Particle-Packing Optimized Aerogel–Perlite–Cement Composite Mortars for High-Performance Building Envelopes
Enhancing the thermal efficiency of building envelopes while preserving mechanical integrity remains a central challenge in sustainable construction. Conventional insulation mortars often struggle to simultaneously optimize low thermal conductivity, moisture resistance, and adequate structural strength. This study develops aerogel–perlite–cement (ACM) composite insulation mortars through particle packing optimization to achieve balanced thermal, mechanical, and hygric performance, while also evaluating their building-scale energy implications. Material Design Based on Particle Packing Optimization ACM mortars were formulated using the modified Andreasen & Andersen particle packing model with distribution moduli of q = 0.2 and 0.3 to optimize aggregate gradation. A silica aerogel slurry was incorporated into expanded perlite carriers to enhance insulation performance while maintaining structural cohesion. This design strategy aims to minimize pore connectivity for improved therma...