Non-autoclaved aerated concrete (NAAC) is a two-phase material with a concrete matrix and air, exhibits good thermal insulation performance and shows good potential in the insulating construction industry. In this study, recycled concrete fine powder was used as an auxiliary cementing material, and the NAAC with different porosity and distribution was fabricated by the non-autoclaved method at different curing temperatures. The effect of porosity on the thermal conductivity and mechanical strength of NAAC is analyzed by experimental tests. A prediction method of thermal conductivity combining pore structure reconstruction and numerical simulation was proposed, which is established by two steps. Firstly, the pore size distributions of NAAC with different porosities were characterized by stereology image analyses. Secondly, the thermal conductivity prediction model based on the pore structure information was established by a COMSOL steady-state heat transfer module. The thermal conductivity results of COMSOL simulations were compared with the experiments and other theoretical models to verify the reliability of the model. The model was used to evaluate the effect of porosity, pore size distribution and the concrete matrix’s thermal conductivity on the thermal conductivity of NAAC; these are hard to measure when only using laboratory experiments. The results show that with the increase in curing temperature, the porosity of NAAC increases, and the number and volume proportion of macropores increase. The numerical results suggest that the error between the COMSOL simulations and the experiments was less than 10% under different porosities, which is smaller than other models and has strong reliability. The prediction accuracy of this model increases with the increase in NAAC porosity. The steady thermal conductivity of NAAC is less sensitive to the distribution and dispersion of pore size in a given porosity. With the increase in porosity, the thermal conductivity of NAAC is linearly negatively correlated with that of the concrete matrix, and the correlation is close to 1.

The shield tunnel is a common solution for natural gas pipelines crossing rivers. Consequently, the development of natural gas tunnel filling materials with excellent performance is crucial to the safe operation and maintenance of pipelines. The foam concrete offers a reasonable solution. Nevertheless, since its inherent compressive strength decreases almost proportionally with the decrease in density, obstacles remain concerning obtaining the high density and relatively low strength required for natural gas tunnel filling. Here, a synergistic optimization strategy was proposed involving the orthogonal test, univariate control, and comprehensive balance method. It involves modifying the type and proportion of cementitious matrix, in particular by incorporating fly ash and PVA fibers in the mix design, and synergetic determining the best mix ratio from the aspects of compressive strength, stability, and dry density. The obtained foam concrete has a compressive strength of 4.29 MPa (FC4) and a dry density of 1060.59 kg/m³ (A11), which meets the requirements of pipeline pressure and pipeline anti-floating. This study is applied to the Yangtze River shield crossing project of the Sino-Russian Eastern Gas Pipeline, and ANSYS was used to simulate the stress and deformation of the foam concrete. This work provides an efficient foam concrete optimization mix scheme, and supports the application of foam concrete in the filling of the long-distance cross-river natural gas tunnels.

Building thermal insulation and energy conservation have become urgent problems in the field of civil engineering because they are important for achieving the goal of carbon neutralization. Thermal conductivity is an important index for evaluating the thermal insulation of materials. To study the influence of different porosity levels on the thermal conductivity of materials, this paper established a random distribution model using MATLAB and conducted a comparative analysis using COMSOL finite element software and classical theoretical numerical calculation formulas. The thermal conductivity of composite materials was determined based on a theoretical calculation formula and COMSOL software simulations, and the theoretical calculation results and simulation results were compared with the measured thermal conductivity of the composites. Furthermore, the influence of the width of the gaps between the materials on the heat transfer process was simulated in the fabricated roof structure. The results showed the following: (1) The thermal conductivity values calculated using the Zimmerman model were quite different from those calculated using the Campbell-Allen model and those calculated using the COMSOL software; (2) The thermal conductivity values calculated using the theoretical calculation formula were lower than the measured data, and the maximum relative error was more than 29%. The COMSOL simulation results were in good agreement with the measured data, and the relative error was less than 5%; (3) When the gap width was less than 60 mm, it increased linearly with the heat transfer coefficient. The heat transfer coefficient increased slowly when the gap width was greater than 60 mm. This was mainly due to the thermal bridge effect inside the insulation system. Based on these research results, a thermal insulation system was prepared in a factory.