With the development of urbanization, the demand for bricks continues to increase. However, traditional brick production methods result in significant energy consumption and environmental pollution. In Hebei Province, China, historical mineral extraction activities have left behind substantial iron ore tailings (IOT). With the objective of recycling IOT resources and promoting ecological restoration and sustainable development, the feasibility of producing alkali-activated bricks using iron ore tailings was explored. This study primarily utilized IOT supplemented with ground granulated blast-furnace slag (GGBS) to successfully synthesize sustainable eco-friendly alkali-activated high-content IOT bricks. Experimental investigations were conducted to explore the effects of the raw material mixing ratio, content, and modulus of the alkaline activator, molding pressure, and grain size distribution on the strength. The research demonstrated that the IOT: GGBS ratio of 85:15 met the requirements of the Chinese JC/T422-2007 MU25 standard, resulting in compressive and flexural strengths of 31.72 MPa and 2.83 MPa, respectively. Increasing the alkali activator content enhanced the brick strength, with an optimal alkali activator modulus of 1 M. Moreover, the molding pressure significantly improved brick strength and also enhanced the particle-to-particle contact density. Bricks prepared using finer particle size IOT exhibited higher compressive strength, whereas flexural strength remained relatively unaffected by particle size distribution. Furthermore, a comprehensive analysis of the microstructure and alkali activation mechanism of IOT-GGBS bricks was performed using XRD, SEM, FTIR, and AFM techniques. The results indicated that IOT primarily acted as an aggregate and partially participated in the reaction, whereas GGBS reacted extensively, generating C-S-H gel and C-A-H, providing robust bonding strength. Additionally, the increase in GGBS content led to the partial disintegration of some IOT particles, forming more stable aggregates under the influence of the C-S-H gel. This study offers theoretical guidance for the efficient utilization of IOT in construction materials, thereby contributing to the promotion of sustainable development and environmental conservation.
