Performance of High-Workability Mortars Incorporating Metakaolin as a Partial Cement Replacement

This study investigates the effect of metakaolin (MK) as a partial replacement of cement (CEM I) in high-workability mortars, with emphasis on fresh-state behaviour, mechanical properties, microstructural development, and carbon footprint implications. Mortars were produced with MK replacement levels ranging from 0 to 50% by mass of binder, under a constant water-to-binder ratio and fixed superplasticiser amount. Fresh-state results showed that increasing MK content reduced flowability due to its high fineness; however, high workability was maintained for replacement levels up to 20%. At 28 days, MK replacement up to 10% retains approximately 90–95% of the control compressive and flexural strength, whereas higher replacement levels lead to gradual strength reductions (to ~55–60% at 50% MK), despite comparable early-age strength gains across all mixes. Durability-related indicators demonstrated reduced water absorption and capillary uptake at moderate MK contents (approximately 20–30%), indicating refined pore structure and reduced pore connectivity. Microstructural analyses using SEM, TGA, and XRD confirmed effective portlandite consumption and the formation of dense C–A–S–H-type hydration products at moderate MK replacement levels, whereas excessive MK contents resulted in unreacted MK. A comparative carbon footprint assessment showed that MK incorporation leads to proportional reductions in embodied CO2 emissions, with replacement levels of 10–20% providing the most favourable balance between mechanical performance, durability, and environmental benefit. Therefore, the results demonstrate that MK can be used as a supplementary cementitious material for producing low-carbon, high-workability mortars.