A comprehensive approach for lightweight polymer concrete production: Determination of the effect of resin and perlite types on high temperature, freeze-thaw behavior and damage mechanisms of polymer concrete

The purpose of this study is to examine the durability performance of lightweight polymer concrete produced using natural and expanded perlite aggregates under extreme conditions. Within this scope, the effects of perlite aggregates on both the macroscopic performance and microstructural properties of polyester and vinylester resin polymer concrete matrices have been evaluated in an original manner using a comprehensive and comparative approach. In the experimental study, 5% and 10% by volume of quartz aggregates were replaced with natural and expanded perlite. The durability performance of the produced polymer concrete has been tested under extreme environmental conditions, including exposure to high temperatures (50°C, 100°C, 150°C, and 200°C) and freeze-thaw cycles (up to 300 cycles). Additionally, microstructural analyses were performed using weight loss, compressive strength loss, visual evaluations, and scanning electron microscopy (SEM) to investigate the damage mechanisms. The results obtained show that significant changes occur in the durability performance of polymer concrete under extreme conditions, depending on the type of perlite and the ratio of use. Natural perlite aggregates have demonstrated higher durability and minimal performance loss by providing better adhesion with both resin types. However, the high porosity of expanded perlite increased the permeability of the matrix and caused significant deterioration. Vinylester resin polymer concrete has been found to exhibit superior resistance to both high temperatures and freeze-thaw cycles compared to polyester resin concrete. Among all mixtures, vinylester resin polymer concrete containing 5% natural perlite showed the most stable internal structure with the lowest durability losses. These results reveal that natural perlite, a local and sustainable lightweight aggregate, offers an important alternative for the low-carbon building material concept by enhancing the environmental performance of polymer concrete. © 2026 Elsevier Ltd.