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The primary objective of this study was to develop an autoclaved light concrete (ALC) material with ultra-thermal insulation property and to investigate the relationship between its physical characteristics and mechanical properties. Through tests of dry bulk density and compressive strength, relationship of physical characteristics and mechanical properties of samples were studied, resulting in a material with ultra-thermal insulation property. Scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDX) were applied to analyze the micro-morphology and elemental composition of samples. To identify the product phases, X-ray diffraction (XRD) was engaged. The test results showed that compressive strength and thermal coefficient were reduced with the increasing of aluminum powder within the mixtures. As a result the optimal thermal coefficient and compressive strength of samples were improved to 0.061 W/(m·k) and 1.2 MPa, respectively. SEM, EDX and XRD analyses showed that calcium silicate hydrate and tobermorite crystal were main resultant phases.