Tailoring the strength and porosity of rapid-hardening magnesia phosphate paste via the pre-foaming method

High-porosity magnesia phosphate paste (HPMPP) was prepared via the pre-foaming method. In the pre-foaming method, sintering treatment was not required. The bulk density and maximum compressive strength of the HPMPP prepared according to the ratio of water to solids (W/S(o)) of 0.32 reached 464.00 ± 5.00 Kg/m(3) and 0.30 ± 0.05 MPa, respectively. The compressive strength increased with the increases in the addition amounts of sodium silicate and polypropylene fibers. The bulk density of HPMPP increased with the increase in the addition of sodium silicate and decreased with the increase in the addition of polypropylene fibers. Besides, the porosity of the magnesia phosphate paste increased from 79.85% to 81.27% and from 80.31% to 83.75% after the addition of sodium silicate and polypropylene fibers respectively. The highest porosity (83.75%) of the prepared HPMPP was realized under the addition proportion (sodium silicate: polypropylene fibers: solids = 0.06:0.0025:1). The average pore size of the prepared HPMPP is about 180 μm and the pore distribution range is relatively narrow. The hydration product (struvite) is combined with MgO particle one by one and then coated on the surface of bubbles. With the decrease of the water content, after breaking bubbles, the porous structure can be achieved.