Simultaneous Effects of Perlite Fine Aggregate and Silica Fume on the Physical Properties of Lightweight Cement Mortars

This research investigates the influence of incorporating perlite aggregate and silica fume on the properties of cement mortar, with a focus on compressive strength, flexural strength, density, water absorption, and thermal conductivity. The results show that increasing the percentage of perlite (Pe) in the mixes causes a marked reduction in the compressive strength, reflecting the lightweight nature and low density of perlite. For mixes with Pe-20% through Pe-100%, the compressive strength decreased by up to 78% compared to the reference mix. However, the addition of silica fume (SF) in mixes with SF-20% to SF-100% partially offset this effect, limiting the strength losses to 18–71%, which indicates that silica fume contributes to strength enhancement over time. The flexural strength followed a similar trend, decreasing with a higher perlite content: reductions of up to 40% were observed for Pe mixtures, while SF mixes showed slightly smaller decreases, reaching 36%. The density also declined consistently with increasing perlite replacement, with a maximum reduction of 57% in mix Pe-100% due to the inherent porosity of perlite. The water absorption increased substantially in the same mix (Pe-100%), by 327% compared to the reference one, whereas the addition of silica fume (SF-100%) limited the increase to 181%, confirming its role in refining the pore structure. The thermal conductivity decreased with a higher perlite content, attributed to the formation of voids in the matrix. The lowest value was observed for Pe-100%, with an 82% reduction, while silica fume mixes also showed reductions of 37–81% relative to the reference mix. Based on a comprehensive evaluation of strength, density, water absorption, and thermal performance, mix SF-60% was identified as the optimal mixture, offering a balanced profile with a compressive strength of 4.4 MPa, thermal conductivity of 0.28 W/(m·K), and density of 1089 kg/m3. These performance levels make the developed mortars particularly suitable for non-load-bearing masonry units, lightweight blocks, and insulation panels, where reduced weight and enhanced thermal efficiency are essential. The study therefore provides practical guidance for the design of sustainable, lightweight mortars for energy-efficient construction applications.