Bioaerated Low-Density Composites from Industrial Byproducts: Advancing Carbon-Neutral and Energy-Efficient Material Systems in the Building Sector

The transition towards carbon-neutral construction materials requires innovative solutions that combine reduced embodied energy, enhanced durability and improved building energy efficiency. This study investigates and compares two novel bioaerated low-density composites—BAAC and BIOAERMAC—developed through biologically driven aeration processes incorporating industrial byproducts. BAAC is produced using Saccharomyces cerevisiae and hydrogen peroxide, replacing conventional aluminum powder and improving safety while enabling the valorization of waste-derived yeast. BIOAERMAC is a gypsum-based composite incorporating synthetic anhydrite, microorganisms, peroxides, and recycled rubber from end-of-life tires. The materials were characterized in terms of hygrothermal behavior and dimensional stability, and compared with commercial autoclaved aerated concrete under equivalent mechanical strength conditions. The results highlight significant differences in moisture transport and shrinkage, primarily governed by pore structure and connectivity. BAAC exhibits behavior comparable to conventional AAC, whereas BIOAERMAC shows reduced capillary and hygroscopic absorption, indicating limited pore connectivity, but higher drying shrinkage. These findings demonstrate the effectiveness of bioaeration in tailoring pore structure and controlling the trade-off between moisture transport, durability, and dimensional stability, highlighting the potential of bioaerated composites for low-carbon and energy-efficient building applications.