Calcined Clays as Concrete Additive in Structural Concrete: Workability, Mechanical Properties, Durability, and Sustainability Performance

Calcined clays (CCs) as supplementary cementitious materials (SCMs) can be a promising option to reduce clinker content and CO₂ emissions in eco-friendly concretes. Although CCs as components of composite cements in combination with Ordinary Portland Cement (OPC) and limestone powder (LSP) have attracted industry interest, their use as concrete additives is limited. This study investigates the effects of the addition of CCs on the fresh and hardened properties of industry-standard ready-mixed concretes. Four concrete mix designs, each with three superplasticizer dosages, were tested, resulting in 12 variations. The CCs used, which are typical of 2:1 bentonite clays with low metakaolin content, reflect the clays available in Germany. The results showed that CCs significantly influenced the workability, which could be controlled with a high superplasticizer dosage. Increased CC contents reduced bleeding tendencies, which was beneficial for certain structural applications. Early age strength decreased with CCs, but the 28-day strength exceeded that of pure OPC concretes up to 30 wt% CCs. Resistance to CO₂-induced carbonation decreased with higher levels of CCs but was comparable up to 15 wt%. Freeze-thaw damage decreased, and chloride migration resistance improved due to a denser microstructure. The global warming potential (GWP) of the concretes tested is in line with that reported in the literature for concretes made from highly blended cements, suggesting that CCs can improve the sustainability of concrete production.