A Study on the Preparation and Performance Optimization of Alkali-Activated Fly Ash-Based Aerogel-Modified Foam Concrete

To address the energy and environmental challenges, this study targets the need for ultra-low energy buildings in China’s hot summer-cold winter region (HSCW) by developing high-performance alkali-activated foam concrete (AAFC) insulation material. Initially, a target performance indicator system was established. Subsequently, a mix proportion design method based on the volume method was proposed, and preliminary mix proportions were designed and tested to achieve the target performance. Accordingly, eight factors, including alkali equivalent and SiO2 aerogel content, were selected for further optimization. A systematic optimization of performance was then conducted using an L32(48) orthogonal experimental design. Range analysis and analysis of variance indicated that foam content significantly affected all target properties. The water-to-binder ratio notably influenced mechanical performance and dry density. Alkali equivalent and activator modulus directly regulated the reaction process. Notably, the incorporation of 2.5 wt% SiO2 aerogel reduced the thermal conductivity to 0.1107 W/(m·K), highlighting its significant role in improving thermal insulation and effectively resolving the common trade-off between insulation and mechanical properties in FC. Furthermore, the waterproofing agent played a critical role in reducing water absorption and enhancing frost resistance. Finally, the optimal mix proportion was determined through matrix analysis, with all material properties meeting the expected targets. Test results confirmed that the optimized FC achieved a dry density of 576.34 kg/m3, compressive and flexural strengths of 5.83 MPa and 1.41 MPa, respectively, a drying shrinkage rate of only 0.614 mm/m, a mass water absorption of 3.87%, and strength and mass loss rates below 10.5% and 1.8% after freeze–thaw cycles. Therefore, this material presents a novel solution for the envelope structures of low-energy buildings.