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This paper aims to produce lightweight concrete by combining aerated concrete with expanded polystyrene beads concrete to create structural aerated-polystyrene lightweight concrete that satisfies the criteria of sustainability for thermal and sound insulation properties and the structural criteria of having satisfactory compressive strength for structural elements.

The experimental study was carried out to reach the largest compressive strength while maintaining the lowest possible density by preparing nine mixes of concrete, involving different ratios of aluminum waste powder and polystyrene beads as 0%, 0.2% and 0.3% and 0%, 0.1% and 0.2%, respectively, by weight of cement to produce the lightweight concrete with different densities. The performance of mechanical properties, thermal conductivity, ultrasonic pulse velocity, density, modulus of elasticity, acoustic impedance and scanning electron microscopy were studied and discussed.

Results showed that aerated-expended polystyrene beads concrete had the most suitable properties when the proportions of aluminum waste powder and expanded polystyrene beads were 0.2% and 0.1%, respectively. The compressive strength, density, thermal conductivity and acoustic impedance were 38.5 MPa, 1,768 Kg/m³, 0.358 W/(m.k) and 4.91 Kg/m² s, respectively.

The experimental work was done using aluminum scrap waste powder as an expanding agent to produce aerated concrete and combining it with expanded polystyrene bead concrete to produce structural aerated-polystyrene concrete, which contains fine materials (silica fume and local natural raw limestone) and superplasticizers.