The relatively high cost and limited availability of the constituent materials, are among the factors which limit the adoption of the magnesium silica hydrate (M-S-H) binder system in practice. Furthermore, the fresh and hardened properties of M-S-H binder systems vary significantly with the proportion of MgO and amorphous silica available for the hydration. In this paper, we demonstrate the application of metakaolin (Mk), a highly reactive aluminosilicate, to replace silica fume to develop a M-S-H-based binder system. To investigate the effects of component proportions on the workability, through variations in the required amount of super plasticizer, and compressive strength of the M-S-H-based mortar, a response surface methodology (RSM) is used where a series of mortar samples were prepared based on a central composite experimental design. The response surface model thus developed allowed optimization of the proportions of the mortar ingredients for a target set of workability and compressive strength. The model illustrates the highest sensitivity of water to cementitious material (w/cm) ratio for both workability and strength while revealing minor sensitivities to the other two variables of MgO/Mk ratio, and fine aggregate content. The mineralogical composition of the hydrated paste was investigated through FTIR and X-Ray diffraction and revealed the formation of a hydrotalcite-like phase along with the M-S-H gel.
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