Research on the Preparation of Red Mud High-Performance Cement Mortar and the Corresponding Resistance to Dry–Wet Alternation Cycles of Exposure to Chloride and Sulfate Solutions

The accumulation of highly alkaline red mud poses serious environmental risks due to land occupation and potential soil/groundwater contamination. Recycling red mud as a secondary resource offers an eco-friendly solution, yet its influence on the performance of high-performance mortar (HPM) remains incompletely understood, particularly in aggressive environments. This study aims to systematically evaluate the effects of red mud on the fresh and hardened properties of HPM, including rheological parameters, setting time, mechanical strength, drying shrinkage, and sulfate dry–wet erosion resistance. The novelty lies in (1) quantifying the nonlinear relationships between red mud content and rheological/setting behaviors, (2) revealing the dual effect of red mud with curing age, and (3) using XRD/SEM-EDS to elucidate the micro-mechanisms related to hydration products and elemental changes (Al and Fe). The results show that increasing red mud content reduces slump flow (max 76.03%), plastic viscosity (46.7%), and yield stress (42.3%) while also shortening initial/final setting times (67.91% and 76.18% max reductions). At curing ages below 7 days, flexural and compressive strength increase (up to 64.53% and 33.35%, respectively), following cubic functions; however, at 7 and 28 days, both strength values decrease (max reductions of 13.43% and 12.98%). Red mud increases drying shrinkage and delays sulfate-induced degradation. Microstructural analysis reveals improved compactness of hydration products at early ages but reduced compactness at later ages, accompanied by increased Al/Fe content and enhanced SiO2/calcium silicate hydrate crystals. These findings provide valuable insights for applying red mud HPM in marine environments.