This study presents a novel method to produce self-setting inorganic foams with a unique setting time and pore structure. The combination of the particle- stabilized foams with Portland cement (Ca3SiO5) reaction leads to a macro porous ceramic material which can be shaped and consolidated at room temperature. The foam microstructure and porosity can be tailored varying different parameters such as setting temperature, humidity, cement and setting accelerator concentration. The final microstructure featured a porosity of nearly 65% and a unique pore structure with prevailing hydration reaction of cement. As a result, self-setting ceramic composites with porosities ranging from 40 to 65% and pores with sizes between 100 μm to 1 mm were achieved. Compared with other methods, this process used to produce self-setting inorganic macro porous materials is simple and cost effective, and opens a door for applications where until now drying and sintering phases were the limiting factors.

Keywords: Self-setting,Wet foams, Portland cement, Porous ceramics, Microstructure.