Metakaolin-Enhanced Laterite Rock Aggregate Concrete: Strength Optimization and Sustainable Cement Replacement

The growing demand for concrete in tropical regions faces two unresolved challenges: the high carbon footprint of ordinary Portland cement (OPC) and limited understanding of how supplementary cementitious materials affect the mechanical performance of laterite rock aggregates concrete. Although metakaolin (MK) is a highly reactive pozzolan, its combined use with laterite rock aggregates concrete and its influence on strength development and microstructure have not been sufficiently clarified. This study investigates the mechanical behavior and sustainability potential of laterite rock aggregate concrete in which OPC is partially replaced by MK at 0%, 5%, 10%, 15%, and 20% by weight. All mixes were prepared at a constant water–binder ratio of 0.50 and tested for workability, compressive strength, split-tensile strength, and flexural strength at 7, 14, and 28 days, with and without a polycarboxylate-based superplasticizer. The results show that MK significantly enhances the mechanical performance of laterite rock concrete, with an optimum at 10% replacement: the 28-day compressive strength increased from 35.6 MPa (control) to 53.9 MPa in the superplasticized mix, accompanied by corresponding gains in tensile and flexural strengths. SEM–EDS analyses revealed microstructural densification, reduced portlandite, and a refined interfacial transition zone, explaining the improved strength and cracking resistance. From an environmental perspective, a 10% MK replacement corresponds to an approximate 10% reduction in clinker-related CO2 emissions, while the use of locally available laterite rock reduces the dependence on quarried granite and transportation impacts. The findings demonstrate that MK-modified laterite rock concrete is a viable and eco-efficient option for structural applications in tropical regions. The study concludes that MK-enhanced laterite rock aggregate concrete can deliver higher structural performance and improved sustainability without altering conventional mix design and curing practices.