Foam Stabilization Process for Nano-Al2O3 and Its Effect on Mechanical Properties of Foamed Concrete

Abstract

Foamed concrete is increasingly utilized in engineering due to its light weight, excellent thermal insulation, fire resistance, etc. However, its low strength has always been the most crucial factor limiting its large-scale application. This study introduced an innovative method to enhance the strength of foamed concrete by using nano-Al2O3 (NA) as a foam stabilizer. NA was introduced into a foaming agent containing sodium dodecyl sulfate (SDS) and hydroxypropyl methylcellulose (HPMC) to prepare a highly stable foam. This approach significantly improved the foam stability and the strength of foamed concrete. Its drainage volume, settlement distance, microstructure, and stabilizing action were investigated, along with the strength, microstructure, and hydration products of foamed concrete. The presence of NA effectively reduced the drainage volume and settlement distance of the foam. NA is distributed at the gas–liquid interface and within the liquid film to play a hindering role, increasing the thickness of the liquid film, delaying the liquid discharge rate from the liquid film, and hindering bubble aggregation, thereby enhancing foam stability. Additionally, due to the stabilizing effect of NA on the foam, the precast foam forms a fine and uniform pore structure in the hardened foamed concrete. At 28 d, the compressive strength of FC0 (0% NAs in foam) is 2.18 MPa, while that of FC3 (0.18% NAs in foam) is 3.90 MPa, increased by 79%. The reason for this is that NA promotes the formation of AFt, and its secondary hydration leads to the continuous consumption of Ca(OH)2, resulting in a more complete hydration reaction. This study presents a novel method for significantly improving the performance of foamed concrete by incorporating NA.