Investigating embodied carbon, mechanical properties, and durability of high-performance concrete using ternary and quaternary blends of metakaolin, nano-silica, and fly ash

Research for alternative binders has become a necessity due to cement's embodied carbon, climate change, and depletion of natural resources. These binders could potentially reduce our reliance on cement as the sole binder for concrete while simultaneously enhancing the functional characteristics of concrete. Theoretically, the use of finer particles in the cement matrix densifies the pore structure of concrete and results in improved properties. To validate this hypothesis, current research was designed to investigate how the value-added benefits of nano-silica (NS) and metakaolin (MK) in fly ash (FA)-blended cement affect the mechanical and durability characteristics of concrete when used as ternary and quaternary blends. Additionally, the cost-benefit analysis and environmental impact assessment were conducted. It was observed that the synergy of MK and NS used in FA-blended cement had a greater impact on enhancing the functional characteristics of concrete, while 10% MK as ordinary Portland cement (OPC) replacement and 1% NS as an additive in FA-blended OPC concrete was the optimum combination which achieved 94-MPa compressive strength at the age of 91 days and showed more than 25% increment in the flexural and splitting tensile strengths compared to the control mix (MS00). The ultrasonic pulse velocity and dynamic modulus of elasticity were significantly improved, while a significant reduction in chloride migration of 50% was observed. In terms of environmental impact, MS100 (30% FA and 10% MK) exhibited the least embodied CO2 emissions of 319.89 kgCO2/m3, while the highest eco-strength efficiency of 0.268 MPa/kgCO2·m-3 with respect to 28-day compressive strength was exhibited by MS101. In terms of cost-benefit, MS00 was determined the cheapest, while the addition of MK and NS increased the cost. The lowest cost of producing 1 MPa was exhibited by MS01 with a merely 0.04-$/MPa/m3 reduction compared to MS00.