Green360 uses red mud waste to make game-changing greener cement

ASX-listed innovator Green360 Technologies has pulled off a world-first breakthrough by converting red mud – one of the mining industry’s most toxic by-products – into a high-performance, low-carbon building material.

The company has successfully developed a proprietary cement blend using red mud and kaolin, which dramatically slashes environmental risks and carbon emissions while retaining the strength and reliability of traditional concrete. Green360 says the product’s performance has exceeded international safety and performance tests.

Red mud is a problematic waste left behind after alumina is extracted from bauxite. Every tonne of alumina produces up to 1.5 tonnes of the red sludge, which is loaded with heavy metals and has long created hazardous headache.

Laboratory results showed Green360’s production process reduced highly toxic chromium leachate by a whopping 95 per cent and put a complete check on remedial uranium and thorium.

‘These results are extremely encouraging.’

Green360 Technologies executive chairman Aaron Banks

Chromium levels came in at just 0.023 and 0.026 milligrams per litre (mg/L), which is well below the 0.5mg/L inert waste threshold, while uranium and thorium were undetectable. These results easily surpassed the European standard for inert waste, putting it on par with clean fill.

Adding serious muscle to its green cement credentials, Green360 showed that when 30 per cent of traditional Portland cement was swapped out of a cement mix for its red mud-kaolin blend, the batch still packed a punch, hitting a 28-day compressive strength of 30 megapascals. The company says at that level, the modified cement is still more than 85 per cent of the strength of standard cement, proving the eco-friendly alternative is no lightweight in the commercial arena.

The company now plans to scale up testing through a commercial trial with joint venture partner PERMAcast to prove the product across a range of precast concrete applications, such as structural panels and cement pipes.

Green360 Technologies executive chairman Aaron Banks said: “These results are extremely encouraging. We’ve not only addressed a significant environmental challenge by repurposing red mud – a major industrial by-product – but also unlocked its commercial potential in sustainable construction. Alongside PERMAcast, we are rapidly developing alternatives to traditional Portland cement that still perform to commercial standards and are suitable for real-world applications.”