Strength Development of Geopolymer Composites Made from Red Mud–Fly Ash as a Subgrade Material in Road Construction

Abstract The application of industrial waste in construction reduces the dependency on natural resources. The materials, including red mud (RM) and fly ash (FA), proved to be favorable materials. However, the materials potential together as a geopolymer composite for road applications has rarely been explored. This study will examine the possibility of the replacement of natural materials in subgrade applications. To achieve this, the geopolymer compositions will be prepared by replacing RM with FA at replacement rates of 10%, 20%, and 30% by dry weight basis. The alkaline activator solution of 8 M will be prepared using sodium hydroxide (NaOH) and sodium silicate to develop geopolymer composites. The strength properties will be studied using the California Bearing Ratio (CBR) and unconfined compression strength (UCS) and validated with microstructural analysis using scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier-transform infrared spectroscopy (FTIR). The results reveal that geopolymer composites could achieve a maximum CBR value of 12% and UCS of 2,700 kPa. The microstructural analysis revealed that the formation of dense calcium aluminate hydrate (C-A-H) and calcium silicate hydrate (C-S-H) are the reason for strength improvement. The leaching studies show that the toxic elements were within the permissible limits. Overall, the test results confirmed that the geopolymer composites meet the required strength and could be used as a subgrade material in road construction.