Effects of expanded polystyrene (EPS) sizes and arrangements on the properties of lightweight concrete

Multisource solid waste development of low-carbon ultra-light foamed insulation materials: A feasibility study

The continuous increase in building energy consumption, and the increasing types and quantities of solid waste have seriously hindered the rapid development of social economy. Therefore, reducing building energy consumption while realizing the recycling of waste has become the mainstream topic of environmental protection construction in the new era. An alkali-activated ultra-light foamed insulation material (AFIM) for building walls was prepared using EPS particles as lightweight aggregates. The effects of EPS dosage, particle size, and gradation on the compressive strength, dry density, thermal conductivity, and volumetric water absorption of AFIM were studied. The results showed that while ensuring good mechanical properties of AFIM, EPS particles can significantly reduce the dry density, thermal conductivity, and volumetric water absorption of AFIM. Excitingly, the optimal thermal conductivity and dry density of AFIM were 0.0408 W/(m·K) and 127.03 kg/m3, respectively. The microscopic morphology results showed that there was good compatibility between EPS particles and AFIM slurry, and the interface transition zone (ITZ) between them was dense and without obvious cracks. In addition, the feasibility of AFIM was evaluated from four aspects: performance, energy consumption, carbon emissions, and life cycle cost (LCC). It was encouraged that the performance of AFIM was comparable to that of traditional insulation materials, and showed significant advantages in energy conservation, emission reduction and economic benefits compared to traditional insulatin materials.

Improvement of Core-Shell Lightweight Aggregate by Modifying the Cement-EPS Interface

To improve the interfacial compatibility between cement matrix and expanded polystyrene (EPS) in core-shell lightweight aggregates (CSLA), the effects of sodium silicate, polyvinyl acetate (PVA) emulsion, vinyl acetate-ethylene (VAE) emulsion, acrylic acid, and acetic acid on the cement-EPS interface were investigated. The density of the interface was studied by scanning electron microscopy (SEM), and the effect of interfacial agents on the hydration process of cement was studied by the heat of hydration and induction resistivity. The macroscopic properties of the interface of the CSLA were characterized by the "leak-white" rate, drop resistance, and numerical crushing strength. The results show that the sodium silicate densifies the interface by generating hydration products on the EPS surface. At the same time, organic acid enhances the interfacial properties of EPS and cement by increasing the surface roughness, and allowing hydration products to grow in the surface micropores. In terms of the cement hydration process, both interfacial agents delay the cement hydration. Above all, with comprehensive interface properties, "leak-white" rate, and mechanical properties, VAE emulsion and sodium silicate can achieve the best performance with a final crushing resistance of 5.7 MPa, which had a 46% increase compared with the reference group.

Study of the Compressive Properties of Heavy Calcium Carbonate-Reinforced Epoxy Composite Spheres (HC-R-EMS) Composite Lightweight Concrete

Lightweight concrete is one of the effective means to solve the problems of structural component weight, energy efficiency, and fire safety in modern civil engineering. Heavy calcium carbonate-reinforced epoxy composite spheres (HC-R-EMS) were prepared by the ball milling method, and HC-R-EMS, cement, and hollow glass microspheres (HGMS) were mixed into the mold by the molding method to prepare composite lightweight concrete. The relationship between the HC-R-EMS volumetric fraction, the initial inner diameter of the HC-R-EMS, the number of layers of HC-R-EMS, the HGMS volume ratio, the basalt fiber length and content, and the multi-phase composite lightweight concrete density and compressive strength was studied. The experimental results show that the density of the lightweight concrete ranges between 0.953-1.679 g/cm³ and the compressive strength ranges between 1.59-17.26 MPa, where the volume fraction of HC-R-EMS is 90%, the initial internal diameter is 8-9 mm, and the number of layers of HC-R-EMS is three. The lightweight concrete can meet the requirements of high strength (12.67 MPa) and low density (0.953 g/cm³). In addition, the addition of basalt fiber (BF) can effectively improve the compressive strength of the material without changing the density of the material. From a micro-level perspective, HC-R-EMS is closely combined with the cement matrix, which is conducive to increasing the compressive strength of concrete. Basalt fibers connect the matrix into a network, improving the maximum limit force of the concrete.

Optimizing the Composition Design of Cement-Based Expanded-Polystyrene (EPS) Exterior Wall Based on Thermal Insulation and Flame Retardance

The use of thermal insulated decorative panel materials with low thermal conductivity and high flame retardance is a key step toward energy-saving buildings. However, traditional thermal insulation materials are always highly conductive and inflammable, which restricts their application for new buildings. This study aims to prepare the non-combustible, cement-based EPS mixtures with thermal conductivity lower than 0.045 and density less than 140 kg/m³ and characterize it with mechanical, thermal, and flame retardant properties. The effect of particle size, Silica coated and content of EPS on the physical, mechanical, thermal, and combustion performance are conducted in this paper. The comprehensive indoor tests including density, water absorbing, softening coefficient, compressive strength, tensile strength, moisture susceptibility, thermal conductivity, and scanning electron microscopy (SEM) along with combustion performance are reported to evaluate the effects of several variables on the investigated cement-based nonflammable EPS (CEPS)mixtures. The results show that small and gradation EPS particles significantly improve the comprehensive performance of mixtures. In addition, Silica coated ESP significantly improve the flame retardance of mixtures while reduce the mechanical characteristics slightly. These results contribute to the selection of appropriate materials to enhance the thermal insulation, flame retardance and mechanical properties of CEPS.

An Investigation of the Properties of Expanded Polystyrene Concrete with Fibers Based on an Orthogonal Experimental Design

Expanded polystyrene (EPS) concrete is commonly used as the core material of commercial sandwich panels (CSPs). It is environmentally friendly and lightweight but has poor strength. Adding fibers can improve the microstructure of EPS concrete and reduce the weakening effect of EPS beads on the mechanical properties of concrete. An orthogonal experimental design (OED) was used in this paper to analyze the influence of length and content of polypropylene fiber (PF), glass fiber (GF), and carbon fiber (CF) on the physical and mechanical properties and micromorphology of EPS concrete. Among them, CFs have the most apparent impact on concrete and produce the most significant improvements in all properties. According to the requirements of the flexural performance of CSPs, the splitting tensile strength was taken as the optimization index, and the predicted optimal combination (OC) of EPS concrete with fibers was selected. The variations in the material properties, mechanical properties, and microstructure with age were analyzed. The results show that with increasing age, the dry density, compressive strength, and splitting tensile strength of concrete are markedly improved relative to those of the CSP core material and the control case (CC), and even the degree of hydration is improved.

Structural Applications of Thermal Insulation Alkali Activated Materials with Reduced Graphene Oxide

Development of low thermal conductivity and high strength building materials is an emerging strategy to solve the heavy energy consumption of buildings. This study develops sustainable alkali activated materials (AAMs) for structural members from waste expanded polystyrene (EPS) beads and reduced graphene oxide (rGO) to simultaneously meet the thermal insulation and mechanical requirements of building energy conservation. It was found that the thermal conductivity of AAMs with 80 vol.% EPS and 0.04 wt.% rGO (E8-G4) decreased by 74% compared to the AAMs without EPS and rGO (E0). The 28-day compressive and flexural strengths of E8-G4 increased by 29.8% and 26.5% with the addition of 80 vol.% EPS and 0.04 wt.% rGO, compared to the sample with 80 vol.% EPS without rGO (E8). In terms of compressive strength, thermal conductivity, and cost, the efficiency index of E8-G4 was higher than those of other materials. A building model made from AAMs was designed using building information modeling (BIM) tools to simulate energy consumption, and 31.78% of total energy consumption (including heating and cooling) was saved in the building operation period in Harbin City, China. Hence, AAMs made of waste EPS beads and rGO can realize the structural and functional integrated application in the future.

Physical and Mechanical Properties of a Bulk Lightweight Concrete with Expanded Polystyrene (EPS) Beads and Soft Marine Clay

The variation of physical and mechanical properties of the lightweight bulk filling material with cement and expanded polystyrene (EPS) beads contents under different confining pressures is important to construction and geotechnical applications. In this study, a lightweight bulk filling material was firstly fabricated with Singapore marine clay, ordinary Portland cement and EPS. Then, the influences of EPS beads content, cement content, curing time and confining pressure on the mass density, stress-strain behavior and compressive strength of this lightweight bulk filling material were investigated by unconsolidated and undrained (UU) triaxial tests. In these tests, the mass ratios of EPS beads to dry clay (E/S) were 0%, 0.5%, 1%, 2%, and 4% and the mass ratios of cement to dry clay (C/S) were 10% and 15%. Thirdly, a series of UU triaxial tests were performed at a confining pressure of 0 kPa, 50 kPa, 100 kPa, and 150 kPa after three curing days, seven curing days, and 28 curing days. The results show that the mass density of this lightweight bulk filling material was mainly controlled by the E/S ratio. Its mass density decreased by 55.6% for the C/S ratio 10% and 54.9% for the C/S ratio 15% when the E/S ratio increased from 0% to 4% after three curing days. Shear failure more easily occurred in the specimens with higher cement content and lower confining pressure. The relationships between compressive strength and mass density or failure strain could be quantified by the power function. Increasing cement content and reducing EPS beads content will increase mass density and compressive strength of this lightweight bulk filling material. The compressive strength with curing time can be expressed by a logarithmic function with fitting correlation coefficient ranging from 0.83 to 0.97 for five confining pressures. These empirical formulae will be useful for the estimation of physical and mechanical properties of lightweight concretes in engineering application.