This study investigates the effects of various components on the performance of aerogel-phosphogypsum (APG) thermal insulation mortar. This study investigates the effects of various components on the performance of aerogel-phosphogypsum (APG) thermal insulation mortar, with a special focus on optimizing the composition to enhance mechanical properties. The parametric range explored included phosphogypsum content from 10 to 30 wt%, hollow glass microspheres (HGS) from 5 to 15 wt%, and aerogel slurry from 40 to 80 wt%. Our findings reveal that the optimal composition, which provided the best balance between thermal insulation and mechanical strength, consisted of 20 wt% phosphogypsum, 10 wt% HGS, and 60 wt% aerogel slurry. Notably, the introduction of 0.14 % hydroxypropyl methylcellulose (HPMC) and 1.89 % re-dispersible polymer powder (RPP) significantly enhanced the compressive strength of the mortars. Specifically, compressive strength increased from an initial 0.05 MPa–0.27 MPa post-enhancement with HPMC and RPP. This research provides a detailed understanding of how individual components influence the formulation of APG and offers insights for optimizing the overall performance of aerogel-phosphogypsum composites, contributing to advancements in sustainable building materials.
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