Multi-Scale Optimization of Volcanic Scoria Lightweight Aggregate Concrete via Synergistic Incorporation of Styrene-Acrylic Emulsion, Foaming Agent, and Straw Fibers

Volcanic Scoria Lightweight Aggregate Concrete (VSLAC) has been identified as a material with considerable potential for use in carbon-neutral construction; however, its application is often hindered by two main issues. Firstly, the low density of scoria often results in aggregate segregation and stratification. Secondly, its high hygroscopicity can lead to shrinkage cracking. In order to address the aforementioned issues, this study proposes a multi-scale modification strategy. The cementitious matrix was first strengthened using a binary blend of Fly Ash and Ground Granulated Blast Furnace Slag (GGBS), followed by the incorporation of a ternary admixture system containing Styrene-Acrylic Emulsion (SAE), a foaming agent (FA), and alkali-treated Straw Fibres (SF) to enhance workability and durability. The findings of this study demonstrate that a mineral admixture comprising 10% Fly Ash and 10% GGBS results in a substantial enhancement of matrix compactness, culminating in a 20% increase in compressive strength. An orthogonal test was conducted to identify the optimal formulation (D13), which was found to contain 4% SAE, 0.1% FA, and 5% SF. This formulation yielded a compressive strength of 35.2 MPa, a flexural strength of 7.5 MPa, and reduced water absorption to 8.0%. A comparative analysis was conducted between the mineral admixture mix ratio (Control group) and the Optimal mix ratio (Optimization group). The results of this analysis reveal that the Optimization group exhibited superior durability and thermal characteristics. Specifically, the water penetration depth of the optimized composite was successfully restricted to within 3.18 mm, while its thermal insulation performance demonstrated a significant enhancement of 12.3%. In the context of freeze–thaw cycles, the modified concrete demonstrated notable durability, exhibiting a 51.4% reduction in strength loss and a marginal 0.64% restriction in mass loss. SEM analysis revealed that the interaction between SAE and the FA resulted in the densification of the Interfacial Transition Zone (ITZ). In addition, the 3D network formed by SF redistributed internal stresses, thereby shifting the failure mode from brittle fracture to ductile deformation. The findings demonstrate that modifying VSLAC at both micro- and macro-levels can effectively balance structural integrity with thermal efficiency for sustainable construction applications.