Preparation of foam concrete from solid wastes: Physical properties and foam stability

The method for preparation of foam concrete from solid wastes were proposed in this study, where soda residue (SR), calcium carbide slag (CS), grand granulated blast-furnace slag (GGBS) and fly ash (FA) were used as raw materials for the binder and Al powder was used as the foam agent. The effects of Al powder, stabilisers and FA content on the dry density as well as compressive strength were assessed to determine the optimal mix proportions. Moreover, to understand the foaming process, the influence of stabilisers on the zeta potential and surface tension of the fresh mixes were measured and Low-Field Nuclear Magnetic Resonance (LF-NMR) was employed to qualitatively characterize the pore size distribution. Finally, the hydration products were analyzed by X-Ray Diffraction (XRD), Fourier transform infrared spectrometer (FTIR), Thermogravimetric Analysis-Differential scanning calorimetry (TGA-DSC), Scanning electron microscope-Energy dispersive X-ray spectroscopy (SEM-EDS). The results suggested that the optimal content of Al powder was 1–2%, and the combination of S and P (SP) stabilisers showed better stabilization effect than the single use of S or P, leading to well distributed foam with smaller size. The stabilization effect was attributed to the dissolved negative complex that absorbed on the foam film to increase the repulsion between foams as well as to reduce the surface tension of the fresh mixture. The substitution of GGBS by FA generally resulted in reduced dry density and compressive strength, while the extent varied with the addition of stabilizers, and thus the optimal amount of FA depended on the selection of stabilisers. Overall, our study highlighted the potential of using industrial waste materials for producing sustainable light weight concrete with satisfactory dry density and compressive strength.