Manufacturing Large Concrete Blocks from Red Mud for Infrastructure Applications

About this project

This project aims to utilise red mud by incorporating it into large dry-mix concrete blocks, transforming a significant environmental liability into a valuable asset for the construction industry. This initiative not only reduces mining waste and conserves natural resources but also supports a circular economy. Building on successful laboratory research, the University of South Australia (UniSA) and BSMART team has successfully demonstrated the technical feasibility of partially replacing sand or cement with raw or calcined red mud to produce red mud concrete blocks (RMCB). Prototypes of RMCBs with up to 30% red mud content to replace cement have shown promising performance in terms of compressive strength, breaking load, and water absorption capacity. 

This project aims to expand the applications of red mud utilization by developing larger RMCBs for use in more demanding applications, such as retaining walls, coastal barriers and highway noise barriers. Achieving this will require modifications to the current mix design, with adjustments to key parameters to ensure that the larger blocks maintain consistent quality and performance. The success of this project will not only advance the TRL to 6 but also validate the scalability of the mix design, material pretreatment methods, and casting techniques for further commercialization. The environmental benefits will be twofold: removal of bauxite processing waste from operations present and past and the replacement of large quantities of cement otherwise required in the manufacture of RMCBs. This will lead to significant reductions in CO2 emissions.

What you’ll do

The first phase involves developing the optimal mix design for large-sized Red Mud Concrete Blocks (RMCB) using the dry-mix (cast) method. In the second phase, to demonstrate the applicability of large-sized RMCB, a comprehensive testing program will be carried out through mechanical and durability tests. You may be required to travel to interstate for field testing.

Where you’ll be based

The successful applicant is expected to study full-time, and to be based at our Mawson Lakes campus in the north of Adelaide. 

The Civil Group at UniSA is highly research-active and currently includes more than 50 PhD students. UniSA’s assessed Civil Engineering research achieved a “Well Above World Class” (5) rating. The structural laboratory facilities include the largest strong-floor in Australia, which has already been used for many research and consulting projects. Investment of nearly $3 million in new and upgraded equipment and facilities will be available for this project. The concrete and structural labs are well serviced by skilled technical staff. Financial Support  

This project is funded for reasonable research expenses. Additionally, a living allowance scholarship of $35,200 per annum is available to eligible applicants. Australian Aboriginal and/or Torres Strait Islander applicants will be eligible to receive an increased stipend rate of $52,352 per annum (2025 rate). A fee-offset or waiver for the standard term of the program is also included. For full terms and benefits of the scholarship please refer to our scholarship information for domestic students or international students. 

Eligibility and Selection

This project is open to applications from both Domestic and International applicants. Note that international students on a student visa will need to study full-time.

Applicants must meet the eligibility criteria for entrance into a Master of Research. Applicants who can also demonstrate the following will be highly regarded:

• previous experience on cementitious material and waste utilisation.

All applications that meet the eligibility and selection criteria will be considered for this project. A merit selection process will be used to determine the successful candidate.

Essential Dates

Applicants are expected to start in a timely fashion upon receipt of an offer. Extended deferral periods are not available. Applications close on Tuesday 15 July 2025.