Advanced moisture control in porous aggregates for improved lightweight high-performance concrete

The porous lightweight aggregates in concrete experience a process of water absorption and desorption. This study aims to improve the performance of water-sensitive low water/binder (w/b) systems by effectively utilizing these water regulations. The effects of expanded shale (ES) substitutions and saturation levels (dry, half saturation, and saturation) on the fresh and hardened properties of mixtures with a w/b of 0.18 were investigated. The results indicated that, during the fresh stage, water absorption reduced workability and shortened the setting time. In the hardening stage, the released water improved hydration, increased internal relative humidity, and caused volumetric expansion, which reduced autogenous shrinkage. A comprehensive evaluation revealed that the optimal condition for ES was half-saturation with 4.0 wt% pre-absorbed water. This condition achieved the best internal curing effect, improved workability, and optimal structural efficiency (strength/density). This study provides practical insights for the effective integration of porous aggregates in the mixture design and engineering applications.