Fine-Fraction Brazilian Residual Kaolin-Filled Coating Mortars

This study investigates the use of the fine fraction of Brazilian residual kaolin, a material with no pozzolanic activity according to the modified Chapelle test, as a partial cement replacement in rendering mortars. The kaolin was classified into three granulometric fractions (coarse: 150–300 µm, intermediate: 75–150 µm, and fine: <75 µm) and incorporated at two filler contents (10% and 20% by weight). Mineralogical and chemical analyses revealed that the fine fractions contained higher proportions of kaolinite and accessory oxides, while medium and coarse fractions were dominated by quartz. Intensity ratios from XRD confirmed greater structural disorder in the fine fraction, which was associated with higher water demand but also improved particle packing and pore refinement. Fresh state tests showed that mortars with fine kaolin maintained higher density and exhibited moderate increases in air content, whereas medium and coarse fractions promoted greater entrainment. In the hardened state, fine kaolin reduced water absorption by immersion and capillary rise, while medium and coarse fractions led to higher porosity. Mechanical tests confirmed these trends: although compressive and flexural strengths decreased with increasing substitution, mortars containing the fine kaolin fraction consistently exhibited more moderate strength losses than those with medium or coarse fractions, reflecting their enhanced packing efficiency and pore refinement. Tensile bond strength results further highlighted the positive contribution of the kaolin additions, as the mixtures with 10% coarse kaolin and 20% fine kaolin achieved adhesion values only about 7% and 4% lower, respectively, than the control mortar after 28 days. All mixtures surpassed the performance requirements of NBR 13281, demonstrating that the incorporation of residual kaolin—even at higher substitution levels—does not compromise adhesion and remains compatible with favorable cohesive failure modes in the mortar layer. Despite the lack of pozzolanic activity, residual kaolin was used due to its filler effect and capacity to enhance particle packing and pore refinement in rendering mortars. A life cycle assessment indicated that the partial substitution of cement with residual kaolin effectively reduces the environmental impacts of mortar production, particularly the global warming potential, when the residue is modeled as a by-product with a negligible environmental burden. This highlights the critical role of methodological choices in assessing the sustainability of industrial waste utilization.