Abstract The rising demand for ultra-high-performance concrete (UHPC) necessitates innovations in sustainable materials. This study explores the substitution of ordinary Portland cement (OPC) with thermally and mechanically activated nano-kaolin in varying proportions from 0.5 to 0.25%. A uniform quantity of double-hooked end steel fibers was added to all the mixes. Activated nano-kaolin variants showed significant enhancement in UHPC properties. Specifically, UHPC with 0.20% thermally activated kaolin (B3-TAK-20) exhibited a 21.6% increase in compressive strength and a 25.5% increase in modulus of elasticity at 90 days, with the modulus of rupture doubling compared to the reference mix. These improvements are attributed to the amorphous nature of thermally activated nano-kaolin, resulting in a denser concrete matrix and reduced porosity. Beyond the optimal 0.20% kaolin replacement, an increase to 0.25% diminished compressive strength. Durability tests showed enhanced acid resistance, with only a 6.7% mass loss for the thermally activated nano-kaolin mix and a consistent reduction in water absorption by 14.4% as kaolin proportions increased from 0.5 to 0.25%. The study also noted a decrease in water absorption by 22.9 and 12.3% at 56 and 90 days, respectively, indicating the thermally activated nano-kaolin’s enhanced performance. This research underscores the potential of activated kaolin as a viable alternative to OPC, paving the way for more sustainable UHPC production.

Experimental research on mechanically and thermally activation of nano-kaolin to improve the properties of ultra-high-performance fiber-reinforced concrete