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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\u00a0\u00b0C to achieve near-complete dihydroxylation, ground to fineness levels of 45\u00a0\u00b5m and 80\u00a0\u00b5m, and then incorporated into the cement at replacement ratios of 10\u201330% by weight of the cement. Compressive and flexural strengths were assessed at 2, 7, and 28\u00a0days, 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\u201315%), the 80\u00a0\u00b5m fraction of clay enhanced early-age compressive strength (13.6\u00a0MPa at 2\u00a0days), whereas at higher replacements (20\u201330%), the 45\u00a0\u00b5m fraction exhibited superior long-term strength (36.85\u00a0MPa at 28\u00a0days), which was attributed to improved pozzolanic reactivity and matrix densification. Flexural strength increased by 7\u201320% for substitution rates up to 20%, in turn confirming the structural benefits of calcined clay. Life-cycle analysis indicated significant reductions in energy consumption, CO\u2082 emissions, and production costs, with the M30\u201345 and M30\u201380 mixtures achieving reductions of approximately 10.6%. The statistical modeling of compressive strength at 2 and 28\u00a0days demonstrated high predictive accuracy, with coefficients of determination (R<jats:sup>2<\/jats:sup>) 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 (<jats:italic>p<\/jats:italic>\u2009&lt;\u20090.05). 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.<\/jats:p>","DOI":"10.1038\/s41598-025-04342-4","type":"journal-article","created":{"date-parts":[[2025,7,1]],"date-time":"2025-07-01T18:24:50Z","timestamp":1751394290000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":12,"title":["Utilization of Algerian calcined clay in sustainable mortars considering thermal treatment and granulometry effects on mechanical properties"],"prefix":"10.1038","volume":"15","author":[{"given":"Mouna","family":"Badaoui","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Kamel","family":"Hebbache","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Abdellah","family":"Douadi","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Lamia","family":"Mansouri","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Abdelghani","family":"Merdas","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Soria","family":"Gherbi","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Karima","family":"Kada","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Mourad","family":"Boutlikht","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Cherif","family":"Belebchouche","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Jacek","family":"Szymanowski","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2025,7,1]]},"reference":[{"key":"4342_CR1","unstructured":"Herbst, A., Fleiter, T., Sensfu\u00df, F., Pfluger, B. & Maranon-Ledesma, H. 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