This study investigates the influence of varying water-to-cement (W/C) ratios and fine aggregate compositions on the performance of concrete incorporating expanded perlite aggregate (EPA) as a lightweight alternative to natural sand. A total of eighteen concrete mixes were produced, each with different W/C ratios and fine-to-coarse aggregate (FA/CA) ratios, and evaluated for workability, compressive strength, flexural and tensile strength, water absorption, density, and thermal conductivity. Perlite was used to fully replace natural sand in half of the mixes, allowing a direct assessment of its effects across low-, medium-, and high-strength concrete formulations. The results demonstrate that EPA can improve workability and reduce both density and thermal conductivity, with variable impacts on mechanical performance depending on the W/C and FA/CA ratios. Notably, higher cement contents enhanced the internal curing effect of perlite, while lower-strength mixes experienced a reduction in compressive strength when perlite was used. These findings suggest that expanded perlite can be effectively applied in structural and non-structural concrete with optimized mix designs, supporting the development of lightweight, thermally efficient concretes. Mixture W16-100%EPS was considered the ideal mix because its compressive strength at the age of 65 days 44.2 MPa and the reduction in compressive strength compared to the reference mix 14% and the reduction in density 5.4% compared with the reference mix and the reduction in thermal conductivity 14% compared with the reference mix.

In order to better understand the mechanical properties of lightweight cement-based composite concrete (LWC), expanded polystyrene (EPS) beads are used as lightweight aggregate (LWA) in this paper. 50%, 70%, and 90% of EPS foam beads by volume are used to partially replace normal fine aggregate in different EPS concrete compositions. In addition, Ordinary Portland cement (OPC) was substituted with silica fume (SF) in EPS concrete at varying weight percentages of 15%. Nine mixes are made in order to examine the properties of EPS concrete. In the testing program, fresh density, slump, compressive strength, splitting tensile strength, flexural strength, thermal conductivity, and absorption are all determined. Although workability is improved, the mechanical properties of concrete are generally decreased when EPS beads are used. The addition of silica fume (SF) successfully counteracted the mixture’s overall decline in mechanical properties across all the mixtures that have been used. More solid material can be found per square inch of surface area in materials with a higher density, which results in more continuous heat-conduction pathways. In comparison to the control mix, the compressive strength of the polystyrene modified mixes showed a noticeable decline, falling by roughly 62% for P-50%, 69% for P-70%, and 71% for P-90%. In contrast, mixes P-90%-1.2, P-90%-1.4, and P-90%-1.6 reduced absolute strength compared to P-90%; their performance is nonetheless noteworthy because of their extraordinarily high EPS content. Despite having lesser absolute strengths than P-90%, mixes of P-90%-1.2, P-90%-1.4, and P-90%-1.6 nevertheless performed admirably considering their remarkably high EPS content.

Developing lightweight cementitious materials incorporating recycled constituents while maintaining appropriate functional performance requires a balance between density, mechanical resistance, durability-related properties, and thermal efficiency. This study comparatively evaluates lightweight mortars incorporating expanded clay (LECA), expanded perlite, and recycled crumb rubber, used individually and in binary combinations, and examines the influence of combined styrene–butadiene rubber (SBR) latex and polypropylene fiber (PPF) modification. Ten mortar mixtures were produced, comprising five unmodified mixtures with a water-to-cement ratio of 0.40 and five corresponding mixtures containing 10% SBR and 1% PPF by cement weight, for which the added mixing water was reduced to account for the water supplied by the SBR latex. Flowability, compressive and flexural strength, hardened density, and water absorption were experimentally assessed, while thermal conductivity was estimated from oven-dry density correlations. The mortars exhibited densities between 760 and 1072 kg/m³, confirming their lightweight character. The SBR–PPF-modified LECA–perlite mixture achieved the highest 56-day compressive strength of 8.1 MPa, whereas rubber-containing mixtures generally exhibited the lowest strength levels, a trend consistent with mechanisms reported in the literature, including weak rubber–matrix interaction and increased internal defects or voids. Estimated thermal conductivity ranged from 0.19 to 0.28 W/m·K. The mixtures incorporating SBR and PPF together with reduced added mixing water exhibited improved flexural performance and later-age strength more clearly in LECA- and perlite-based systems than in rubber-dominated mixtures. The results demonstrate that aggregate selection governs the principal performance trade-offs in these lightweight mortars, while the combined modified mixture design can improve selected properties without fully overcoming the detrimental interfacial effects associated with high crumb rubber contents. The investigated mortars may therefore be considered candidates for further evaluation in non-load-bearing lightweight applications. The density-based thermal conductivity estimates provide only a comparative indication of potential thermal behavior; direct standardized measurements are required before thermal insulation performance or suitability for insulation applications can be established.