’s Red Mud and Waste Foundry Sand in Clay Brick. Indian Geotech J 53, 473–483 (2023). https://doi.org/10.1007/s40098-022-00683-3

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  • DOI: https://doi.org/10.1007/s40098-022-00683-3

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