Characteristics of Lightweight Foam Concrete Manufactured Using Water-Soluble Polymers and Lightweight Aggregates

This study aimed to analyze the effects of PVA aqueous solution as a new foaming agent, and the production and characteristics of ultralight foam concrete using a mixed lightweight aggregate of perlite (PL) and cenosphere (CP). In addition, the application of a new high-temperature curing process was proposed to improve the foaming effect of PVA and reduce the weight of concrete. The mixing ratios (s/c) of the PVA solution and OPC were 1.0, 1.5, and 2.0, and the ratio of the PVA solution-OPC-lightweight aggregate (perlite and cenosphere) (s/(c + CP + PL)) was 0.43-1.0. As a result, an ultralight foam concrete with a dry density of less than 1.0 g/cm³, an average pore diameter of 0.1-2.3 mm, and a compressive strength of 1.5-10.5 MPa could be manufactured. From the experimental results, PVA showed sufficient usability as a foaming agent. And the new high-temperature curing process proposed in this study could be suggested as a method applicable to the expansion of pores and lightweight reduction in the manufacture of foamed concrete. The diameter of the foamed pores changed depending on the mixing ratio of CP and PL, and the diameter of the foamed pores increased as the ratio of PL increased. However, an increase in the ratio of CP improved the insulation properties. The increase in the OPC ratio increased the mechanical strength, but increased the dry density and decreased the insulation properties. Therefore, the mixing ratio of CP and PL was an important factor affecting the properties of ultralight foam concrete. From the experimental results, PVA was suggested to have sufficient potential as a new foaming agent, and the new high-temperature curing process proposed in this study is expected to be applicable to the production of foam concrete using PVA.