Lightweight concrete is widely used in the construction industry due to its low density and high strength. In this paper, lightweight concrete was prepared by a simple two-step method. Firstly, the light calcium carbonate reinforced epoxy macrospheres (LCR-EMS) material was obtained by adhering calcium lighter carbonate powder to the expanded polystyrene foam spheres (EPS) material using the “balling method”. In the second step, the LCR-EMS was mixed with water, cement, and the hollow glass microspheres (HGMS) material using the “molding method” to obtain lightweight concrete. The combination of macroscopic photographs and microscopic morphology shows that the LCR-EMS material itself is uniformly encapsulated and well bonded to the matrix. Test results show that the density of the lightweight concrete decreases with an increase in the volume fraction of stacked LCR-EMS, the diameter, and the proportion of HGMS in the matrix, but it decreases with a decrease in the number of layers of LCR-EMS. The compressive strength of lightweight concrete exhibits a completely opposite trend. When three layers of LCR-EMS were used as filler material, the density and compressive strength of the concrete were 1.246 g/cm³ and 8.19 MPa, respectively. The density and maximum compressive strength of lightweight concrete were 1.146 g/cm³ and 6.37 Mpa, respectively, when filled with 8–9 mm-2L-90 svol% of LCR-EMS and 40 wt% of HGMS in the matrix. Compared with lightweight concrete filled with 90% EPS, the density increased by 20% while the compressive strength increased by 300%.

Lightweight concrete is one of the effective means to solve the problems of structural component weight, energy efficiency, and fire safety in modern civil engineering. Heavy calcium carbonate-reinforced epoxy composite spheres (HC-R-EMS) were prepared by the ball milling method, and HC-R-EMS, cement, and hollow glass microspheres (HGMS) were mixed into the mold by the molding method to prepare composite lightweight concrete. The relationship between the HC-R-EMS volumetric fraction, the initial inner diameter of the HC-R-EMS, the number of layers of HC-R-EMS, the HGMS volume ratio, the basalt fiber length and content, and the multi-phase composite lightweight concrete density and compressive strength was studied. The experimental results show that the density of the lightweight concrete ranges between 0.953–1.679 g/cm³ and the compressive strength ranges between 1.59–17.26 MPa, where the volume fraction of HC-R-EMS is 90%, the initial internal diameter is 8–9 mm, and the number of layers of HC-R-EMS is three. The lightweight concrete can meet the requirements of high strength (12.67 MPa) and low density (0.953 g/cm³). In addition, the addition of basalt fiber (BF) can effectively improve the compressive strength of the material without changing the density of the material. From a micro-level perspective, HC-R-EMS is closely combined with the cement matrix, which is conducive to increasing the compressive strength of concrete. Basalt fibers connect the matrix into a network, improving the maximum limit force of the concrete.

Reducing the structural load and operational energy consumption of buildings is a trend in the development of the construction industry, and lightweight concrete has become a research hotspot because of its dual characteristics of low density and high strength. In this paper, a three-step method is used to prepare lightweight concrete composites. In the first step, basalt fiber powder was adhered to polystyrene foam ball expanded polystyrene spheres (EPSs) by the “ball rolling method” to obtain basalt fiber reinforced epoxy composite balls. In the second step, the epoxy resin composite ball and the configured cement matrix are filled into a prefabricated mold. Finally, the lightweight concrete specimens were overlaid, pressed into shape, and cured for 28 days. By changing the volume ratio, size, and wall thickness of the epoxy composite balls, as well as the length and content of basalt fibers, the lightweight concrete was exhibited a reduction in density and increase in strength. The results showed that the smaller the epoxy composite spheres and the larger the wall thickness are, the higher the compressive strength of the material for a certain volume ratio of epoxy composite spheres will be. The addition of appropriate hollow glass beads can reduce the number of pores in the matrix, but excessive hollow glass beads will reduce the bonding force of the concrete matrix. Basalt fibers not only improve the strength of EPSs but also serve to connect matrix–matrix and matrix–epoxy composite spheres.