Microstructural Evolution and Performance of Red Mud-Incorporated Cement Composites under Carbonation Curing

International Concrete Abstracts Portal

The International Concrete Abstracts Portal is an ACI led collaboration with leading technical organizations from within the international concrete industry and offers the most comprehensive collection of published concrete abstracts.

  


Title: Microstructural Evolution and Performance of Red Mud-Incorporated Cement Composites under Carbonation Curing

Author(s): Muhammad Talha Shafique, Henry Ssenyonjo, Salman Siddique, Hammad R. Khalid, and Asad Hanif

Publication: Symposium Paper

Volume: 370

Issue:

Appears on pages(s): 125-138

Keywords: Carbonation Curing, Calcium Carbonate, Red Mud Utilization, pH regulation CO2 uptake

DOI: 10.14359/51751754

Date: 5/1/2026

Abstract:
Alternative methods are needed to reduce the negative impacts of the cement industry as a main contributor to CO2 emissions. This research investigates red mud utilization as a partial cement replacement with CO2 curing to decrease the carbon footprint of the cement industry. Mortar and paste specimens with partial substitution of red mud at 0 to 15% were prepared and exposed to 72 hours of carbonation curing. Fresh properties, including flow and setting time, compressive strength, pH evolution, drying shrinkage, and microstructural characteristics, including FTIR, XRD, and SEM-EDS, were evaluated. The increased amounts of red mud decreased the mixtures’ flowability and increased the setting times. This also led to a decrease in the strength of the specimens due to a decrease in the cementitious material. The strength was improved by the carbonation curing due to calcite formation and the densification of the pore structure. Red mud incorporation helps maintain higher pore alkalinity in carbonated specimens due to its strongly alkaline phases. Microstructural analysis confirmed the precipitation of calcium carbonate, with FTIR revealing calcite formation on the surface of specimens and amorphous CaCO₃ within the specimen core. XRD further validated the formation of calcite in specimens exposed to carbonation.

Related References:

1. Q. Zhang, P. Feng, X. Shen, J. Lu, S. Ye, H. Wang, T. Ling, Q. Ran, Utilization of solid wastes to sequestrate carbon dioxide in cement-based materials and methods to improve carbonation degree: A review, Journal of CO₂ Utilization 72 (2023) 102502. doi: 10.1016/j.jcou.2023.102502

2. N. Mohamad, K. Muthusamy, R. Embong, A. Kusbiantoro, M.H. Hashim, Environmental impact of cement production and Solutions: A review, Mater Today Proc 48 (2022) 741–746. doi: 10.1016/j.matpr.2021.02.212

3. M. Zajac, A. Lechevallier, P. Durdzinski, F. Bullerjahn, J. Skibsted, M. Ben Haha, CO₂ mineralisation of Portland cement: Towards understanding the mechanisms of enforced carbonation, Journal of CO₂ Utilization 38 (2020) 398–415.

4. M. Wang, X. Liu, Applications of red mud as an environmental remediation material: A review, J Hazard Mater 408 (2021) 124420. doi: 10.1016/j.jhazmat.2020.124420

5. S. Xue, X. Kong, F. Zhu, W. Hartley, X. Li, Y. Li, Proposal for management and alkalinity transformation of bauxite residue in China, Environmental Science and Pollution Research 23 (2016) 12822–12834. doi: 10.1007/s11356-016-6478-7

6. M.S.S. Lima, L.P. Thives, V. Haritonovs, K. Bajars, Red mud application in construction industry: Review of benefits and possibilities, in: IOP Conf Ser Mater Sci Eng, IOP Publishing, 2017: p. 12033.

7. A.-R. M., S.L.M. Gómez, C.M.A. Piñeiro, M.B. Olazaran, Uses of Red Mud as a Construction Material, in: AEI 2017, 2017: pp. 388–399. doi: 10.1061/9780784480502.032

8. S.-P. Kang, S.-J. Kwon, Effects of red mud and Alkali-Activated Slag Cement on efflorescence in cement mortar, Constr Build Mater 133 (2017) 459–467. doi: 10.1016/j.conbuildmat.2016.12.123

9. J.M. Ortega, M. Cabeza, A.J. Tenza-Abril, T. Real-Herraiz, M.Á. Climent, I. Sánchez, Effects of Red Mud Addition in the Microstructure, Durability and Mechanical Performance of Cement Mortars, Applied Sciences 9 (2019). doi: 10.3390/app9050984

10. S. von Greve-Dierfeld, B. Lothenbach, A. Vollpracht, B. Wu, B. Huet, C. Andrade, C. Medina, C. Thiel, E. Gruyaert, H. Vanoutrive, I.F. Saéz del Bosque, I. Ignjatovic, J. Elsen, J.L. Provis, K. Scrivener, K.-C. Thienel, K. Sideris, M. Zajac, N. Alderete, Ö. Cizer, P. Van den Heede, R.D. Hooton, S. Kamali-Bernard, S.A. Bernal, Z. Zhao, Z. Shi, N. De Belie, Understanding the carbonation of concrete with supplementary cementitious materials: a critical review by RILEM TC 281-CCC, Mater Struct 53 (2020) 136. doi: 10.1617/s11527-020-01558-w

11. K. Ilahi, S. Debbarma, G. Mathew, H.I. Inyang, Carbon capture and mineralisation using red mud: A systematic review of its principles and applications, J Clean Prod 473 (2024) 143458. doi: 10.1016/j.jclepro.2024.143458

12. L. Zhang, X. Zha, J. Ning, W. Li, Research Status on the Application Technology of Early Age Carbon Dioxide Curing, Buildings 13 (2023). doi: 10.3390/buildings13040957

13. S. Duraisamy, P. Chaunsali, Effect of CO₂ mineralization on properties of red mud incorporated portland cement, Indian Concr J 9 (2025) 40–48.

14. R. Raj, B. Yadav, J.S. Yadav, S. Kumar, Red mud utilisation for sustainable construction and soil improvement: a comprehensive review, Discover Sustainability 5 (2024) 398. doi: 10.1007/s43621-024-00619-2

15. W. Zhang, R. Gao, X. Sha, G. Liu, X.-Y. Wang, R.-S. Lin, Y. Tong, Strength development and thermal stability analysis of carbonation-cured red mud-based cementitious materials, Constr Build Mater 470 (2025) 140724. doi: 10.1016/j.conbuildmat.2025.140724

16. A.-R. M., S.L.M. Gómez, C.M.A. Piñeiro, M.B. Olazaran, Uses of Red Mud as a Construction Material, in: AEI 2017, 2017: pp. 388–399. doi: 10.1061/9780784480502.032

17. X. Yang, J. Zhao, H. Li, P. Zhao, Q. Chen, Recycling red mud from the production of aluminium as a red cement-based mortar, Waste Management and Research 35 (2017) 500–507. doi: 10.1177/0734242X16684386

18. H.J. Qureshi, J. Ahmad, A. Majdi, M.U. Saleem, A.F. Al Fuhaid, M. Arifuzzaman, A Study on Sustainable Concrete with Partial Substitution of Cement with Red Mud: A Review, Materials 15 (2022). doi: 10.3390/ma15217761

19. A.B. Sawant, M.B. Kumthekar, V. V Diwan, K.G. Hiraskar, Experimental study on partial replacement of cement by neutralized red mud in concrete, Int J Eng Adv Technol 2 (2012) 282-286.

20. R.-X. Liu, C.-S. Poon, Utilization of red mud derived from bauxite in self-compacting concrete, J Clean Prod 112 (2016) 384-391.

21. J. Zhang, G.W. Scherer, Comparison of methods for arresting hydration of cement, Cem Concr Res 41 (2011) 1024-1036.

22. W.O. Alimi, S.K. Adekunle, S. Ahmad, A.O. Amao, Carbon dioxide sequestration characteristics of concrete mixtures incorporating high-volume cement kiln dust, Case Studies in Construction Materials 17 (2022) e01414.

23. ASTM C 191-21, Standard Test Method for Time Setting of Hydraulic Cement by Vicat Needle, American Society for Testing and Materials 1 (2021) 5-7. doi: 10.1520/C0191-21.2

24. Standard Test Method, F. of H.C. Mortar, Standard Test Method for Flow of Hydraulic Cement Mortar, ASTM C1437 (2009) 15-16.

25. A.C. ASTM, 596-18 Standard Test Method for Drying Shrinkage of Mortar Containing Hydraulic Cement, West Conshohocken, PA, USA (2018).

26. O. Chowaniec, Limestone addition in cement, EPFL, 2012.

27. E. Berodier, K. Scrivener, Evolution of pore structure in blended systems, Cem Concr Res 73 (2015) 25-35.

28. R.C.O. Romano, H.M. Bernardo, M.H. Maciel, R.G. Pileggi, M.A. Cincotto, Hydration of Portland cement with red mud as mineral addition, J Therm Anal Calorim 131 (2018) 2477-2490. doi: 10.1007/s10973-017-6794-2

29. L. Senff, R.C.E. Modolo, A.S. Silva, V.M. Ferreira, D. Hotza, J.A. Labrincha, Influence of red mud addition on rheological behavior and hardened properties of mortars, Constr Build Mater 65 (2014) 84–91.

30. L. Senff, D. Hotza, J.A. Labrincha, Effect of red mud addition on the rheological behaviour and on hardened state characteristics of cement mortars, Constr Build Mater 25 (2011) 163–170.

31. Y. Liu, Y. Zhuge, X. Chen, W. Duan, R. Fan, L. Outhred, L. Wang, Micro-chemomechanical properties of red mud binder and its effect on concrete, Compos B Eng 258 (2023) 110688. doi: 10.1016/j.compositesb.2023.110688

32. L. Jiang, Q. Wu, Z. Huo, Z. Zhu, F. Wu, B. Lu, An approach to improve compressive strength of cement paste at low temperature by carbonation curing, Constr Build Mater 365 (2023) 130128. doi: 10.1016/j.conbuildmat.2022.130128

33. M.T. Shafique, S. Siddique, H.R. Khalid, S.K. Adekunle, A. Hanif, S. Ahmad, S. Al-Dulaijan, Impact of precarbonation duration on carbonation-induced physicochemical changes in OPC, J Sustain Cem Based Mater (n.d.) 1–17. doi: 10.1080/21650373.2025.2525538.

34. P. Rattanadecho, N. Suwannapum, B. Chatveera, D. Atong, N. Makul, Development of compressive strength of cement paste under accelerated curing by using a continuous microwave thermal processor, Materials Science and Engineering: A 472 (2008) 299–307.

35. M.T. Shafique, S. Siddique, H.R. Khalid, S.K. Adekunle, A. Hanif, S. Ahmad, S. Al-Dulaijan, Investigating the Impact of Red Mud Substitution on Physicochemical Properties of Carbonated Cement Composites, Journal of Building Engineering (2025) 114087. doi: 10.1016/j.jobe.2025.114087

36. W. Zhang, R. Gao, X. Sha, G. Liu, X.Y. Wang, R.S. Lin, Y. Tong, Strength development and thermal stability analysis of carbonation-cured red mud-based cementitious materials, Constr Build Mater 470 (2025) 140724. doi: 10.1016/J.CONBUILDMAT.2025.140724

37. Z.X. Chen, C.Y. Zhang, Y. Jia, L.Y. Lin, Q.X. Zhao, S.H. Chu, CO₂ Sequestration in Green Porous Concrete Using Red Mud, ACS Sustain Chem Eng 13 (2025) 3036–3051. doi: 10.1021/acssuschemeng.4c06004

38. R. Vahid, S. Yixin, B.A. J., Carbonation Curing versus Steam Curing for Precast Concrete Production, Journal of Materials in Civil Engineering 24 (2012) 1221–1229. doi: 10.1061/(ASCE)MT.1943-5533.0000462

39. K. Tuutti, Corrosion of steel in concrete, (1982).

40. A.B. Sawant, M.B. Kumthekar, S.G. Sawant, A.R. Mud, Utilization of neutralized red mud (industrial waste) in concrete, Int. J. Inven. Eng. Sci 1 (2013) 9–13.

41. S. Siddique, A. Naqi, J.G. Jang, Influence of water to cement ratio on CO₂ uptake capacity of belite-rich cement upon exposure to carbonation curing, Cem Concr Compos 111 (2020) 103616. doi: 10.1016/j.cemconcomp.2020.103616

42. Y. Bo, Y. Sensen, S. Chris, C. Wei, Activation of Binary Binder Containing Fly Ash and Portland Cement Using Red Mud as Alkali Source and Its Application in Controlled Low-Strength Materials, Journal of Materials in Civil Engineering 32 (2020) 4019356. doi: 10.1061/(ASCE)MT.1943-5533.0003023

43. D. V Ribeiro, J.A. Labrincha, M.R. Morelli, Effect of the addition of red mud on the corrosion parameters of reinforced concrete, Cem Concr Res 42 (2012) 124–133. doi: 10.1016/j.cemconres.2011.09.002

44. E.G. Nawy, Fundamentals of high-performance concrete, John Wiley & Sons, 2000.

45. L. Tang, Study of the possibilities of using Red Mud as an additive in concrete and grout mortar, Svensk Kärnbränslehantering AB Swedish Nuclear Fuel and Waste Management Co., Stockholm, Sweden (2014).

46. R. Liu, C. Poon, Effects of red mud on properties of self-compacting mortar, J Clean Prod 135 (2016) 1170–1178. doi: 10.1016/j.jclepro.2016.07.052

47. B. Lu, C. Shi, Z. Cao, M. Guo, J. Zheng, Effect of carbonated coarse recycled concrete aggregate on the properties and microstructure of recycled concrete, J Clean Prod 233 (2019) 421–428. doi: 10.1016/j.jclepro.2019.05.350

48. A. Vollpracht, B. Lothenbach, R. Snellings, J. Haufe, The pore solution of blended cements: a review, Mater Struct 49 (2016) 3341-3367.

49. D. Zhang, X. Cai, B. Jaworska, Effect of pre-carbonation hydration on long-term hydration of carbonation-cured cement-based materials, Constr Build Mater 231 (2020) 117122. doi: 10.1016/j.conbuildmat.2019.117122

50. S. Siddique, J.G. Jang, T. Gupta, Developing marble slurry as supplementary cementitious material through calcination: Strength and microstructure study, Constr Build Mater 293 (2021) 123474.

51. D.A.D. Silva, H.R. Roman, P.J.P. Gleize, Evidences of chemical interaction between EVA and hydrating Portland cement, Cem Concr Res 32 (2002) 1383–1390.

52. P. Yu, R.J. Kirkpatrick, B. Poe, P.F. McMillan, X. Cong, Structure of calcium silicate hydrate (C‐S‐H): Near‐, Mid‐, and Far‐infrared spectroscopy, Journal of the American Ceramic Society 82 (1999) 742–748.

53. H.K. Choudhary, A. V Anupama, R. Kumar, M.E. Panzi, S. Matteppanavar, B.N. Sherikar, B. Sahoo, Observation of phase transformations in cement during hydration, Constr Build Mater 101 (2015) 122–129.

54. R.I. Khan, M. Intesarul Haque, S. Siddique, E.N. Landis, W. Ashraf, Effects of amino acids on the multiscale properties of carbonated wollastonite composites, Constr Build Mater 374 (2023) 130816. doi: 10.1016/j.conbuildmat.2023.130816

55. L. Addadi, S. Raz, S. Weiner, Taking advantage of disorder: amorphous calcium carbonate and its roles in biomineralization, Advanced Materials 15 (2003) 959–970.

56. R.I. Khan, W. Ashraf, J. Olek, Amino acids as performance-controlling additives in carbonation-activated cementitious materials, Cem Concr Res 147 (2021) 106501. doi: 10.1016/j.cemconres.2021.106501

57. S. Liu, C. Pan, H. Zhang, S. Yao, P. Shen, X. Guan, C. Shi, H. Li, Development of novel mineral admixtures for sulphoaluminate cement clinker: The effects of wet carbonation activated red mud, Journal of Building Engineering 67 (2023) 105920. doi: 10.1016/j.jobe.2023.105920

58. L. Jiang, Q. Wu, Z. Huo, Z. Zhu, F. Wu, B. Lu, An approach to improve compressive strength of cement paste at low temperature by carbonation curing, Constr Build Mater 365 (2023) 130128. doi: 10.1016/j.conbuildmat.2022.130128

59. X. Xian, Y. Shao, Microstructure of cement paste subject to ambient pressure carbonation curing, Constr Build Mater 296 (2021) 123652. doi: 10.1016/j.conbuildmat.2021.123652

60. P. Liu, J. Zhong, M. Zhang, L. Mo, M. Deng, Effect of CO₂ treatment on the microstructure and properties of steel slag supplementary cementitious materials, Constr Build Mater 309 (2021) 125171. doi: 10.1016/j.conbuildmat.2021.125171

61. Z. He, X. Shao, X. Chen, Effect of Carbonation Treatment on the Strength and CO₂ Uptake Rate of Composite Cementitious Material with a High Steel Slag Powder Content, Materials 16 (2023). doi: 10.3390/ma16186204