Enhancing Properties of Bayer Red Mud–Class F Fly Ash Geopolymer Composites via Ground Granulated Blast Furnace Slag and Calcium Carbide Slag Incorporation

Red mud, fly ash, ground granulated blast furnace slag, and carbide slag are industrial byproducts posing significant environmental challenges. The synthesis of geopolymers represents a promising approach for their sustainable valorization. This study investigated the strength development mechanisms and microstructural evolution of Red Mud–Class F Fly Ash-Based Geopolymer under co-incorporation of ground granulated blast furnace slag and carbide slag through compressive strength tests, X-Ray Diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR), and Scanning Electron Microscopy–Energy Dispersive Spectrometer (SEM-EDS). Key findings include the following: (1) single incorporation of ground granulated blast furnace slag achieved a 60-day compressive strength of 11.6 MPa—6.4× higher than carbide slag-only systems (1.8 MPa); (2) hybrid systems (50% ground granulated blast furnace slag/50% carbide slag) reached 8.8 MPa, demonstrating a strength peak at balanced ground granulated blast furnace slag/carbide slag ratios; (3) the multi-source geopolymer systems were dominated by monomeric gels (C-A-H, C-S-H, C-A-S-H), crystalline phases (ettringite and hydrocalumite), and poly-aluminosilicate chains ((-Si-O-Al-Si-O-)n); (4) elevated Ca levels (>40 weight percent in ground granulated blast furnace slag/carbide slag) favored C-S-H formation, while optimal Si/Al ratios (1.5–2.5) promoted gel polycondensation into long-chain polymers (e.g., Si-O-Al-O), consolidating the matrix. These results resolve the critical limitation of low strength (≤3.1 MPa) in ambient-cured red mud–fly ash geopolymers reported previously, enabling scalable utilization of red mud (46.44% Fe2O3) and carbide slag (92.43% CaO) while advancing circular economy paradigms in construction materials.