In this paper, we study the influence of density and the water–cement (W/C) ratio on the slurry fluidity, compressive strength, and water absorption of foamed concrete (FC) and its mechanism of action, with the aim of proposing an optimal mix ratio for FC to reduce cement usage and carbon emissions in the construction industry and ensure the good overall performance of FC. In this experiment, two groups of experiments were designed using the control variable method. Fluidity and uniaxial compression tests showed that when the density was 600 kg/m³ and the W/C ratio was 0.6, the FC slurry had maximum fluidity, but its mechanical properties were poor and it collapsed easily. Conversely, by analyzing the uniaxial compressive strength/cement (UCS/C) ratio, it was observed that the mix ratio had a maximum cement utilization rate (W/C ratio) of 0.5 and a density of 1000 kg/m³. Nondestructive testing methods were used to measure the ultrasonic pulse velocity (UPV) and rebound value of the FC test block, and the strength and durability of FC were analyzed. The water absorption rate of the FC test block was tested, and the final analysis showed that the optimal mix ratio of FC in this test was W/C = 0.5, with a density of 1000 kg/m³.

This study aims to enhance the performance of an innovative steel slag–ceramsite foam concrete (SSCFC) to advance sustainable green building materials. An eco-friendly composite construction material was developed by integrating industrial by-product steel slag (SS) with lightweight ceramsite. Employing a three-factor, three-level orthogonal experimental design at a fixed density of 800 kg/m³, 12 mix proportions (including a control group) were investigated with the variables of water-to-cement (W/C) ratio, steel slag replacement ratio, and ceramsite replacement ratio. The governing mechanisms of the W/C ratio, steel slag replacement level, and ceramsite replacement proportion on the SSCFC’s fluidity and compressive strength (CS) were elucidated. The synergistic application of range analysis and analysis of variance (ANOVA) quantified the significance of factors on target properties, and partial least squares regression (PLSR)-based prediction models were established. The test results indicated the following significance hierarchy: steel slag replacement > W/C ratio > ceramsite replacement for fluidity. In contrast, W/C ratio > ceramsite replacement > steel slag replacement governed the compressive strength. Verification showed R² values exceeding 65% for both fluidity and CS predictions versus experimental data, confirming model reliability. Multi-criteria optimization yielded optimal compressive performance and suitable fluidity at a W/C ratio of 0.4, 10% steel slag replacement, and 25% ceramsite replacement.