This research focuses on the development of sustainable lightweight concrete with enhanced thermal insulation properties by systematically incorporating materials like SFA (Sintered Fly Ash), LECA (Lightweight Expanded Clay Aggregate), Micron Balls Aggregate (MB), Perlite, and Polystyrene (PS). The study begins by identifying and selecting these thermal insulating materials based on their effectiveness and compatibility for concrete applications. Using the guidelines of IS 10262, an M30 grade concrete mix design is developed, carefully integrating the chosen materials to optimize the balance between structural strength and thermal performance.

To evaluate the performance of the developed concrete, a series of mechanical and physical tests are conducted, including compressive and flexural strength, specific gravity, and water absorption tests. Further, thermal conductivity testing was carried out to assess the material's heat transfer behavior, which is crucial for its real-world application in building insulation. The research further explores the field applications of Aluminum bubble sheets and the newly developed thermal insulating concrete, highlighting their potential to improve energy efficiency in buildings. This work aims to contribute toward more eco-friendly, energy-saving construction practices.