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Metacaulim HP ULTRA is the ideal solution for major projects such as dams, ports and piers, sanitation plants, among others, commonly used in Brazil and worldwide. It consists of pure metakaolin, applied on concrete, cement slurry and mortar.
Main advantages of Metacaulim HP ULTRA
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Increase in mechanical strengths to compression, tensile and abrasion, at all ages, for up to 40%. |
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Reduction and control of alkali-aggregate reactions. |
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Higher resistance to sulfate attack, acids and other chemicals. |
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Reduction of chloride penetration up to 75%. |
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Reduction of corrosion in steel rebars. |
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Decrease in the heat of hydration and thermal cracking. |
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Decrease in porosity and permeability for up to 90%. |
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Aesthetic enhancement of the surface: control of efflorescence, cracking and wear. |
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Enhanced rheology: higher cohesion, up to 90% bleeding reduction; up to 50% rebound reduction in shotcretes; higher flowability and less segregation in self-compacting concretes. |
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INFRASTRUCTURE WORKS:
dams, ports, wind farms, railways, bridges and viaducts, water and sewage treatment facilities, pavements.
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COMMERCIAL, INDUSTRIAL AND RESIDENTIAL BUILDINGS
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ARTIFACTS, PRECAST AND TILT-UP
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INDUSTRIAL FLOORINGS AND PAVEMENTS
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SPECIAL APPLICATIONS:
sanitary wares and porcelain, ceramics, refractories, mineral fillers (for paint, paper and resin), chemicals (aluminum sulfate, aluminum polychloride, among others).
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Physical
Due to the small size of its particles, Metacaulim HP ULTRA fills the voids left by cement paste, reducing its porosity and also contributing to water retention, thus improving hydration of the cement and reducing cracks caused by capillarity and drying during the curing process.
Chemical
Metacaulim HP ULTRA reacts with the free lime (calcium hydroxide) present in cement paste, leading to, over time, composites much more chemically stable and more resistant such as C-S-H (hydrated calcium silicate) and C-A-S-H (hydrated calcium aluminum silicate).
Photos
Electronic microscopies of hardened cement paste, showing reduction of porosity:
Cement paste WITHOUT Metacaulim HP ULTRA
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Cement paste WITH Metacaulim HP ULTRA
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Without Metacaulim HP ULTRA
Increased maintenance and cost; reduced durability and safety of projects and jobsites:
Chloride Penetration
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Rebar Corrosion
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Alkali-aggregate reaction
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PATHOLOGY |
APPLICATIONS |
BRAZIL |
WORLD |
Rebar Corrosion |
Ports, viaducts and bridges, railways, pre-cast structures, buildings and reinforced concrete in general. |
US$ 2,6 bi |
US$ 153 bi |
Alkali-aggregate reactivity |
Foundations, dams, channels and galleries, tunnels and concrete in general (whether reinforced or not). |
US$ 600 mi |
US$ 104 bi |
Acid and sulfate attack |
Water and sewage treatment facilities, pipes, industrial structures and floors and concrete in general (whether reinforced or not). |
US$ 1 bi |
US$ 85 bi |
Physical deterioration |
Pavements, industrial floors, canals and galleries, pipes and concrete subject to superficial wear, fatigue or high intensity mechanical stress (whether reinforced or not). |
US$ 2,4 bi |
US$ 136 bi |
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TOTAL (US$ per year) |
US$ 6,6 bi |
US$ 478 bi |
Data related to 2011
"Considering all other pathologies found in concrete and mortar, maintenance expenditure and project reconstruction are estimated to be at least US$ 60 billion a year, only in Brazil, and over US$ 2 trillion a year worldwide".
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WITHOUT
Metacaulim |
WITH
Metacaulim HP ULTRA |
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Standard |
Fixed compressive strength, at 28 days |
Fixed amount of binders |
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Metacaulim HP ULTRA (10%) |
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31 |
38 |
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Cement type CP V ARI |
420 |
310 |
382 |
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Natural Washed Sand |
743 |
789 |
710 |
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Stone 12.5/25mm |
1055 |
1110 |
1130 |
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Water |
174 |
174 |
174 |
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Superplasticizer Additive |
3,36 |
2,73 |
3,36 |
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Factor Water/Binders |
0,414 |
0,510 |
0,414 |
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Estimated Cost |
Market Cost |
5% Reduction in Market Cost |
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REFERENCE LIMITS |
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1 day (MPa) |
31,4 |
29,4 |
34,3 |
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7 days(MPa) |
55,3 |
57,4 |
64,8 |
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28 days (MPa) |
61,5 |
61,2 |
73,6 |
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182 days (MPa) |
63,8 |
67,9 |
81,4 |
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Modulus of Elasticity GPa (28 days) |
36,3 |
35,5 |
38,7 |
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Alkali-aggregate reaction expansion % (16 days) |
0,26 |
0,03 |
0,03 |
< 0,10% |
Sulphate Resistance expansion % (42 days) |
0,06 |
0,01 |
0,01 |
< 0,03% |
Chloride Penetration
Coulombs (28 days) |
1680 |
670 |
460 |
< 1000 Coulombs |
Electrical Resistivity Kohm.cm (28 days) |
25 |
90 |
115 |
> 60 Kohm |
Adiabatic Elevation º Celsius, max. (7 days) |
74 |
63 |
73 |
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Drying Shrinkage % (28 days) |
0,17 |
0,05 |
0,07 |
< 0,10% |
Water Penetration under Pressure, mm (28 days) |
14 |
7 |
5 |
< 10 mm |
Water Absorption % (28 days) |
5,3 |
3,2 |
2,5 |
< 4,5% |
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METACAULIM HP ULTRA |
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Color |
Light bege to off-white |
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Physical & Chemical Properties |
Typical Values |
Limit Values(Brazilian Standard NBR 15.894) |
SiO2 |
57% |
44% to 65% |
Al2O3 |
34% |
32% to 46% |
CaO + MgO |
< 0,1% |
< 1,5% |
SO3 |
< 0,1% |
< 1% |
Na2O |
< 0,1% |
< 0,5% |
Alkaline Eq. Na2O2O |
< 1,5% |
< 1,5% |
Fe2O3 |
2% |
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TiO2 |
1,5% |
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Humidity |
0,5% |
< 2% |
Loss on Igniton |
3% |
< 4% |
Residue #325 |
6% |
< 10% |
Pozzolanic activity index with OPC (7 days) |
115% |
> 105% |
Chapelle Pozzolanic Activity |
880mg Ca(OH)2/g |
> 750mg
Ca(OH)2/g |
BET Specific Area |
230.000cm²/g |
150.000cm²/g |
Specific Gravity |
2,56kg/dm³ |
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Handling Instructions:
Add Metacaulim HP ULTRA directly into the mixture, along with cement. It does not require pre-mixing in water. Use between 5% and 15% cement replacement by weight, according to concrete performance specifications.
Chemical Composition:
Saluminum silicate
Available in:
20 kg palletized paper bags
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600 to 800kg super-sacks
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Bulk/silo-truck (for projects located within 3.000 km from São Paulo, Brazil) |
Download of the Material Safety Data Sheet:
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Material Safety Data Sheet (MSDS).
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Studies carried out at Universidade de São Paulo (USP – University of São Paulo), under supervision of Professor PAULO HELENE, PhD, show that the addition of Metacaulim HP increases in several times the life service of concrete structures, and contributes to considerable increase of mechanical strengths.
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Material Safety Data Sheet (MSDS).
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