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Palm-based lightweight concrete system

A palm-based polyurethane system was used as a polymeric phase in a concrete system. It comprised of palm kernel oil-based polyol reacted with 2,4-methylene diphenyl diisocyanate (crude MDI). A development in the formulation of the polymer concrete in achieving the lowest possible density at an optimal level of polyurethane (PU) system was conducted. The PU system, in the concrete mixture comprised of 5–50% w/w, targeted a density of less than 1800 kg/m3. The rise time, indicating the end of reaction time was obtained at 80 s. The lightweight concrete underwent a phase change in 5–8 min. Excessive PU in the concrete generated more bubbles and resulted in the existence of voids. Optical microscopy analysis was carried out. PU system comprised of palm-based polyol and MDI at a ratio of 1:1 was favored with loading of 20–30% w/w in the concrete mixture in order to produce a lightweight concrete. The specified load bearing structure capability was set above 1500 kg/m3. The palm-based lightweight concrete has excellent compressive strength 10 MPa and thermal insulation characteristics.