ICDS12

International Conference DURABLE STRUCTURES: from construction to rehabilitation

LNEC Lisbon Portugal 31 May - 1 June 2012

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Lime-Metakaolin Mortars for

Historical Buildings Repair

DS

Study of the hardening reaction

Andr Gameiro - National Laboratory of Civil Engineering, Av. do Brasil, 101, Lisbon, Portugal

A. Santos Silva - National Laboratory of Civil Engineering, Av. do Brasil, 101, Lisbon, Portugal
R. Veiga - National Laboratory of Civil Engineering, Av. do Brasil, 101, Lisbon, Portugal

A. Velosa - Department of Civil Engineering, Geobiotec, University of Aveiro, Aveiro, Portugal

IC

P. Faria Department of Civil Engineering, University Nova de Lisboa, Caparica, Portugal

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Introduction

LNE
C

This study is part of an extensive work being developed in Portugal,

aiming to characterize lime-metakaolin mortars to be employed in
building restoration pruposes.
Finding mortars with adequate durability and strength is one of the
major challenges nowadays.
Pozzolanic materials have been used throughout history acting as
agents to improve the mechanic and durability characteristics of
mortars.

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

DURABLE STRUCTURES

12

LNEC Lisbon 31 May - 1June 2012

Introduction II

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DS

Metakaolin (MK) is a thermally

activated aluminosilicate material
(Al2O3.2SiO2) obtained by
calcinations of clay or soils rich in
kaolinite (Al2(OH)4Si2O5) within the
temperature range of 600 -900 C.

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Overview

LNE
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Metakaolin (MK) is a well-known pozzolanic material with

several applications in cement/mortar matrixes.
Enhancement of the durability of aerial lime mortars.
Increase in mechanical resistance
Conservation and restoration of historic buildings.

Reaction of MK and lime (calcium hydroxide) and water

originate hydration products
Pozzolanic Reaction

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

DURABLE STRUCTURES

12

LNEC Lisbon 31 May - 1June 2012

Aims

MORTARS

DS

The results regarding the hardening reaction up to 90 days of curing

in humid conditions (905% RH and 203 C).
Study the compounds formed in lime/MK mortars.
Carbonation vs. Pozzolanic reaction

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Study their stability over time.

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LNE
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Main discussion points

> Evolution of the hardening reaction of specimens cured in a humid

ambient (905% RH and 20 3 C):
In mortars up to 90 days of curing

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

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Materials Mortar Preparation I

Commercial Portuguese CL90 hydrated air lime (NP EN 459-1):

Ca(OH)2 93%

Al2O3

Fe2O3

MnO

MgO

CaO

Na2O

K2O

TiO2

P2O5

L.O.I.*

(%)

(%)

(%)

(%)

(%)

(%)

(%)

(%)

(%)

(%)

(%)

Metakaolin

54.39

39.36

1.75

0.01

0.14

0.10

1.03

1.55

0.06

1.90

CL90 air
lime

0.01

0.15

0.01

3.09

76.74

0.02

0.04

0.01

20.45

DS

SiO2

Material

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Metakaolin (ARGICAL M1200S) (SiO2 +Al2O3 > 93%)

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Experimental Mortar Preparation II

LNE
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Mortars were prepared by mixing air lime CL90 with siliceous river sand.
Different volumetric ratios (binder:aggregate) were formulated 1:1, 1:2 and
1:3 with 30 and 50 wt. % replacement of lime by metakaolin.
The amount of water added was estimated respecting the required
consistency flow values around 140 mm.

The mortars were cured at 905% RH and 203 C.

The hardening reaction was accompanied at certain ages recurring to XRD
and TG-DTA and techniques.

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

DURABLE STRUCTURES

12

LNEC Lisbon 31 May - 1June 2012

IC

DS

Experimental Mortar Preparation III

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Experimental Characterization methods

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Characterization techniques:
X-ray diffraction (crystalline compounds)
Thermal analysis (evolution of mass loss related to the formation
of hydrated phases)

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

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LNEC Lisbon 31 May - 1June 2012

Notation:

DS

Hardening reaction evolution 1:1 (0, 30 and 50% MK)

The main hydrated phases present in the lime-MK mortars are

stratlingite, monocarboaluminate and a calcium aluminate
hydrate.

Carbonation seems to be delayed at 28 days of curing with the

MK introduction, however increasing with ageing for all mortars.

Monocarboaluminate and the calcium aluminum hydrate

unstable after 28 days of curing.

Portlandite not detected for 50% MK blended mortars (complete

consumption may have taken place either by pozzolanic reaction
and/or in the carbonation reaction

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St Stratlingite (2CaO.SiO2.Al2O3.8H2O)
M Monocarboaluminate (3CaO.Al2O3.CaCO3.11H2O)
D Calcium aluminum hydrate (Ca2Al(OH)7.6.5H2O)
P Portlandite (Ca(OH)2)
C Calcite (CaCO3)
Q Quartz (SiO2)
F Feldspar (KAlSi3O8)
V Vaterite (CaCO3).

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LNE
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Hardening reaction evolution 1:2 (0, 30 and 50% MK)

Notation:

St Stratlingite (2CaO.SiO2.Al2O3.8H2O)
M Monocarboaluminate (3CaO.Al2O3.CaCO3.11H2O)
D Calcium aluminum hydrate (Ca2Al(OH)7.6.5H2O)
P Portlandite (Ca(OH)2)
C Calcite (CaCO3)
Q Quartz (SiO2)
F Feldspar (KAlSi3O8);
V Vaterite (CaCO3).

The main hydrated phases present in the lime-MK mortars are

stratlingite, monocarboaluminate and a calcium aluminate hydrate.

Carbonation seems to be delayed at 28 days of curing with the MK

introduction, however increasing with ageing for all mortars.

Monocarboaluminate and the calcium aluminum hydrate unstable

after 28 days of curing.

Portlandite not detected for 50% MK blended mortars (complete

consumption may have taken place either by pozzolanic reaction
and/or in the carbonation reaction).

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

DURABLE STRUCTURES

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LNEC Lisbon 31 May - 1June 2012

Notation:

DS

Hardening reaction evolution 1:3 (0, 30 and 50% MK)

The main hydrated phases present in the lime-MK mortars are

stratlingite, monocarboaluminate and a calcium aluminate hydrate.

Carbonation seems to be delayed at 28 days of curing with the MK

introduction, however increasing with ageing for all mortars.

Monocarboaluminate and the calcium aluminum hydrate unstable

after 28 days of curing.

Portlandite not detected for 50% MK blended mortars (complete

consumption may have taken place either by pozzolanic reaction
and/or in the carbonation reaction

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St Stratlingite (2CaO.SiO2.Al2O3.8H2O)
M Monocarboaluminate (3CaO.Al2O3.CaCO3.11H2O)
D Calcium aluminum hydrate (Ca2Al(OH)7.6.5H2O)
P Portlandite (Ca(OH)2)
C Calcite (CaCO3)
Q Quartz (SiO2)
F Feldspar (KAlSi3O8)
V Vaterite (CaCO3).

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LNE
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Hardening reaction evolution II

Pozzolanic vs. Carbonation reaction (28 and 90 days)

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

DURABLE STRUCTURES

12

LNEC Lisbon 31 May - 1June 2012

Conclusions

Hydrated phases formed in lime-MK blended mortars are stratlingite, calcium aluminate hydrate,
monocarboaluminate and portlandite.

Stratlingite, a hydrated compound responsible for the high mechanical resistance in the lime-MK
mortars, was favoured by mortars possessing high MK content and with increasing ageing,
independently of the chosen binder:aggregate mortar ratio.

This hydrated phases was found to be more abundant with the 1:1 binder:aggregate mortar ratio.

The pozzolanic reaction is favoured in relation to the carbonation reaction at early ages of curing (28
days).

Carbonation reaction at longer curing times (90 days) for almost all mortar compositions, except
L1MK30 and L1MK50.

Mortars with 1:1 binder:aggregate ratio and 50 MK wt. % appears to be the mortar composition
showing the highest pozzolanic reaction.

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DS

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LNE
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Future works

Physical and mechanical characterization are in progress, and should be

evaluated and taken into account before any recommendation for
application in the work site.

ICDS12
International Conference DURABLE STRUCTURES: from construction to rehabilitation
LNEC Lisbon Portugal 31 May - 1 June 2012

DURABLE STRUCTURES

12

LNEC Lisbon 31 May - 1June 2012

Acknowledgements

LNE
C

IC

Thank You!

DS

The authors wish to acknowledge the Fundao para a Cincia e

Tecnologia (FCT) and COMPETE for the financial support under project
METACAL (PTDC/ECM/100431/2008). The companies IMERYS and
Lusical are also acknowledged for the supply of metakaolin and lime,
respectively, used in this work.