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G. Sang et al. / Construction and Building Materials 91 (2015) 133–137
composite and the density in the region of 150–170 kg/m3 [12].
The methods above mentioned are considerably complicated.
Foam collaboration is easy to appear if these methods are
employed to prepare high porosity cement-based foam material
[13,14].
A simple mechanical air-entraining method is adopted to pre-
pare cement-based foam material, which is using mechanical stir-
ring to bring a great quantity of air into a modified cement paste
with foaming admixture. After the setting and hardening of cement
paste, foams solidified gradually. Some correlated researches on
adopting mechanical mixing air-entraining method to prepare high
porosity cement-based foam material are still under the explora-
tory stage so that few research achievements have been reported.
In this research, the porosity, strength, water absorption, thermal
conductivity and other relevant properties of foam materials were
tested. Microstructure of pore was also observed by electronic
microscopy. Some relevant effective factors on the properties of
cement-based foam materials were investigated in this paper.
2.4. Test of compressive strength and water absorption
Pressure testing machine was adopted to estimate the compressive strength.
The load was added to cubic dried samples with the side length of 70.7 mm at
the speed of (10 1) mm/min till the testing sample was damaged.
Water absorption was measured as follows: weighed the mass of the cubic
dried sample with side length of 70.7 mm, and then soaked the sample into water
for 2 h under the room temperature. Water surface must be higher 25 mm than the
surface of testing sample. When soaked process finished, the residual water of the
samples taken out of water was absorbed by sponge. The water absorption can be
calculated in terms of Eq. (1) as follows:
m1 ꢁ m0
W
¼
ꢃ 100%
V0 qw
ꢃ
ð1Þ
v
where, W – water absorption, %; m0 – the mass of dried testing sample, g; m1 – the
v
mass of sample saturated with water, g; V0 – the sample volume, cm3; qw – water
density, taking 1 g/cm3.
2.5. Thermal conductivity test
Samples of specification with size of 300 ꢂ 300 ꢂ 30mm3 were dried to con-
stant weight at the temperature of 100–110 °C and cooled to the room temperature
for thermal conductivity measuring. Thermal conductivity was measured using
TPMBE-300 flat plate thermal conductivity meter and the steady-state guarded
hot plate method according to the Chinese Standard [17]. A JEOL JSM-6700F scan-
ning electronic microscope (SEM) was utilized to observe the microstructure of
the samples after hydration for 3 days. The samples were dried to reach constant
weight at the temperature of 100–110 °C. Fracture surfaces were sputter coated
with gold.
2. Experimental
2.1. Materials
Grade 42.5 rapid-hardening sulfate aluminate cement was used and its perfor-
mance is shown in Table 1. When mechanical mixing air-entraining method was
used to prepare cement-based foam material, cement type had some influences
on the pore structure. The rapid-hardening sulfate aluminate cement is character-
ized by fast setting, hardening and micro-expansion. Compared with Portland
cement, these characteristics are more helpful to shorten solidification time and
form small and uniform cells in cement matrix [15]. Modified sodium alcohol ether
sulfate was used as foaming agent. The addition of superplasticizer was necessary
to ensure foaming cement paste with a low water volume. The pore structure of
the hardened foam material was optimized by using additive Hydroxypropyl
Methyl Cellulose (HPMC) with viscosity value of 400 mPa S. Foaming agent to
cement ratio by weight was 6% and superplasticizer was 0.2%.
3. Results and discussion
3.1. Influence of water–cement ratio upon material properties
When mechanical mixing air-entraining method was used to
prepare cement-based foam material, water–cement ratio has cru-
cial influence on the material pore structure and properties, due to
the variable water–cement ratio was taken to prepare the
cement-based foams material. The physical and mechanical prop-
erties of samples are shown in Table 2.
It can be seen from Table 2 that the porosity of each group is
higher than 80% and the porosity increase with the water–cement
ratio increase. When water–cement ratio is 0.95, porosity can
reach as high as 93.3%, while the water absorption increased grad-
ually, inversely the apparent density, compressive strength and
thermal conductivity values decreased gradually. The water
absorption to porosity can reflect the pore connectivity of foam
material [18].
It can be seen from Fig. 1 that the ratio of water absorption to
porosity changes little when water–cement ratio is between 0.75
and 0.85. The ratio of water absorption to porosity increases when
water–cement ratio is over 0.85. Connected pores can be filled with
water when sample is soaked into water. The numerical value of
water absorption is equal to the numerical value of connected
porosity. The ratio of water absorption to porosity means the ratio
of connected porosity to the total porosity. The curve in Fig. 1 indi-
cates that pore connectivity increases with the increasing of
water–cement ratio.
2.2. Preparation of high porosity cement-based foam material
The procedure of sample preparation is described as follows. (1) Cement and
other dry powder materials were weighed accurately and poured into a mixer.
(2) Making the mixer run to stir the materials for 3 min at the speed of
140 5 r/min to obtain the dry powder mixture, where the weighed water with
foaming agent was then added into. (3) After stirring the mixed material paste
evenly for 10 s at the speed of 140 5 r/min, and then continually stirring the
mixed material paste for 5 min at the speed of 285 10 r/min, the mixed material
paste was full foamed, and then poured into molds which were removed after cur-
ing at room temperature for 8 h. (4) The materials were further cured for 3 days in
the standard curing condition. According to the Chinese Standard [15], the 3 days
age compressive strength of this kind of cement exceeds the 28 days age compres-
sive strength 90%.
2.3. Porosity test
Before testing, the samples should be dried until the constant weight was
obtained under the temperature of 100–110 °C. The porosity of cement-based foam
ꢀ
ꢁ
material was calculated using P ¼ 1 ꢁ q
ꢂ 100% with apparent density
apparent
qth
From Fig. 2 the relation curve of strength-apparent density rate
and water–cement rate is obtained. It can be seen that the decrease
rate of strength is larger than that of apparent density and the
decreasing rate of strength is aggravated when water–cement ratio
is over 0.85. The above mentioned results show a high pore con-
nectivity which could aggravate the stress concentration when
foam material was subjected to loads.
derived from weighing a known volume of dried foam material, and theoretical
P
n
density qth
nent i) [16].
¼
i¼1viqi
(
vi = volume fraction of component i, qi = density of compo-
Table 1
Physical performances of grade 42.5 rapid-hardening sulfate aluminate cement.
Setting time (min)
Compressive
Flexural
strength (MPa)
strength (MPa)
Initial setting
time
Final setting
time
1d
3d
28d
1d
3d
28d
3.2. Influence of cellulose ether on material properties
29
48
35.2 46.5 48.8 6.7 7.1 8.0
When mechanical mixing air-entraining method was used to
prepare cement-based foam materials, the stability of air bubbles