Novel Core-Shell Non-Sintered Lightweight Aggregate Concrete for Better Properties in Wallboard

Abstract Shrinkage of foam concrete can easily cause cracking and thus makes it difficult for a manufacturer to maintain quality. The density of lightweight aggregate concrete is too high to meet specifications for lightweight and thermal insulation for wallboard. Two types of concrete with dry density in the range 1000–1200 kg/m3 for use in wallboard were designed and prepared using foam and lightweight aggregate. The properties of porous lightweight aggregate concrete with core-shell non-sintered lightweight aggregate were compared with sintered lightweight aggregate concrete along with several dimensions. The two aggregates were similar in particle size, density, and strength. The effects of each aggregate on the workability, compressive strength, dry shrinkage, and thermal conductivity of the lightweight concrete were analyzed and compared. Pore structures were determined by mercury intrusion porosimetry and X-ray computed tomography. Compressive strength ranged from 7.8 to 11.8 MPa, and thermal conductivity coefficients ranged from 0.193 to 0.219 W/m/K for both types of concrete. The results showed that the core-shell non-sintered lightweight aggregate bonded better with the paste matrix at the interface transition zone and had a better pore structure than the sintered lightweight aggregate concrete. Slump flow of the core-shell non-sintered lightweight aggregate concrete was about 20% greater than that of the sintered lightweight aggregate concrete, 28d compressive strength was about 10% greater, drying shrinkage was about 10% less, and thermal conductivity was less. Porous lightweight aggregate concrete using core-shell non-sintered lightweight aggregate performs well when used in wallboard because of its low density, high thermal insulation, and improved strength.