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 thermal resistance while preserving load-bearing capacity.
Thermal, Mechanical, and Hygric Performance Evaluation
Compared to conventional cement mortars (CM), optimized ACM samples achieved a 19% reduction in bulk density and an 18% improvement in water resistance. Thermal conductivity was reduced to 0.059 W·m⁻¹·K⁻¹, while compressive strength remained at an acceptable level of 1.49 MPa. These results confirm that particle packing optimization effectively balances lightweight structure with mechanical and durability requirements.
Mechanistic Interpretation through EMT and Numerical Simulation
Experimental thermal conductivity results were interpreted using effective medium theory (EMT) combined with finite-element simulations. This integrated analytical approach reveals the influence of aggregate gradation, interfacial thermal resistance, and structural heterogeneity on heat transfer mechanisms within aerogel-modified mortars. The findings provide theoretical validation for the observed thermal performance improvements.
Building-Scale Energy Performance Assessment
EnergyPlus simulations of a six-story residential building were conducted to assess the practical energy-saving potential of ACM insulation. Application of a 100 mm ACM insulation layer resulted in annual HVAC energy reductions of 50.9% in cold climates and 33.8% in mixed climates, demonstrating strong climate-adaptive performance benefits.
Implications for Climate-Adaptive Envelope Design
The study demonstrates that aerogel-enhanced composite mortars designed through particle packing optimization can significantly improve envelope thermal performance without compromising structural integrity. By linking material-scale innovation with whole-building energy simulation, the research provides a scalable pathway toward high-performance, climate-responsive building envelope solutions.
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