Ultra-light foamed concrete mechanical properties and thermal insulation perspective: A comprehensive review

Ultra-lightweight foam concrete (ULFC) is a relatively new construction material that has gained attention recently due to its unique properties. This material is not very heavy and low-density, making it easy to form into different shapes and sizes. Its excellent thermal insulation makes it popular for building walls, roofs, and floors. This review paper provides an in-depth examination of the properties and characteristics of ULFC. Its composition typically consists of cement, water, foam, additives, and the various manufacturing methods used to produce it—the mechanical properties of ULFC, including its compressive strength. The density of ULFC can vary greatly, usually falling between 100 and 600 kg/m3. The diversity of this can be affected by different factors, such as the kind and number of additives applied and the methods of foaming and thickening employed. The paper highlights the various applications of ULFC in the construction industry. Its use is as a TC material, which can help reduce heating and cooling costs; as a structural material, it can help reduce dead loads of structures. The review paper also discusses the challenges associated with ULFC production, including foam stability. Foam insulation concrete emits 302–508 kg CO2 per cubic meter, primarily due to Portland cement, but enhances building energy efficiency, reducing household CO2 emissions, while advanced recycled insulation materials offer superior thermal and acoustic properties with lower environmental impact. Additionally, we examine the current research on ULFC and suggest potential avenues for future investigation. This paper aims to introduce and put forward a range of cutting-edge and original recommendations and informative guidelines, with the ultimate objective of directing and shaping future research endeavors that focus on effectively exploiting and utilizing ultra-light foamed concrete.