Utilization of recycled coral sand and aluminum scraps in foam concrete: Preparation, insulation of environmental noise and heat, and pore structure

Abstract

The utilization of industrial and marine wastes in building materials can significantly mitigate resource consumption and environmental hazards. In this study, the waste aluminum scraps and coral sand were utilized as foaming agent and fillers for foam concrete (FC) to address application challenges associated with industrial and marine wastes. Simultaneously, their impact on the mechanical property, heat and noise insulation properties, as well as pore structure of FC were investigated. The response surface methodology was used to optimize the mix design of FC. Heat and noise insulation characteristics of FC were tested by a visible infrared thermometer and a self-manufactured soundproof device, while the pore characteristic was analyzed by digital image processing technique. Additionally, the effect of foaming agents and coral sand on the internal pore structure of FC was studied by means of microscopic analysis(FTIR, XRD, SEM). The results show that foam content significantly influenced the performance of FC. As the foam content reached 15%, the compressive strength was the worst (ranging from 1.26 to 1.59MPa). Additionally, foam and coral sand inhibited the expansion of sulfoaluminate cement. At 15% foam content and 30% coral sand content, the thermal conductivity decreased to 0.082 W/(m·℃), representing a reduction of 52.5% compared to the control group. Regarding noise reduction performance, a foam content of 10% yields optimal results. The heat and noise insulation properties were both improved due to the enhanced porous structure of coral sand. However, excessive admixtures, such as 50 % content of coral sand, could weaken the strength by destroying the fine pore structure. Microscopic analysis further revealed that foaming agents could affect the hydration of cement with little impact on macro performance. Moreover, they also enhanced the toughness of bubbles and changed the surface structure of pore walls to ensure the integrity of the pore structure of FC.