Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties
Abstract This study investigates the potential of calcined Algerian clay as a supplementary cementitious material (SCM) for enhancing the sustainability of cement production by reducing the consumption of clinker and emissions of carbon dioxide (CO₂). The research novelty lies in the comprehensive e...
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Nature Portfolio
2025-07-01
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| Online Access: | https://doi.org/10.1038/s41598-025-04342-4 |
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| author | Mouna Badaoui Kamel Hebbache Abdellah Douadi Lamia Mansouri Abdelghani Merdas Soria Gherbi Karima Kada Mourad Boutlikht Cherif Belebchouche Jacek Szymanowski |
| author_facet | Mouna Badaoui Kamel Hebbache Abdellah Douadi Lamia Mansouri Abdelghani Merdas Soria Gherbi Karima Kada Mourad Boutlikht Cherif Belebchouche Jacek Szymanowski |
| author_sort | Mouna Badaoui |
| collection | DOAJ |
| description | Abstract This study investigates the potential of calcined Algerian clay as a supplementary cementitious material (SCM) for enhancing the sustainability of cement production by reducing the consumption of clinker and emissions of carbon dioxide (CO₂). The research novelty lies in the comprehensive evaluation of fineness effects, the statistical modelling of mechanical performance, and the assessment of the environmental impact. A case study of practical significance is also provided. Clay was thermally activated at 700 °C to achieve near-complete dihydroxylation, ground to fineness levels of 45 µm and 80 µm, and then incorporated into the cement at replacement ratios of 10–30% by weight of the cement. Compressive and flexural strengths were assessed at 2, 7, and 28 days, while thermal and structural modifications were analysed using thermogravimetric analysis (TGA) and Fourier-transform infrared spectroscopy (FTIR). The results demonstrated that at lower substitution levels (10–15%), the 80 µm fraction of clay enhanced early-age compressive strength (13.6 MPa at 2 days), whereas at higher replacements (20–30%), the 45 µm fraction exhibited superior long-term strength (36.85 MPa at 28 days), which was attributed to improved pozzolanic reactivity and matrix densification. Flexural strength increased by 7–20% for substitution rates up to 20%, in turn confirming the structural benefits of calcined clay. Life-cycle analysis indicated significant reductions in energy consumption, CO₂ emissions, and production costs, with the M30–45 and M30–80 mixtures achieving reductions of approximately 10.6%. The statistical modeling of compressive strength at 2 and 28 days demonstrated high predictive accuracy, with coefficients of determination (R2) of 0.93 and 0.81, respectively. These models were statistically validated using analysis of variance (ANOVA), confirming their significance at a 95% confidence level (p < 0.05). These findings showed calcined Algerian clay to be a viable SCM, with it demonstrating enhanced mechanical performance, environmental sustainability, and economic feasibility, thereby contributing to the decarbonization of the cement industry. |
| format | Article |
| id | doaj-art-7e16ce27b6954edca7dd6c063b9bca63 |
| institution | Kabale University |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Nature Portfolio |
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| spelling | doaj-art-7e16ce27b6954edca7dd6c063b9bca632025-08-20T03:38:12ZengNature PortfolioScientific Reports2045-23222025-07-0115112310.1038/s41598-025-04342-4Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical propertiesMouna Badaoui0Kamel Hebbache1Abdellah Douadi2Lamia Mansouri3Abdelghani Merdas4Soria Gherbi5Karima Kada6Mourad Boutlikht7Cherif Belebchouche8Jacek Szymanowski9Emerging Materials Research Unit (URME), Department of Civil Engineering, Ferhat Abbas University of Sétif 1Civil Engineering Research Laboratory of Sétif (LRGCS), Department of Civil Engineering, Setif 1 University-Ferhat AbbasEmerging Materials Research Unit (URME), Department of Civil Engineering, Ferhat Abbas University of Sétif 1Department of Process Engineering, Setif 1 University-Ferhat AbbasEmerging Materials Research Unit (URME), Department of Civil Engineering, Ferhat Abbas University of Sétif 1Emerging Materials Research Unit (URME), Department of Civil Engineering, Ferhat Abbas University of Sétif 1Emerging Materials Research Unit (URME), Department of Civil Engineering, Ferhat Abbas University of Sétif 1Civil Engineering Research Laboratory of Sétif (LRGCS), Department of Civil Engineering, Setif 1 University-Ferhat AbbasCivil Engineering Research Laboratory of Sétif (LRGCS), Department of Civil Engineering, Setif 1 University-Ferhat AbbasDepartment of Materials Engineering and Construction Processes, Faculty of Civil Engineering, Wrocław University of Science and TechnologyAbstract This study investigates the potential of calcined Algerian clay as a supplementary cementitious material (SCM) for enhancing the sustainability of cement production by reducing the consumption of clinker and emissions of carbon dioxide (CO₂). The research novelty lies in the comprehensive evaluation of fineness effects, the statistical modelling of mechanical performance, and the assessment of the environmental impact. A case study of practical significance is also provided. Clay was thermally activated at 700 °C to achieve near-complete dihydroxylation, ground to fineness levels of 45 µm and 80 µm, and then incorporated into the cement at replacement ratios of 10–30% by weight of the cement. Compressive and flexural strengths were assessed at 2, 7, and 28 days, while thermal and structural modifications were analysed using thermogravimetric analysis (TGA) and Fourier-transform infrared spectroscopy (FTIR). The results demonstrated that at lower substitution levels (10–15%), the 80 µm fraction of clay enhanced early-age compressive strength (13.6 MPa at 2 days), whereas at higher replacements (20–30%), the 45 µm fraction exhibited superior long-term strength (36.85 MPa at 28 days), which was attributed to improved pozzolanic reactivity and matrix densification. Flexural strength increased by 7–20% for substitution rates up to 20%, in turn confirming the structural benefits of calcined clay. Life-cycle analysis indicated significant reductions in energy consumption, CO₂ emissions, and production costs, with the M30–45 and M30–80 mixtures achieving reductions of approximately 10.6%. The statistical modeling of compressive strength at 2 and 28 days demonstrated high predictive accuracy, with coefficients of determination (R2) of 0.93 and 0.81, respectively. These models were statistically validated using analysis of variance (ANOVA), confirming their significance at a 95% confidence level (p < 0.05). These findings showed calcined Algerian clay to be a viable SCM, with it demonstrating enhanced mechanical performance, environmental sustainability, and economic feasibility, thereby contributing to the decarbonization of the cement industry.https://doi.org/10.1038/s41598-025-04342-4PozzolanRaw clayCalcined clayFlexural strengthCompressive strength |
| spellingShingle | Mouna Badaoui Kamel Hebbache Abdellah Douadi Lamia Mansouri Abdelghani Merdas Soria Gherbi Karima Kada Mourad Boutlikht Cherif Belebchouche Jacek Szymanowski Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties Scientific Reports Pozzolan Raw clay Calcined clay Flexural strength Compressive strength |
| title | Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties |
| title_full | Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties |
| title_fullStr | Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties |
| title_full_unstemmed | Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties |
| title_short | Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties |
| title_sort | utilization of algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties |
| topic | Pozzolan Raw clay Calcined clay Flexural strength Compressive strength |
| url | https://doi.org/10.1038/s41598-025-04342-4 |
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