Mortar Designed from Red Mud with Iron Tailings and Moulded by 3D Printing

A specific mortar material (abbreviated as RFT) was designed from industrial solid wastes, such as red mud, fly ash, and iron tailings. It was mainly developed for 3D printing in this work. Mechanical properties, microstructure and heavy metal leaching properties were discussed. The RFT composed of 15% red mud, 45% iron tailings, 9% fly ash, 30% cement, and 1% FDN water reducing agent attained good mechanical properties. Hydration products including Ca(OH)₂, ettringite and C-S-H gel were found in RFT through SEM observation. Iron tailings mainly acted as fine aggregates in RFT, and they were wrapped by the C-S-H gels, producing a strong bonding effect between aggregates and cementitious matrix. The leaching toxicity test results proved that the developed RFT mortar materials were environmentally acceptable. Finally, RFT was subjected to a 3D printing test to verify its feasibility as 3D printable construction material.