Preparation and Characterization of Novel Sulfoaluminate-Cement-Based Nonautoclaved Aerated Concrete

Abstract

The production of autoclaved aerated concrete via the autoclaving process incurs substantial energy consumption, posing a challenge to sustainable economic development. Herein, a novel nonautoclaved aerated concrete (NAAC) was prepared using sulfoaluminate cement as the primary raw material and aluminum powder as the aerating agent. The physicomechanical characteristics and pore structures of the sulfoaluminate-cement-based (SAC) NAAC (SAC-NAAC) were examined through X-ray diffraction, thermogravimetry, and scanning electron microscopy. The findings revealed that the optimal mechanical attributes of the SAC-NAAC were achieved at a water–cement ratio of 0.55, with a specific content ratio of polycarboxylate superplasticizer–borax–calcium stearate–sodium hydroxide at 0.24%:0.32%:0.36%:2.90%, along with 0.40% aluminum powder. The SAC-NAAC samples, with a bulk density range of 600–750 g/m3, exhibited a compressive strength of 3.55–4.16 MPa, porosity of 45.9–63.5%, and water absorption rate of 60.2–74.4%. The weight loss in the SAC-NAAC with different aluminum powder contents ranged between 15.23% and 16.83%. The prismatic ettringite (AFt) crystals served as the main source of strength for the SAC-NAAC, and AH3 was attached to the AFt surfaces in a microcrystalline gel phase, thereby further enhancing the strength of the SAC-NAAC. Thus, the lightweight, high-strength SAC-NAAC has great potential as a nonautoclaved aerated concrete.