Admixture Metakaolin
Metakaolin for High-Performance
Concrete
Special Correspondent
C
ement concrete is the most extensively used con-
struction material. Maintenance and repair of con-
crete structures is a growing problem involving
significant expenditure. As a result carried out worldwide, it
has been made possible to process the material to satisfy
more stringent performance requirements, especially long
– term durability. High performance is generally assumed
to be synonymous with high strength, although this is not
true in every case. Unacceptable rates of deterioration due
to environmental effects indicate that only compliance with
strength requirements, although need, is not adequate to
ensure long-term, durability, which is the primary requirement
for high performance. It is generally accepted, that the high
102 The Masterbuilder - July 2012 • www.masterbuilder.co.in
performance of the very concrete contributes to low
permeability, stronger and denser transition zone between
aggregate and cement paste in the concrete. This also adds
to the abrasion resistance of concrete. According to ACI
“High Performance Concrete is defined as concrete which
meets special performance and uniformity requirements
that cannot always be achieved routinely by using con-
ventional materials and normal mixing, placing and curing
practices.
High Performance Concrete (HPC)
Concrete is probably the most extensively used construction
material in the world. However, when the high range water

reducer or super plasticizer was invented and began to be
used to decrease the water/cement (w/c) or water/binder
(w/b) ratios rather than being exclusively used as fluid
modifiers for normal-strength concretes, it was found that
in addition to improvement in strength, concretes with very
low w/c or w/b ratios also demonstrated other improved
characteristics, such as higher fluidity, higher elastic modulus,
higher flexural strength, lower permeability, improved abra-
sion resistance, and better durability. This fact led to the
development of HPC. HPC is the latest development in
concrete. It has become more popular these days and is
being used in many prestigious projects such as Nuclear
power projects, flyovers, multistoried buildings etc. Since
1990s, HPC has become very popular in construction
works. At present, the use of HPC has spread throughout
the world. In 1993, the American Concrete Institute (ACI)
published a broad definition for HPC and is defined as the
concrete which meets special performance and uniformity
requirements that cannot always be achieved by using only
the conventional materials and mixing, placing and curing
practices. The addition of mineral admixture in cement
has dramatically increased along with the development of
concrete industry, due to the consideration of cost saving,
energy saving, environmental protection and conservation
of resources. However, environmental concerns both in
terms of damage caused by the extraction of raw material
and carbon dioxide emission during cement manufacture
have brought pressures to reduce cement consumption
by the use of supplementary materials. Mineral admixtures
such as fly ash, rice husk ash, metakaolin, silica fume
etc are more commonly used in the development of HPC
mixes. They help in obtaining both higher performance
and economy. These materials increase the long term
performance of the HPC through reduced permeability
resulting in improved durability. Addition of such materials
has indicated the improvements in the strength and durability
properties of HPC.
Admixture Metakaolin
“As far as India is concerned
metakaolin actually came
into the market as a cheaper
material than micro silica.
It was only after reputed
companies started using
metakaolin that the product
Jayant Basu Ray
MD, Constromat Consultancy
began to generate a buzz in
& Services India PVT LTD the market.”
About Metakaoline & Its Role in Concrete and High Per-
formance Concrete
Metakaolin differs from other supplementary cementitious
materials (SCMs), like fly ash, silica fume, and slag, in that it is
not a by-product of an industrial process; it is manufactured
for a specific purpose under carefully controlled conditions.
Metakaolin is produced by heating kaolin, one of the
most abundant natural clay minerals, to temperatures of
650-900°C. This heat treatment, or calcination, serves to
break down the structure of kaolin. Bound hydroxyl ions
are removed and resulting disorder among alumina and
silica layers yields a highly reactive, amorphous material
with pozzolanic and latent hydraulic reactivity, suitable
for use in cementing applications. Metakaolin reacts with
portlandite (CH) to form calcium-silicate-hydrate (C-SH)
supplementary to that produced by portland cement
hydration. This reaction becomes important within the
interfacial transition zone (ITZ) located between aggregate
and paste fractions. This region typically contains a high
concentration of large, aligned CH crystals, which can lead
to localized areas of increased porosity and lower strength.
Metakaolin can react with some of the CH produced by
cement hydration, there by densifying the structure of the
hydrated cement paste. The rates of pozzolanic reaction and
CH consumption in metakaolin systems have been shown
to be higher than in silica fume systems, indicating a higher
initial reactivity.6 Because this reaction with CH occurs early
and rapidly, metakaolin incorporation may contribute to
reduced initial and final set times. In addition, this refinement
in the ITZ can result in increased strength in metakaolin
concrete. As portlandite in the ITZ and elsewhere in the
paste is water soluble and is susceptible to deterioration in
aggressive chemical environments, metakaolin has great
potential for improving concrete durability. Also, because
(a) (b)
Figure 1: (a) Metakaolin, (b) Self-consolidating concrete using metakaolin
www.masterbuilder.co.in • The Masterbuilder - July 2012 103
Admixture Metakaolin
the supplementary C-S-H formed during the pozzolanic
reaction with metakaolin has a lower Ca/Si ratio than
ordinary C-S-H, these products are believed to be better
able to bind alkali ions from the pore solution, thus reducing
concrete’s susceptibility to alkali-silica reaction (ASR).
This potential beneficial use of metakaolin is particularly
relevant, as silica fume agglomerates have been shown to
contribute to ASR expansion in some cases. Metakaolin
has also been shown to decrease concrete permeability,
which in turn increases its resistance to sulfate attack and
chloride ion ingress. Additionally, metakaolin may reduce
autogenous and drying shrinkage, which could otherwise
lead to cracking. Thus, when used as a partial replacement
for Portland cement, metakaolin may improve both the
mechanical properties and the durability of concrete. In
general, metakaolin offers a set of benefits similar to those
imparted by silica fume, including comparable strengths,
permeability, chemical resistance, and drying shrinkage
resistance. Physically, metakaolin particles measure
approximately one-half to five micro meters across, making
them an order of magnitude smaller than cement grains
and an order of magnitude larger than silica fume particles.
Both metakaolin and silica fume are typically used to
replace 5 to 20 weight % of the cement. Metakaolin is white
in color, whereas standard silica fume ranges from dark
grey to black (although white silica fume is available at
higher cost). This makes metakaolin particularly attractive
in color matching and other architectural applications. For
these reasons, metakaolin is increasingly used in the
production of high-performance concrete. ASTM C618
and AASHTO M 295 classify metakaolin as a Class N (or
natural) pozzolan. Figure 1 (a) and (b) shows metakaoline
and self-consolidating concrete using metakaolin.
Metakaolin’s Contribution in HPC
- Improved Strength
Metakaolin’s reaction rate is rapid, significantly increasing
compressive strength, even at early ages, which can allow
for earlier release of formwork. As stated by Mr. Atil Parikh,
Joint Managing Director of 20Microns “Globally metakaolin
“Globally metakaolin is a
very well accepted product.
In India too the demand is
fast picking up. Initially we
had to educate people. We
first targeted Mumbai– the
high rise capital of India.
This is because metakaolin
finds use in the M60 or M80
Atil Parikh
grade concrete that is
Joint Managing Director of typically used in high-rise
20Microns construction projects”
104 The Masterbuilder - July 2012 • www.masterbuilder.co.in
is a very well accepted product. In India too the demand
is fast picking up. Initially we had to educate people. We
first targeted Mumbai– the high rise capital of India. This
is because metakaolin finds use in the M60 or M 80 grade
concrete that is typically used in high-rise construction
projects”
(a) Control (b) With Meta Star 501
Figure 2: (a) Control Mix floor, (b) Metakaolin mix floor
- Improved Durability
In addition to increasing strength, the densification of the
microstructure that results from the pozzolanic and hydraulic
reactions of metakaolin also leads to greater impermeability.
In concretes containing metakaolin at 8 to 12% of the total
cementitious materials, 50-60% decreases in chloride
diffusion coefficient suggest that significant improvements
in service life can be achieved through metakaolin utilization
in chloride environments. In addition, metakaolin has been
shown to be highly effective in mitigating expansion due to
alkali-silica reaction (ASR) and sulfate attack.
- Improved Early Age Behavior
The relative fineness of metakaolin can result in decreased
slump, but the use of water reducing admixtures or use in
combination with fly ash in ternary mixes can compensate
for this. Slumps of 125 to 180 mm have been achieved
with metakaolin at water cementitious materials ratio (w/
cm) of 0.36 to 0.38, using 25-35% less high-range water
reducing admixture than comparable mixes. Metakaolin
concrete tends to exhibit a creamy texture, resulting in
better finishability compared to other finely divided SCMs.
This quality also improves pumpability and can be used to
impart detailed surface textures to cast surfaces. In addition,
the cohesiveness provided by the metakaolin allows for
relatively simple formulation of self-consolidating concrete,
when using an appropriate dosage of polycarboxylate water
reducer as shown in the photograph at the beginning of this
article. Data on the potential contributions of metakaolin to
chemical, autogenous, and drying shrinkage are inconsistent,
with authors reporting both decreases and increases in
each form at various ages and at various addition rates. For
applications with restrictions on shrinkage, additional testing,
including the assessment of shrinkage-reducing admixtures
and fiber reinforcement, may be advised.
Admixture Metakaolin

- Contributions to Sustainability

Because of the lower processing temperature compared to

cement clinker, use of metakaolin can contribute to sustain-
ability through energy savings, as well as reductions in
greenhouse gas emissions. After examining various SCMs
alone and in combination and considering performance,
economic, and environmental criteria, metakaolin concrete
was identified as a “very promising solution” for the precast
industry for reducing clinker content in concrete.

Available Brands and Applications

1. MetaStar 501: METASTAR 501 is a metakaolin pozzolanic

additive that:

- Improves strength, durability, and workability of Portland

cement concrete
- Makes Portland cement easier to apply
- Provides smoother finish
- Has bright white color for white and color plasters
- Reduces permeability, efflorescence, and cracking
- Reduces the porosity of hardened concrete
- Contains no undesirable impurities, such as carbon or
sulphur, which could affect the curing rate or strength of
the final PC product
- Readily disperses in cement-based systems
- Is safe and easy to handle
quirements. 20microns has its calcined clay mines located
Refer Figure 2 (a) and (b) for judging the difference of in Gujarat, Bhuj. For the production of calcined kaolin the
control and Metakaolin mix. material has to be put through heating up to a certain
2. In India 20Microns is considered one of the leading temperature – around 1200oC. Metakaolin is an intermediary
producers of white minerals. The company offers a wide product which is produced at about 700-750oC during the
range of products including functional fillers, extenders, process.
and specialty chemicals. The company’s mines are spread Figure 2: (a) Control Mix floor, (b) Metakaolin mix floor
across the country. The company offers a diverse range
of customized products based on specific industry re- 3. PALAIS ROYALE, Mumbai: First project in India to use
M80 grade of self consolidating concrete. The Project is
around 300 metres high comprising of Duplexes and Villas
in it. The developers have used metakaolin as one of the
supplementary cementitious material.

Conclusion

The beneficial effects of using metakaolin is it reacts with

calcium hydroxide almost as fast as it is formed in the
cement during hydration. The overall effect of removing
calcium hydroxide, refining the pore structure and densifying
the interfacial zone is to reduce:

- Re-bar corrosion
- Sulphate attack
- Acid attack (e.g. silage clamps, food factories)
- Freeze-thaw damage
- Alkali-silica reaction (even when using active aggregates,

106 The Masterbuilder - July 2012 • www.masterbuilder.co.in

Admixture Metakaolin
high alkali cementsand where the concrete is exposed
to salt solutions)
- Efflorescence
Till three-four years ago, hardly anybody in India was aware
of the use of metakaolin in concrete. During these four
years, the developments that have taken place include
increased awareness of the huge potential of production of
metakaolin in the country (with huge mineral resource, that
is, kaolin availability across the country), start of indigenous
commercial production and many investigations on the
development of concrete mixes containing metakaolin. The
metakaolin is a low cost, locally produced, highly effective
pozzolonic material, particularly for the early strength de-
velopment, without appreciable loss in workability. It makes
finish easier, reduces efflorescence, increase resistance to
sulphate and chlorine attack. It maintains colour of concrete,
especially in white concrete. So it can be very well used
in Architectural work. As silica fume is to be imported, it
is dare necessity to find locally available material at an
affordable price, substitute of it, Metakaolin could be an
answer to it seeing its vast exploring opportunity in India.
It can bring a huge export possibilities to India; as quoted
by Mr. Atil Parikh, “The US is a high consumption market.
It was during the last decade or so that people started to
switch from micro silica to metakaolin there in a big way.
Canada is another major market”.
Reference
- Justice, J. M. and Kurtis, K. E., “Influence of Metakaolin Surface
Area on Properties of Cement-based Materials”, ASCE Journal
108 The Masterbuilder - July 2012 • www.masterbuilder.co.in
of Materials in Civil Engineering, September 2007, Vol.19, No.
9, pp. 762-771.
- Tafraoui, A. et al., “Metakaolin in the Formulation of UHPC,”
Construction and Building Materials, Vol. 23, 2009, pp.669-674.
- Justice, J. M. et al., “Comparison of Two Metakaolins and
Silica Fume Used as Supplementary Cementitious Materials,”
Seventh International Symposium on Utilization of High-
Strength / High Performance Concrete, Ed. Russell, H. G.,
Publication SP-228, Vol. 1, American Concrete Institute,
Farmington Hills, MI, 2005, pp.213-236. Also on Compact Disc.
- Gruber, K. A. et al., “Increasing Concrete Durability with High-
Reactivity Metakaolin,” Cement and Concrete Composites,
Vol. 23, 2001, pp. 479-484.
- Khatib, J. M. and Wild, S., “Sulphate Resistance of Metakaolin
Mortar,” Cement and Concrete Research, Vol. 28, No. 1, 1998,
pp. 83-92.
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Concrete Research, Vol. 30, 2000, pp. 339-344.
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Optimising Ternary Blended Concrete Containing Metakaolin,”
Magazine of Concrete Research, September 2008, Vol. 60,No.
7, pp. 499-510.
- Caldarone, M. A., Gruber, K. A., and Burg, R. G., “High-
Reactivity Metakaolin: A New Generation Mineral Admixture,”
Concrete International, Vol. 16, No. 11, November 1994,
pp.37-40.
- Cassagnabere, F. et al., “Metakaolin, A Solution for the Precast
Industry to Limit the ClinkerContent in Concrete: Mechanical
Aspects,” Construction and Building Materials, Vol. 24, 2010,
pp. 1109-1118.
- www.imerys-perfmins.com
- www.alcongoa.com/pdf/Alccofine_Tech_Info.pdf