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Article

Increase of Efficient at Aerated Concrete Compositions Based on Mineral Powders

by
Abbas Guvalov (Kapanakchi)
1 and
Mahir Dursun
1,2,*
1
Abbas Guvalov, Department of Materials Science, Faculty of Construction, Azerbaijan University of Architecture and Construction, Baku AZ1073, Azerbaijan
2
Department of Electrical and Electronics Engineering, Faculty of Technology, Gazi University, 06560 Ankara, Turkey
*
Author to whom correspondence should be addressed.
Appl. Sci. 2025, 15(23), 12364; https://doi.org/10.3390/app152312364
Submission received: 10 September 2025 / Revised: 4 November 2025 / Accepted: 5 November 2025 / Published: 21 November 2025
(This article belongs to the Section Materials Science and Engineering)
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Abstract

Autoclaved aerated concrete has been widely used in recent years and has gradually begun to replace classical concrete systems. In this paper, the optimal compositions of D500 and D600 autoclaved aerated concrete, which are widely used as structural and insulation materials with low cement consumption, were determined using mathematical regression models. The data obtained from the experimental results were converted into a dataset in the Matlab program, and optimization was performed to achieve maximum strength and minimum cement consumption. This study identified the stages of the process for developing and adjusting the properties of an efficient autoclaved aerated concrete composition using a cement matrix with the addition of various microfillers. The amount of components and mineral and chemical additives in the composition of autoclaved aerated concrete was optimized. With the application of carbonate filler and microsilica, aerated concrete compositions with an average density of 500 and 600 kg/m3 and a strength of 1.1–2.24 MPa were developed, which correspond to the D500 brand in terms of density and D600 to B1–B2 in terms of strength class. As a result of this study, it was determined that despite a 16.4% decrease in cement consumption when various microfillers were added to the cement matrix, the compressive strength of the D600 brand aerated concrete at 7 days was 1.35 MPa, and at 28 days, it was 2.25 MPa. Since the prepared aerated concrete composition is more efficient than traditional porous concrete, it can be widely used in the production of lightweight structures and insulation blocks. This research supports the Sustainable Development Goals (SDGs), particularly Goal 9 (Industry, Innovation and Infrastructure), Goal 11 (Sustainable Cities and Communities), and Goal 12 (Responsible Consumption and Production), by promoting the development of resource-efficient and environmentally sustainable building materials.

1. Introduction

In the modern age of construction development, aerated concrete is considered the most effective thermal insulation and, at the same time, a structural material. They have low thermal conductivity and sufficient mechanical strength, and they are made from cost-effective raw materials [1,2,3,4,5]. Therefore, the need for the production and application of low-density aerated concrete, such as aerated concrete, is constantly increasing.
Panels made on the basis of aerated concrete are characterized by durability, fire safety, and fire resistance, so they can be used in buildings for various purposes [6,7,8,9,10,11]. Materials obtained on the basis of aerated concrete are characterized by low density and thermal conductivity, which are the most important indicators of thermal insulation properties [2,12,13,14,15,16]. While the thermal conductivity of aerated concrete based on sand at the same density (400 kg/m3) is 0.15 W/(mK), the thermal conductivity of aerated concrete based on fly ash is 0.085 W/(mK).
Reducing energy consumption at the stages of production and operation of products, as well as increasing production volumes and improving their quality, can be achieved by developing and applying modern resource-saving technologies [17]. One of the most relevant studies for solving this problem is the use of local mineral raw materials, industrial waste, and efficient gasifiers in the production of non-autoclaved aerated concrete [18,19,20,21,22,23,24]. This will provide production with a source of cost-effective mineral raw materials, creating real opportunities for saving energy resources and capital investments [9,25,26]. In order to save cement, various aggregates, carbonate rocks, and vermiculite are used in the composition of non-autoclaved aerated concrete [8,27,28,29,30]. One of the ways to improve the properties of composite materials, including non-autoclaved aerated concrete, is to select the optimal granular composition of raw materials [31]. When using fine sand fractions (≤0.315 mm), both the strength and thermal insulation properties of aerated concrete are improved, ensuring a uniform porous structure. Researchers have analyzed the porosity of aerated concrete and predicted its thermal conductivity using numerical modeling and multivariate regression [32,33]. Using machine learning methods, the strength and density of aerated concrete using local raw materials, ash, and waste in seismic areas have been modeled [34]. Using convolutional neural networks, thermal conductivity is predicted by analyzing the visual structure, i.e., porosity, of non-autoclaved aerated concrete products [32].
Studies have shown that [1,35] in order to increase the strength of aerated concrete, it is necessary to ensure a dense arrangement of the inter-pore partition using polydisperse fillers. Considering the effect of clinker minerals on hydration and cement stone structure formation, non-autoclaved porous concrete with an average density of 580 kg/m3, compressive strength of 3.3 MPa, and thermal conductivity of 0.131 W/(m°C) was obtained by applying dispersed wollastonite and diopside as mineral additives [36].
The dispersed part of any concrete is made up of various types of mineral fillers and cement. Currently, the use of micro- and nano-sized fillers is practically very important to improve the operational and technological properties of concrete. This is due to the fact that the finely dispersed component compacts the structure of the cement stone and enters into chemical interaction with the hydration products of cement to form the corresponding cementitious compounds [37,38]. These zones and complex salts of the hydrated microcrystals of clinkers form the internal “honeycomb” structure of the composite filled with binding components and additives [39].
Studies of the effect of fillers consisting of polydisperse and polymorphic particles on the properties of concrete [3,40,41,42,43,44,45,46] have shown that the use of fly ash, ground limestone, and superplasticizers as fillers in cement systems allows one to adjust the properties of fine-grained concrete. It is obvious that the improvement of compositions and production technology also applies to non-autoclaved aerated concrete [47]. The use of an ionic-modifying additive obtained from lignin-rich wood sawdust reduces the internal stress arising during hydration and increases the stability of the porous structure [48].
In this regard, it is relevant to conduct research aimed at reducing cement consumption for the preparation of efficient porous concrete types by introducing various microfillers into the cement solution in the formation of porous partitions. However, despite the progress in the study of aerated concrete, many problems still remain. Although many studies have focused on increasing the efficiency of porous concrete formulations, little has been studied about the synergistic effect of microsilica and mineral dust in autoclaved aerated concrete systems [49,50]. In addition, most studies have resorted to single-variable effects rather than multi-parameter optimization, which simultaneously takes into account the composition of cement, water–solid ratio, and dosage of gas-forming substances.
Different from former studies, this paper is focused on the preparation of optimal compositions of non-autoclaved aerated concrete with medium-density D500 and D600 based on microfiller adhesives with low cement consumption. The main direction of this research study is also to determine the effect of mineral powder and microsilica in a complex form on the compressive strength limit and average density of aerated concrete; to build mathematical models based on regression to describe the strength and composition relationships; and to determine the optimal parameters of the mixture to minimize cement consumption [51,52,53,54,55,56].

2. Materials and Methods

This study used Portland cement CEM I-52.5, produced by HOLCIM Azerbaijan (Bakı, Azerbaijan) in accordance with the requirements of the AZS EN 197-1 standard [57], and limestone-shell rock waste from a quarry located in the village of Turkan in the Absheron region. The mineralogical composition of Portland cement is as follows: C3S–67%, C2S–13%, C3A–4.9%, C4AF–11.9%.
PAP-2 (GOST 5494-95) aluminum powder was used to create pores, caustic soda and sodium sulfate were used to accelerate the setting of cement, and CORSO RMX 210 was used as a plasticizing additive.
The components included in the composition of the aerated concrete mixture are weighed and mixed. Water with a temperature of 60 °C is added to the resulting mixture and mixed for 1 min. Then, a pre-prepared aluminum suspension is added to the mixture and mixed for another 1 min. The flowability of the mixture is determined in a Suttard viscometer. When the spreading diameter is 26–28 cm, the consistency of the mixture is considered normal. An aerated concrete mixture with normal consistency is poured into molds measuring 10 × 10 × 10 cm. The mixture is filled to 2/3 of the mold. The mold is placed in a preheating chamber, and after being kept at a temperature of 40–450 °C for 3 h, the part of the solution rising above the mold is cut off with a wire. Then, the mold is opened and placed back in the chamber and kept at a temperature of 60–800 °C for 6–8 h. The samples are then dried to a constant mass, and physical and mechanical tests are performed. A mathematical planning method was used to optimize the results. The results obtained during the research were converted into a dataset in the Matlab program, and the optimization of components was ensured. The structure-block diagram of this study is given in Figure 1.
The average density of non-autoclaved aerated concrete is determined according to GOST 12730.1 “Concretes. Methods for determining density”. The samples are dried to a constant weight in a drying cabinet at a temperature of 110 ± 5 °C for 24 h, and the average density is calculated using Equation (1):
Ρw = m/V
where m is the mass of the sample, kg; V is the volume of the sample, cm3.
The compressive strength limit was determined in accordance with GOST 10180 “Concretes. Methods for determining strength using reference samples” and was calculated using Equation (2).
Rstr = P/S
where P is the destructive load (kg), and S is the area of the sample, cm2.
Thermal conductivity was determined in accordance with GOST 7076 “Building materials and products. Method for determining thermal conductivity and thermal resistance in a steady state” with respect to samples measuring 100 × 100 × 20 mm [58].

3. Experimental Results and Discussion

In order to determine the optimal water/solid (W/S) ratio and the amount of aluminum powder in aerated concrete with an average density of D500 and check the optimal doses of microsilica, superplasticizer CORSO RMX 210, and hardening accelerator Na2SO4, an experiment was conducted by changing the W/S ratio (0.35–0.50), the amount of aluminum powder (520–670 g in 1 m3 of aerated concrete), and the amount of NaOH (1.2% of the mass of cement).
The effect of increasing the amount of microsilica and changing the mineral powder ratio (MT/Sem) on the compressive strength of cement before using the gasifier is given in Figure 2 and Figure 3.
Table 1 shows the 7-day compressive strength (Mpa) values taken from the experiment when MS is 0 in Row 1, Row 2, and Row 3; 1.25 in Row 4, Row 5, and Row 6; and 1.5 in Row 7, Row 8, and Row 9.
As can be seen from Figure 2, the strength of concrete decreases as the MP/Sem ratio increases, despite the increase in the amount of microsilica. Better results are obtained when the amount of microsilica is 7.5%. Since significant decreases in strength are observed when the MP/Sem ratio is increased above 1.25, it is not recommended to exceed this limit.
In Figure 3, the dependence of the compressive strength of the mixture on the content of microsilica at different ratios of mineral stone to cement is shown.
As can be seen in Figure 3, regardless of the ratio of mineral dust to cement, the strength of concrete increases when the amount of microsilica increases to 7.5%, but with a further increase in the amount of microsilica, the strength begins to decrease.
A two-factor experiment was conducted using linear planning to determine the optimal ratio of mineral powder and Portland cement in the presence of microsilica without using a gasifier. One of the variables was the ratio of mineral powder to cement X1 (MP/Cem = 1–1.5), and the second was the ratio of microsilica to cement X2 (MS/Cem = 0–0.15). The mixtures were prepared at the same flowability (the spread of the mixture was taken as 15–16 cm according to the Suttard viscometer) and placed in molds measuring 10 × 10 × 10 cm. The samples were stored under normal conditions for 7 days, and the test results are given in Table 2.
The results of two-factor experiments to optimize the composition of the mixture by changing the ratio of mineral powder to cement are shown (mineral powder to cement ratio X1 = MP/Cem = 1–1.5; microsilica to cement ratio X2 = MS/Cem = 0–0.15).
In Table 2, FL is the factor level; FV is the factor value; SS is the spread according to Suttard, shown in cm; CS is the compressive strength; AD is the average density.
The dependence of the 7-day compressive strength on the MP/Cem and MS/Cem ratios is given in Equation (3):
R7 = 9.6 − 1.57X1 + 0.32X2 − 0.05 X1X2
As can be seen from the formula, the 7-day compressive strength of the cement matrix decreases with an increasing amount of mineral powder in the cement composition, but it increases with the addition of microsilica. When both components are added together, the change in strength is negligible.
When the variables in expression (1) are converted to natural values, the following mathematical model is obtained for the 7-day compressive strength limit using Equation (4):
R7str= 9.6 − 1.57(MP/Cem − 1.25)/0.25 + 0.32(MS/Cem − 0.075)/0.075 − 0.05[(MP/Cem − 1.25)/0.25]·[(MS/Cem − 0.075)/0.075]
After performing the algebraic operations in expression (4), the compressive strength limit at 7 days is expressed in simplified form as follows (Equation (5)):
R7str = 9.6 − 6.28(MP/Cem − 1.25) + 4.267(MS/Cem − 0.075) − 2.667(MP/Cem − 1.25)
(MS/Cem − 0.075)
According to the developed model, we will construct a 3D graph of the compressive strength of concrete at 7 days using the MATLAB program. Figure 4 shows the 3D graph of the dependence of the 7-day compressive strength of D500 aerated concrete on MP/Cem and MS/Cem.
Figure 4 shows the dependence of the 7-day compressive strength limit (R7compact) of concrete on the ratio of mineral dust to cement (MT/Cem) and microsilica to cement (MS/Cem). As can be seen, as MT/Cem increases, strength decreases, and as MS/Cem increases, strength increases.
The results obtained allow us to determine the optimal compositions of the matrix of non-autoclaved aerated concrete and its intercellular partitions based on Portland cement, mineral dust made of carbonate rocks, microsilica, CORSO RMX 210, and Na2SO4. The optimal (in terms of maximum compressive strength and minimum cement consumption) proportions of the components were determined: mineral-dust-to-cement ratio MT/Sem = 1.25; amount of microsilica: 7.5%; CORSO RMX 210—0.6%; Na2SO4—0.5%.
The composition of the non-autoclaved aerated concrete was selected using samples measuring 100 × 100 × 100 mm, the strength of which was tested for 7 and 28 days after hardening under normal conditions (temperature (20 ± 2) °C; air humidity 95−100%). The working consistency (solidity) of the solution mixture was determined using the Suttard device in accordance with the requirements of GOST 23789. It was found that with the addition of an optimal amount of microsilica of 7.5%, in order to obtain a porous concrete of the D500 brand from a mixture with a flowability of 26–28 cm on the Suttard device, the Water/B ratio should be high. This is explained by the fact that microsilica is an additive with high dispersion. Using the components, aerated concrete of the D500 brand was obtained based on the given matrix composition (Water/B—0.5, Al—650 g per 1 m3, NaOH—0.5% of the cement mass). Then, the composition of the mixture was optimized to increase the strength of the D500 aerated concrete by changing the W/B ratio and the amount of aluminum powder.
Table 3 shows the composition and properties of the D500 aerated concrete with an average density of 500 kg/m3.
The dependence of the compressive strength limit and average density of aerated concrete on the amount of Al powder and the W/C ratio is given in Figure 4 and Figure 5. With a decrease in the W/C ratio from 0.50 to 0.44 and a decrease in the amount of aluminum powder from 650 to 600 g per 1 m3 of the mixture, the average density and compressive strength limit increase. The optimal W/C ratio for obtaining porous concrete with a grade of D500 for average density is 0.48, and the amount of aluminum powder is 650 g per 1 m3 of the mixture. The temperature of the mixture when filling the mold is about 40 °C, and the foaming time is 10 min.
As can be seen, when using the same amount of Al powder, the foaming time is extended, and the compressive strength limit and, accordingly, average density increase. The 28-day compressive strength limit of D500 aerated concrete in composition No. 2 is 1.10 MPa (corresponds to class B1). The reduction in cement consumption is 37.3 kg (16.4%) per 1 m3 of non-autoclaved aerated concrete. Figure 5 shows the dependence of the compressive strength of D500 aerated concrete on the W/C ratio and the amount of aluminum powder. Figure 6 shows the dependence of the average density of D500 aerated concrete on the W/C ratio and the amount of aluminum powder.
To determine the optimal composition of non-autoclaved aerated concrete with an average density of D600, a two-factor mathematical planning method was used with changes in the W/C ratio (0.46–0.48) and the amount of aluminum powder (500–550 g per 1 m3 of aerated concrete). During the experiment, the composition of aerated concrete was as follows: MP/Cem = 1.25; MS/Cem = 0.09; CORSO RMX 210—0.6%; Na2SO4—0.5%; NaOH = 0.5%. Samples measuring 100 × 100 × 100 mm were prepared and stored under normal conditions (temperature (20 ± 2) °C; air humidity 95–100%) for 7 days. The composition and properties of aerated concrete are given in Table 4, and the test results are given in Figure 7 and Figure 8.
The dependence of the physical and mechanical properties of D600 aerated concrete on the W/S ratio and the amount of Al in 1 m3 of the mixture is given by Equations (6)–(8):
R7str = 1.35 − 0.15 X1 − 0.18 X2 + 0.15 X1X2
R28str = 2.04 − 0.36 X1 − 0.18 X2 + 0.04 X1X2
D = 150 − 13.25 X1 − 5.75 X2 + 3.25 X1X2
As can be seen from the formulas, the 7-day compressive strength of the cement matrix decreases as the W/S ratio and the amount of aluminum powder increase, but the combined effect of both variables changes slightly. Similarly, the same principle is maintained for the 28-day compressive strength and the average density of aerated concrete. Figure 7 shows that the average density of D600 porous concrete decreases by 585 kg/cm3 depending on the W/C ratio and the amount of aluminum powder. This is due to the fact that as the amount of Al powder increases, the amount of hydrogen gas that provides gasification per unit volume increases.
In Table 4 and Figure 8, the compressive strength decreases with increasing W/C ratios in all compositions. When the amount of Al powder increases, the bulk density of aerated concrete decreases. Since there is a direct proportionality between density and strength, the compressive strength of the composition also decreases accordingly. When the water–cement ratio decreases from 0.46 to 0.48, the strength decreases from 2.45 MPa to 2.0 MPa when the Al content is 500 g.
Thus, the compressive strength decreases with increasing W/C ratios in all compositions prepared depending on the Al content. When the amount of Al powder in aerated concrete is excessively increased, the stratification and loosening of the upper part of the sample are observed. The optimal W/C ratio for obtaining D600-grade aerated concrete with an average density is 0.47, and the amount of aluminum powder is 525 g per 1 m3 of the mixture. The temperature of the mixture when poured into the mold is 40 °C, the foaming time is 10 min, the average density is 600 kg/m3, and the 28-day compressive strength is 2.24 MPa (the expected strength class was B1.5−B2). The reduction in cement consumption is 44.8 kg per 1 m3 (16.4%) in non-autoclaved aerated concrete.
The mathematical models for D600 aerated concrete converted to natural values are as follows:
The compressive strength limit at 7 days is given in Equation (9):
R7 = 1.35 − 0.15 (W/Sem − 0.47) 0.01 − 0.18 (Al − 525)/25 + 0.15 [(W/Cem − 0.47)/0.01]·[(Al − 525)/25]
The compressive strength limit at 28 days is given in Equation (10):
R28 = 2.04 − 0.36 (W/Sem − 0.47) 0.01 − 0.18 (Al − 525)/25 + 0.04[(W/Cem − 0.47)/0.01]·[(Al − 525)/25]
The average density is given in Equation (11):
D = 600 − 13.25 (W/Cem − 0.47)/0.01 − 5.75 (Al − 525)/25 + 13.25[(W/Cem − 0.47)/0.01][(Al-25)/25]
After performing the algebraic operation in Equations (9)–(11), the models in simplified form are as follows:
The 7-day compressive strength is given in Equation (12):
R7 = 1.35 − 15(W/Sem − 0.47) − 0.0072(Al − 525) + 0.6(W/Cem − 0.47)·(Al − 525)
The 28-day compressive strength limit is given in Equation (13):
R28 = 2.04 − 36(W/Sem − 0.47) − 0.0072(Al − 525) + 0.16(W/Cem − 0.47)(Al − 525)
The average density is given in Equation (14):
D = 600 − 1325(W/Cem − 0.47) − 230(Al − 525) + 13(W/Cem − 0.47)(Al − 525)
Let us build a 3D graph of the compressive strength limit of D600 aerated concrete at 7 and 28 days, as well as the dependence of its average density on W/Cem and Al, according to the compiled models (Figure 9, Figure 10 and Figure 11).
Figure 9, Figure 10 and Figure 11 show the dependence of the physical and mechanical properties of D600 aerated concrete on the Water/Sem ratio and the amount of Al powder. As can be seen, an increase in the Water/Sem ratio has a greater effect on the decrease in strength than Al powder. Therefore, the optimal Water/Sem ratio for obtaining D600 aerated concrete with an average density is 0.47, and the amount of aluminum powder is 525 g per 1 m3 of the mixture. The optimized parameters of D600 aerated concrete with natural values are given in Table 5.
The following calculations can be performed to reflect the accuracy of the mathematical model. If we substitute the data in Table 4 for D600 into Equation (15), we obtain the following for R7str:
R7str = 1.35 − 15(0.47 − 0.47) − 0.0072(525 − 525) + 0.6(0.47 − 0.47)(525 − 525) = 1.35 MPa
The value obtained from the mathematical model corresponds to the value given in Table 3. The value obtained in the mathematical model for D600 aerated concrete, R7str = 1.35 MPa, completely coincides with the value in Example 5 of Table 3.
To determine the structure and nature of porosity of autoclaved aerated concrete, photographs of samples prepared based on the composition given in Table 5 were taken (Figure 12).
The study of the macrostructure of aerated concrete was carried out on 28-day samples. As can be seen, aerated concrete has a uniform macrostructure. The pores are evenly distributed throughout the concrete (Figure 12a), and their sizes are small and have a regular geometric shape. When microsilica is not used, along with small-sized pores, large pores are also found, and there is also a small number of interconnected pores (Figure 12b).
X-ray phase analysis was carried out to study the phase composition of mineral powders during cement hardening (Figure 13 and Figure 14).
As can be seen (Figure 13), when microsilica is not used, the amount of portlandite formed during cement hydration is high, while the amount of higher-based calcium hydrosilicates also predominates. This creates problems in the formation of a dense structure of cement stone.
The results of the X-ray phase analysis showed that the intensity of Ca(OH)2 peaks (4.93, 2.63, and 1.93 A) decreases when microsilica is added (Figure 14). In addition, the decrease in the intensity of peaks related to alite (3.04, 2.74 A) indicates that the intensity of the hydration process increases due to the influence of microsilica.
The pulverizing activity of ultradisperse microsilica is based on its ability to interact with calcium hydroxide, Ca(OH)2, formed during cement hydration. In this case, low-basic calcium hydrosilicates, CSH(I), are formed instead of portlandite crystals, densifying the structure of the cement stone and increasing its strength.
One of the important properties of aerated concrete is its thermal insulation capacity. In order to determine the effect of dispersed fillers on the thermal insulation capacity of aerated concrete, the thermal conductivity of aerated concrete prepared on the basis of composition 5 in Table 3 was determined to be 0.12 W/(m.°C). In the absence of microsilica and carbonate waste, the thermal conductivity of the control aerated concrete sample is 0.14 W/(m.°C).
The results of experimental studies have shown that despite the increase in the strength of aerated concrete with the optimal composition prepared with the participation of the proposed modifiers compared to the composition without additives, the total porosity volume decreases by 28.5%. This is due to the fact that the porous partitions in aerated concrete with additives have a denser and more complete structure.

4. Conclusions

The experimental studies demonstrated the effectiveness of using mineral powders and microfillers in the preparation of optimal compositions for non-autoclaved aerated concrete (D500 and D600 grades). The results show that the addition of carbonate fillers and microsilica to the cement matrix provides a density in the range of 500–600 kg/m3 and a compressive strength of 1.1–2.24 MPa. These indicators correspond to strength classes B1–B2 and allow the material to be used for both structural and thermal insulation purposes. One of the main results of the study is a significant (16.4%) reduction in cement consumption due to the use of mineral waste. This approach leads to a reduction in production costs. In this context, our research work makes a significant contribution to the creation of both economically and environmentally sustainable building materials. As a result of the synergistic effect of microsilica and carbonate waste together, the thermal conductivity of the aerated concrete sample with a bulk density of 600 kg/m3 and a strength of 2.24 MPa is 0.12 W/(m.°C). These concretes can be widely used in construction as structural heat-insulating materials. In addition, additional experimental tests are considered necessary before the obtained models are applied in industrial practice. This study will be a source of information for future studies, and it will be possible to find the best values using the mathematical planning method.

Author Contributions

Conceptualization, M.D.; methodology, M.D.; software, M.D.; validation, A.G. and M.D.; formal analysis, A.G.; investigation, A.G.; resources, M.D.; data curation, A.G.; writing—original draft preparation, A.G.; writing—review and editing, M.D. and A.G.; visualization, A.G. and M.D.; supervision, M.D.; project administration, A.G.; funding acquisition, A.G. All authors have read and agreed to the published version of the manuscript.

Funding

This research received no external funding.

Institutional Review Board Statement

Not applicable.

Informed Consent Statement

Not applicable.

Data Availability Statement

The raw data supporting the conclusions of this article will be made available by the authors on request.

Acknowledgments

During the preparation of this manuscript/study, the author(s) used Matlab 21 version for the purposes of 3D graphs. The authors have reviewed and edited the outputs and take full responsibility for the content of this publication.

Conflicts of Interest

The authors declare no conflict of interest.

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Applsci 15 12364 g001
Figure 1. The structure-block diagram of this study.
Figure 1. The structure-block diagram of this study.
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Figure 2. Dependence of the compressive strength of the mixture with different amounts of microsilica on the ratio of mineral powder to cement.
Figure 2. Dependence of the compressive strength of the mixture with different amounts of microsilica on the ratio of mineral powder to cement.
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Figure 3. Dependence of the compressive strength of the mixture on the content of microsilica at different ratios of mineral stone to cement.
Figure 3. Dependence of the compressive strength of the mixture on the content of microsilica at different ratios of mineral stone to cement.
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Figure 4. Three-dimensional graph of the dependence of the 7-day compressive strength of D500 aerated concrete on MP/Cem and MS/Cem.
Figure 4. Three-dimensional graph of the dependence of the 7-day compressive strength of D500 aerated concrete on MP/Cem and MS/Cem.
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Figure 5. Dependence of the compressive strength of D500 aerated concrete on the W/C ratio and the amount of aluminum powder.
Figure 5. Dependence of the compressive strength of D500 aerated concrete on the W/C ratio and the amount of aluminum powder.
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Figure 6. Dependence of the average density of D500 aerated concrete on the W/C ratio and the amount of aluminum powder.
Figure 6. Dependence of the average density of D500 aerated concrete on the W/C ratio and the amount of aluminum powder.
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Figure 7. Dependence of the average density of D600 aerated concrete on the W/C ratio and the amount of aluminum powder.
Figure 7. Dependence of the average density of D600 aerated concrete on the W/C ratio and the amount of aluminum powder.
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Figure 8. Dependence of the compressive strength of D600 aerated concrete on the W/C ratio and the amount of aluminum powder.
Figure 8. Dependence of the compressive strength of D600 aerated concrete on the W/C ratio and the amount of aluminum powder.
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Figure 9. Three-dimensional graph of the W/Cem and Al dependence of the 7-day compressive strength of D600 aerated concrete.
Figure 9. Three-dimensional graph of the W/Cem and Al dependence of the 7-day compressive strength of D600 aerated concrete.
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Figure 10. Three-dimensional graph of the W/Cem and Al dependence of the 28-day compressive strength of D600 aerated concrete.
Figure 10. Three-dimensional graph of the W/Cem and Al dependence of the 28-day compressive strength of D600 aerated concrete.
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Figure 11. Three-dimensional graph of the average density of D600 aerated concrete as a function of W/Cem and Al.
Figure 11. Three-dimensional graph of the average density of D600 aerated concrete as a function of W/Cem and Al.
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Figure 12. Macrostructure of non-autoclaved aerated concrete. (a) Combined use of mineral dust and microsilica and (b) without using microsilica.
Figure 12. Macrostructure of non-autoclaved aerated concrete. (a) Combined use of mineral dust and microsilica and (b) without using microsilica.
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Figure 13. X-ray phase analysis of compounds formed during cement hydration without the use of microsilica.
Figure 13. X-ray phase analysis of compounds formed during cement hydration without the use of microsilica.
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Figure 14. X-ray phase analysis of compounds formed during hydration of a cement composite prepared with microsilica additive.
Figure 14. X-ray phase analysis of compounds formed during hydration of a cement composite prepared with microsilica additive.
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Table 1. Effect of microsilica and mineral-dust-to-cement ratio on compressive strength.
Table 1. Effect of microsilica and mineral-dust-to-cement ratio on compressive strength.
№Composition of the MixtureSpread According to Suttard, smCompressive Strength, 7 Days, MPa
MP/CemMS, % by Mass
11.001610.9
21.250169.0
31.50167.6
41.07.51612.1
51.257.51611.2
61.57.5168.8
71.0151611.4
81.2515169.0
91.515168.4
Table 2. Results of two-factor experiments to optimize the composition of the mixture by changing the ratio of mineral powder to cement (mineral powder to cement ratio X1 = MP/Cem = 1–1.5; microsilica to cement ratio X2 = MS/Cem = 0–0.15).
Table 2. Results of two-factor experiments to optimize the composition of the mixture by changing the ratio of mineral powder to cement (mineral powder to cement ratio X1 = MP/Cem = 1–1.5; microsilica to cement ratio X2 = MS/Cem = 0–0.15).
№FLFVX1X2SS, cmW/CCS,
7 Days,
MPa		AD y, kg/m3
X1X2MP/CemMS/Cem
1−1−110+1160.4010.91630
2+1−11.50−1150.387.61565
3−1+110.15−1160.4211.41640
4+1+11.50.15+1160.418.41605
5−1010.0750160.4012.11700
6+101.50.0750150.398.81610
Table 3. Composition and physical and mechanical properties of D500 aerated concrete.
Table 3. Composition and physical and mechanical properties of D500 aerated concrete.
№FVsToM
(°C)		Foaming Time, minCS,
(MPa)		AD
(kg/m3)
W/S1 m3 Al Content (g)7 Days28 Days
10.506504080.620.95495
20.4865041100.651.10500
30.4665040110.671.12513
40.4465039120.701.20549
50.4860041110.781.27557
60.4460041110.801.35567
70.5060042110.741.15544
Table 4. Composition and physical and mechanical properties of D600 aerated concrete.
Table 4. Composition and physical and mechanical properties of D600 aerated concrete.
№The Value of Factors in Coded FormThe Price of Factors in Their Natural StateFoaming Time, minCompressive Strength, MPaAverage Density, kg/m3
W/CAl Content in 1 m3 MixtureW/C7 Days7 Days28 Days
1−1−10.46500111.622.45623
2+1−10.48500111.242.00590
3−1+10.46550111.382.15605
4+1+10.48550101.151.55585
5000.47525101.352.24600
Table 5. Optimized parameters of D600 aerated concrete.
Table 5. Optimized parameters of D600 aerated concrete.
№SettingsD600
1MP/Cem1.25
2MS/Cem0.075
3W/Sem ratio0.47
4Amount of Al powder, g/m3525
5Superplasticizer CORSO RMX, %0.6
6Na2SO4, %0.5
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, A.G.; Dursun, M. Increase of Efficient at Aerated Concrete Compositions Based on Mineral Powders. Appl. Sci. 2025, 15, 12364. https://doi.org/10.3390/app152312364

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AG, Dursun M. Increase of Efficient at Aerated Concrete Compositions Based on Mineral Powders. Applied Sciences. 2025; 15(23):12364. https://doi.org/10.3390/app152312364

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(Kapanakchi), Abbas Guvalov, and Mahir Dursun. 2025. "Increase of Efficient at Aerated Concrete Compositions Based on Mineral Powders" Applied Sciences 15, no. 23: 12364. https://doi.org/10.3390/app152312364

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, A. G., & Dursun, M. (2025). Increase of Efficient at Aerated Concrete Compositions Based on Mineral Powders. Applied Sciences, 15(23), 12364. https://doi.org/10.3390/app152312364

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