Characteristics of Metakaolin and its use in concrete

Metakaolin
Calcination of clay mineral (kaolin) at moderately-high temperature (650-800oC) Breaks down the crystal structure producing a transition phase (silica and amorphous alumina in reactive form) of high surface area Optimum burning temperature will depend on the base mineral used Burning at higher temperature will cause recrystallization into quartz and mullite (inert materials)

CANMET Materials Technology Laboratory

Metakaolin
Pozzolanic reaction in concrete
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Metakaolin
When used in concrete
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C3 S / C2 S (clinker) + H 2O ----> Calcium Silicate Hydrates (C-S-H) + Ca(OH)2 Ca(OH) 2 + MK ---> C-S-H pouzz. + crystalline pouzz. products (C2ASH 8 , C4 AH13 , C3 AH6 )

Highly-reactive pozzolan with high specific surface

Replacement level of PC will depend on the nature of the constituents and the To and reaction time Produces significant pore refinement --> modifies water transport properties and diffusion rates of harmful ions Enhances several mechanical (early-age compressive strength, flexural strength) and durability properties (chemical attack, ASR expansion, sulphate resistance, F/T cycles) of concrete

Metakaolin
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Increases water demand ==> superplasticizers for workability; may require less SP than SF, have better finishability and being less sticky than SF concrete Could be very beneficial in ternary systems
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Chemical Analysis of Cementititous Materials

Chemical Composition, % Silicon dioxide, SiO 2 Aluminum oxide, Al 2O 3 Ferric oxide, Fe2O 3 Calcium oxide, CaO Loss on Ignition Cementitious Materials Type 1 Silica Metakaolin Cement Fume 20.1 4.51 2.50 61.3 2.41 51.34 41.95 0.52 0.34 0.72 93.6 0.06 0.45 0.50 2.26

PC + GGBFS + MK PC + FA + MK

The contrasting behaviours of FA and MK can be utilized with maximum benefit in terms of the finished products with respect to the flow behaviour, behaviour, strength development and cost

Zhang & Malhotra (1995)

Microtexture of Products

Physical Properties of Cementititous Materials

Physical Properties Specific gravity Cementitious Materials Type 1 Silica Metakaolin Cement Fume 3.09 373 16.8 20.9 2.50 2.20

< 1m

Silica Fume

Metakaolin

Specific Surface Blaine 2 fineness, m /kg Nitrogen Absorption, 2 m /g

Typical median particle size: ~10 m for PC, 1.3 m for MK and 0.1 m for SF
Zhang & Malhotra (1995) Zhang & Malhotra (1995)

Metakaolin - Mineralogy

Type of concrete Investigated

Type of concrete investigated
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Control 10% Metakaolin 10% Silica Fume W / C + SCM = 0.40 Cementititous materials content: 390 kg/m3 Slump : 80 - 170 mm Air Content: 5.5 - 6.1 %
Zhang & Malhotra (1995)

Mixture proportioning
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Properties of fresh concrete

? ? Zhang & Malhotra (1995)

Setting Times of Concrete

Setting Time, h:min Initial Final Set Set n/a 3:06 3:36 5:12 4:24 4:48

Mechanical Properties of Concrete

Concrete Mixture Compressive Strength, Days (Mpa) 1 7 28 90 20.9 28.9 36.4 42.5

Concrete Mixture

SF MK

Con

Control Metakaolin, 10% Silica Fume, 10%

Control

MK, 10% 25.0 37.9 39.9 43.0 SF, 10% 23.2 34.7 44.4 48.0

Zhang & Malhotra (1995)

Zhang & Malhotra (1995)

Mechanical Properties of Concrete

Concrete Mixture Properties of Hardened Concrete Splitting Flexural, E tensile, 28 28 days, Modulus, days, MPa MPa GPa 2.7 3.1 2.8 6.3 7.4 7.0 29.6

Resistance to Chlorideion Penetration (RCIP)

Concrete Mixture Control RCIP 28 days, Coulombs 3175 390 410 RCIP 90 days, Coulombs 1875 300 360

Control Metakaolin, 10% Silica Fume, 10%

32.0 31.1

Metakaolin, 10% Silica Fume, 10%

Zhang & Malhotra (1995)

Zhang & Malhotra (1995)

Resistance to Freezing and Thawing Cycles (ASTM C 666)

Residual Air Durability Concrete Flexural Content, Factor, Mixture Strength, % % % Control MK, 10% SF, 10% 6.6 4.9 5.0 98.3 100.3 100.9 85 89 96

Results of De-icing Salt Scaling Tests

Concrete Mixture Control MK, 10% SF, 10% Visual Scaling Rating, Residue, 2 ASTM kg/m C 672 2 0.3 3 0.9 3 0.8

Rating 0

Rating 1

Rating 3

Rating 5

Zhang & Malhotra (1995)

Zhang & Malhotra (1995)

Drying Shrinkage of Concrete

Heat Generation of Concrete

Zhang & Malhotra (1995)

Zhang & Malhotra (1995)

Conclusion
Metakaolin is a highly pozzolanic and reactive material Metakaolin improves most mechanical and durability properties of concrete Properties of concrete incorporating MK are comparable and sometimes better than SF concrete.