A new approach for lightweight polymer concrete production: Determination of the influence of resin and perlite types on the mechanical performance of polymer concrete

The interest in perlite is increasing significantly in the construction sector in terms of both energy and material in the construction of efficient buildings. This interest arises from the growing demand for environmentally friendly building materials that can mitigate the environmental impact of high cement production. In order for polymer concretes, which have many advantages over traditional concrete, to help reduce damages under earthquake loads and reduce costs, lightweight polymer concrete production should be done using lightweight aggregates. In this study, a new approach for lightweight polymer concrete production was presented for the first time, and the aim was to determine the effect of the compatibility of natural perlite and expanded perlite aggregates with polyester and vinylester resins on the mechanical performance of polymer concrete. For this purpose, natural and expanded perlites were used as fine aggregate in polymer concretes instead of quartz aggregate at the ratios of 0 %, 5 %, and 10 %. As binder materials, unsaturated polyester resin and vinylester resin were selected. Fresh density, compressive, flexural, and splitting tensile strengths, ultrasonic pulse velocity (UPV), modulus of elasticity, and toughness tests were performed on polymer concretes after 7, 28, and 90 days. Furthermore, scanning electron microscope (SEM) analyses were performed to investigate the changes in the microstructure of the polymer concretes. The compressive, flexural, and splitting tensile strength results of polyester resin polymer concretes produced with 5 % natural perlite aggregate were higher than the control concrete. Very high correlations were found between the strength results of polymer concretes and UPV values for all days. Modulus of elasticity and toughness values of vinylester resin polymer concretes with natural perlite aggregate were higher than those of polyester resin polymer concretes. SEM analysis results and experimental results were consistent with each other. Considering all the experimental results, it was revealed that the ideal perlite type and ratio is 5 % natural perlite aggregate. Unlike the literature, and in a unique way, lightweight polymer concretes with high mechanical performance polyester/vinylester resin, especially with natural perlite aggregate, could be produced with a much lower resin ratio (15 %). Thanks to perlite, more sustainable, environmentally friendly, and energy-efficient lightweight polymer concretes can be produced, offering alternative solutions to traditional construction materials. © 2025 Elsevier Ltd