Mechanical and Environmental Properties of Cemented Paste Backfill Prepared with Bayer Red Mud as an Alkali-Activator Substitute

Abstract

This study developed a sustainable high-strength coal gangue backfill material for underground mining applications using coal gangue, fly ash, and cement as primary raw materials, with red mud (RM) as an alternative alkali activator. The mechanical properties of the backfill material were systematically optimized by adjusting coal gangue particle size and alkali activator dosage. The optimized formulation (coal gangue/fly ash/cement = 5:4:1, 3–6 mm coal gangue particle size, 5% RM, which named BF-6-5RM) achieved superior compressive strengths of 8.23 MPa (7 days) and 10.5 MPa (28 days), significantly exceeding conventional backfill requirements and outperforming a CaO-activated reference system (coal gangue/fly ash/cement = 5:4:1, 3–6 mm coal gangue particle size, 2% CaO, which named BF-6-2CaO). Microstructural and physicochemical analyses revealed that both formulations produced calcium silicate hydrate gels (C-S-H gels) and ettringite (AFt) as key hydration products, though BF-6-5RM exhibited a denser microstructure with well-developed ettringite networks and no detectable portlandite (CH), explaining its enhanced early-age strength. Environmental assessments confirmed effective heavy metal immobilization via encapsulation, adsorption, precipitation and substitution, except for arsenic (As), which exceeded Class III groundwater thresholds (DZ/T 0290-2015) due to elevated raw material content, displaying “surface wash-off, diffusion and depletion” leaching behavior. The findings confirm that red mud-based alkali activation is a viable technology for underground backfilling, provided it is coupled with arsenic control strategies like chemical stabilization or the selection of low-arsenic raw materials. This approach not only enables the resource utilization of hazardous industrial waste but also facilitates the production of backfill materials that combine both mechanical strength and environmental compatibility, thereby delivering dual economic and ecological benefits for sustainable mining practices.