The aluminum Bayer production process is widespread all over the world. One of the waste products of the Bayer process is a basic aluminosilicate bauxite residue called red mud. The aluminosilicate nature of red mud makes it suitable as a precursor for alkali-activated materials. In this work, red mud was mixed with different percentages of blast furnace slag and then activated by sodium silicate solution at different SiO₂/Na₂O ratios. Obtained samples were characterized by chemical–physical analyses and compressive strength determination. Very high values of compressive strength, up to 50 MPa, even for high percentage of red mud in the raw mixture (70 wt.% of RM in powder mixture), were obtained. In particular, the higher compressive strength was measured for cubic samples containing 50 wt.% of RM, which showed a value above 70 MPa. The obtained mixtures were characterized by no or scarce environmental impact and could be used in the construction industry as an alternative to cementitious and ceramic materials.

The aluminum Bayer production process is the most diffused process in the world, but it creates a high amount of basic waste material known as red mud (RM). The use of RM as a precursor of alkali-activated materials is one of the best opportunities for both the ecosystem and the economy. In the present work, mortar samples were obtained by alkali activation of RM with various percentages of blast-furnace slag (BFS) and inert construction and demolition sands. This process creates samples that have a low environmental impact and that can be used as an alternative in the construction industry to cement materials or ceramic ones. The development of these new materials could also represent a way to reduce the CO₂ emissions linked to cement and ceramic brick production. In the present study, cubic 40 mm samples reported very interesting values in compressive strength, with a maximum of about 70 MPa for low environmental impact mortars. With such a material, it is possible to create solid bricks for structural use and concrete tiles for road paving or use it for other purposes. Mortar specimens were prepared and characterized, and an LCA analysis with a “cradle-to-gate” approach was carried out for a comparison of the environmental impact of the studied mortars with other materials currently marketed.

In recent years geopolymers have shown increased interest as binders with low CO₂ emission compared to Portland cement. The main goal of this research is focused on connecting green and sustainable characteristics with the mechanical and chemical properties of fly ash-based geopolymer. The samples of different ratios of fly ash (FA) and metakaolin (MK) were prepared. X-ray powder diffraction (XRD) showed that in the geopolymer synthesis reaction a new amorphous phase was formed. Diffuse reflectance infrared Fourier transform spectroscopy (DRIFT) confirmed characteristic bands of the Si-O and O-Si-O groups at 1045 cm⁻¹. Compressive strength analysis revealed that the optimal ratio of FA and MK is 50:50 and exhibits the highest value. X-ray photoelectron spectroscopy (XPS) analysis revealed the total reduction of carbon content in the alkali-activated geopolymer with the optimal stoichiometry of 50:50. This indicates the possibility of obtaining a geopolymer material with an almost complete absence of carbon, which implies further application as a material with a very high environmental potential and of zero carbon emissions.