Rheology dependent pore structure optimization of high-performance foam concrete

Foam concrete encounters a fundamental challenge in balancing lightweight and high strength. Pore optimization is the key to address this problem. This study starts with rheology control to optimize the pore structure of foam concretes, thereby designing high-performance foam concrete (HPFC). X-ray computed tomography was employed to explore the relationship between rheology and pore characteristics, revealing the corresponding control mechanisms. The findings indicated that rheological parameters, particularly viscosity, significantly influenced pore size, uniformity, sphericity, fractal dimension and connectivity. Therefore, there was an optimal viscosity range (1.30 ± 0.15 Pa·s) for achieving the desirable pore structure. Mechanical analysis demonstrated that the viscosity could impact the balance of the added foams under dynamic and static conditions via drag force, resulting in changes to the pore structure. After pore optimization, the HPFCs exhibited high compressive strength (2–3 times higher than normal foam concrete at an equal density) and excellent durability comparable to high-performance concrete.