Mechanical and thermal properties of lightweight concrete produced with polyester-coated pumice aggregate

•Pumice aggregates were coated with polyester to obtain polymer-coated pumice aggregates (PCPA).•Lightweight concretes were produced with different cement dosages (200, 250 and 300) and PCPAs at different ratios (0%, 50% and 100%).•Physical properties, mechanical strength, thermal properties and internal structure analysis (SEM-EDS) of the produced concrete samples were performed.•REF D300 and REF D250 dosage series are in the semi-load-bearing lightweight concrete class, and the other all series are in the insulation concrete class. With the technological advances in the field of building materials, there has been an increasing focus on the research of lightweight concrete made with coated aggregates for improving the durability of concrete. In this study, pumice aggregates were coated with cast-based polyester to obtain polymer-coated pumice aggregates (PCPA). Lightweight concretes were produced with different cement dosages (200, 250 and 300) and PCPAs at different ratios (0%, 50% and 100%). Physical properties, mechanical strength, thermal properties and internal structure analysis (SEM-EDS) of the produced concrete samples were performed. According to the RILEM functional classification of lightweight concrete, the test results showed that REF D300 and REF D250 dosage series are in the semi-load-bearing lightweight concrete class, and the other all series are in the insulation concrete class, and the produced concretes can be classified as lightweight insulation materials. It can also be used in non-load-bearing walls or as an alternative lightweight insulation material.