Achieving high strength and low weight in cement-based composites remains a critical objective in material and structure engineering. This study presents the development of an ultra-high-performance lightweight concrete (UHPLC) composite with a density not exceeding 1950 kg/m³ and a compressive strength of at least 100 MPa. The UHPLC mix design was optimized using the central composite design (CCD) response surface methodology, and a life cycle assessment (LCA) was conducted for the first time on UHPLC from cradle to gate. The interactions between cement content, hollow microspheres, and their effects on workability, mechanical properties, and durability were analyzed. The results show that using the CCD response surface method for designing UHPLC mix proportions is feasible, allowing effective optimization for various objectives, such as balancing both strength and density, highlighting low density, or emphasizing ultra-high strength. the designed UHPLC exhibits mechanical and durability properties comparable to or better than UHPC. LCA results show higher energy consumption and environmental impact for UHPLC in the cradle-to-gate stage, mainly due to the microsphere production phase. Monte Carlo uncertainty analysis reveals that ADP, HTP, POCP, and EP are most sensitive to microsphere content, while GWP and AP are more affected by cement content. The optimized UHPLCs in this study can be selected depending on specific technical or environmental scenarios. Introducing HMs into the UHPC system for UHPLC production shows excellent performance, making it a promising material for advanced structural applications.
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