Ideal solution for major constructions

WHY USE
METACAULIM HP ULTRA

Increased DURABILITY for constructions at short, medium and long terms.

Reduction or elimination of pathologies.

Reduction in maintenance of concrete and projects reconstruction.

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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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

Increase in mechanical strengths to compression, tensile and abrasion, at all ages, for up to 40%.

Reduction and control of alkali-aggregate reactions.

Higher resistance to sulfate attack, acids and other chemicals.

Reduction of chloride penetration up to 75%.

Reduction of corrosion in steel rebars.

Decrease in the heat of hydration and thermal cracking.

Decrease in porosity and permeability for up to 90%.

Aesthetic enhancement of the surface: control of efflorescence, cracking and wear.

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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Applications

INFRASTRUCTURE WORKS:

dams, ports, wind farms, railways, bridges and viaducts, water and sewage treatment facilities, pavements.

» Advantages

COMMERCIAL, INDUSTRIAL AND
RESIDENTIAL BUILDINGS

» Advantages

ARTIFACTS, PRECAST AND TILT-UP

» Advantages

INDUSTRIAL FLOORINGS AND PAVEMENTS

» Advantages

MORTARS AND GROUTS

» Advantages

SPECIAL APPLICATIONS:

sanitary wares and porcelain, ceramics, refractories, mineral fillers (for paint, paper and resin), chemicals (aluminum sulfate, aluminum polychloride, among others).

Effects of Metacaulim HP ULTRA

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

Cement paste WITH Metacaulim HP ULTRA

Contribution

Gráfico Redução e controle das reatividades álcali-agregado

Gráfico Redução da penetração de cloretos

Gráfico Diminuição da porosidade e permeabilidade

Gráfico Redução da corrosão de armaduras

Gráfico Aumento da resistência ao ataque por sulfato

Without Metacaulim HP ULTRA

Increased maintenance and cost; reduced durability and safety of projects and jobsites:

Chloride Penetration

Rebar Corrosion

Alkali-aggregate reaction

Estimated cost of maintenance or project reconstruction

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
	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".

Comparative performance study

		WITHOUT Metacaulim	WITH Metacaulim HP ULTRA
		Standard	Fixed compressive strength, at 28 days	Fixed amount of binders
	Metacaulim HP ULTRA (10%)	-	31	38
	Cement type CP V ARI	420	310	382
	Natural Washed Sand	743	789	710
	Stone 12.5/25mm	1055	1110	1130
	Water	174	174	174
	Superplasticizer Additive	3,36	2,73	3,36
Factor Water/Binders		0,414	0,510	0,414
Estimated Cost		Market Cost	5% Reduction in Market Cost	-	REFERENCE LIMITS
	1 day (MPa)	31,4	29,4	34,3	-
	7 days(MPa)	55,3	57,4	64,8	-
	28 days (MPa)	61,5	61,2	73,6	-
	182 days (MPa)	63,8	67,9	81,4	-
Modulus of Elasticity _{GPa (28 days)}		36,3	35,5	38,7	-
	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	-
	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%

Technical Datasheet

	METACAULIM HP ULTRA
Color	Light bege to off-white

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%	-
TiO₂	1,5%	-
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	-

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

foto Metacaulim HP ULTRA Big-Bag de 600 a 800kg

600 to 800kg
super-sacks

foto Metacaulim HP ULTRA Granel de 15 a 25 toneladas

Bulk/silo-truck (for projects located within 3.000 km from São Paulo, Brazil)

Download of the Material Safety Data Sheet:

Material Safety Data Sheet (MSDS).

- Português: fispq.pdf (73 KB)

- English: metacaulim brasil-MSDS-04-12.01.2012.pdf (71 KB)

Download

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.

- Português: metacaulim-hp-usp.pdf (2,53 MB)

- English: metacaulim HP-USP-1-1-english.pdf (353 KB)

Material Safety Data Sheet (MSDS).

- Português: fispq.pdf (73 KB)

- English: metacaulim brasil-MSDS-04-12.01.2012.pdf (71 KB)

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