Ultra-lightweight Concrete, <1000 kg/m³ (100mm, 125mm, 150mm slab/panel)
Cast Concrete
ATLAS CODE
MIN-CEM-CC-012
Category mineral
Material Family Cementitious
Regulatory Status Non-combustible
Density
400-1000 kg/m3
Carbon (A1-A5)
120-250 kg CO₂e/m³ kgCO₂e
Fire Class
Non-combustible
Lifespan
50+ years (protected) yrs
Description
Ultra-lightweight concrete in this context is typically foamed concrete with high air content. It is used for fills and lightweight slabs where low density is required.
Primary Sectors
[Transport & Infrastructure]
Typical Uses
- Thermal insulation layers for roofs and floors
- Void filling and ground stabilisation
- Lightweight partition walls (non-loadbearing)
- Bridge abutment backfill
- Precast insulation panels
- Tunnel lining and underground applications
- Sound absorption barriers
- Fire-resistant protective layers
Recycled Content 0-30% (fly ash content)
Renewable Content 0%
Recyclability 100% (as aggregate)
Embodied Carbon 120-250 kg CO₂e/m³ kgCO₂e
Embodied Energy 800-1500 MJ/m³ MJ/kg
EPD Available No
Advantages
Excellent thermal insulation (0.06-0.25 W/mK)Self-levelling and self-compactingFire resistant - non-combustible per AS 1530.1Lightweight reduces structural loads by 50-80%Good acoustic absorption (NRC 0.3-0.7)Pumpable over long distances (up to 300m)No vibration required during placementMinimal shrinkage when properly designed
Cautions
Low compressive strength (1-6 MPa)High water absorption (10-25% by mass)Requires protective surface treatmentsLimited freeze-thaw resistance without additivesProne to segregation if incorrectly mixedSpecialised equipment needed for foam generationLimited Australian design standardsQuality control critical for consistency
TECHNICAL DATA: PERFORMANCE PROPERTIES MIN-CEM-CC-012
Density (Dry) 400-1000 kg/m3
Specific Gravity 0.4-1.0
Porosity 30-80 %
Water Absorption 10-25% by mass %
Surface Roughness Ra 50-200 μm (cast surface) μm
UV Resistance Requires protective coating
Chemical Resistance Good alkaline resistance, poor acid resistance
pH Tolerance 10-13 (alkaline)
Compressive Strength 0.5-5 MPa
Tensile Strength 0.1-0.6 MPa (10-15% of compressive) MPa
Flexural Strength 0.2-1.2 MPa MPa
Shear Strength 0.08-0.5 MPa MPa
Elastic Modulus 0.5-3 GPa GPa
Impact Resistance Low - requires surface protection J/m
Bearing Capacity 0.5-3 MPa (service load) kN/m²
Poisson's Ratio 0.15-0.25
Creep Resistance 0.5-2.0 × 10⁻⁶/MPa (long-term)
Abrasion Resistance Poor - protective coating required
Thermal Conductivity 0.06-0.25 W/mK W/mK
Thermal Resistance 0.4-1.67 m²K/W per 100mm m²K/W
Specific Heat Capacity 1000-1200 J/kg·K J/kgK
Thermal Expansion 8-12 × 10⁻⁶/°C μm/m·K
Melting Point >600°C (decomposition) °C
Ignition Temperature Not applicable - non-combustible °C
Sound Transmission Class (STC) 35-45 STC
Noise Reduction Coeff. (NRC) 0.3-0.7 NRC
Optical
Light Transmittance 0% %
Light Reflectance (LRV) 60-80% (surface dependent) %
Foam concrete developed in 1920s Sweden. Widespread adoption in Europe 1980s for insulation applications. Australian use primarily from 2000s, initially for mine void filling, expanding to construction applications. Recent advances in foam stability and admixtures enabling lower densities (<500 kg/m³) with maintained structural integrity. Growing interest for sustainable construction and thermal performance requirements under NCC energy efficiency provisions.
SAFETY, ECOLOGY & INSTALLATION MIN-CEM-CC-012
Flame Spread Index 0
Smoke Developed Index 0-1
Combustibility Class Non-combustible
Ignition Temperature Not applicable - non-combustible °C
Fire Resistance Rating 60-240 minutes (thickness dependent) hours
Heat Release Rate 0 kW/m² kW/m²
Toxicity of Combustion None - non-combustible
Embodied Carbon (A1-A3) 120-250 kg CO₂e/m³ kgCO₂e/kg
Embodied Energy 800-1500 MJ/m³ MJ/kg
Water Footprint 200-400 L/m³ L/kg
EPD Available No
LEED Points 2-4 points (thermal, recycled content)
VOC Emissions <50 μg/m³ g/L
Skill Level Specialist contractor
Crew Size 3-5 persons
Installation Time 100-300 m³/day hr/m²
Curing Time 7 days (70% strength), 28 days (full) hours
Setting Time 4-8 hours initial, 24 hours final min
Temperature Range 5-35°C during placement °C
Humidity Range Any - protect from rain %
Required Tools
Foam generator equipmentConcrete pumpMixing equipmentDensity testing kitFlow coneThickness gauges
Certifications Required
Concrete pumping licenceFoam concrete training
Weather Limitations
Min 5°CMax 35°CProtect from rain 24hrs
COMMERCIAL, LOGISTICS & REGULATORY MIN-CEM-CC-012
Material Cost $80-150/m³
Installation Cost $50-100/m³
Annual Maintenance $0.50-2/m²
Lifecycle Cost (50yr) $200-400/m³ over 50 years
Market Availability Specialised - major cities
Lead Time 2-7 days (on-site production) weeks
Design Life 50+ years (protected) years
Warranty Period 10-15 years typical years
Maintenance Interval 5-10 years (surface treatment) months
Service Temp Range -30°C to +100°C °C
Freeze/Thaw Resistance 25-50 cycles (requires additives)
Dimensional Stability Shrinkage 0.1-0.3%
Certifications Held
AS/NZS ISO 9001Potential Green Star creditsLow VOC emissions
Fire Code Compliance
AS 1530.1 - Non-combustibleAS 1530.3 - Indices 0/0/0/0-1
Standards Compliance
NCC 2022 (via AS 3600)BCA thermal requirementsASTM C869 (foaming agents)ASTM C796 (foam concrete)ASTM C495 (compressive strength)ISO 9229 (thermal insulation vocabulary)EN 14063 (thermal insulating materials)
DISCLAIMER: This specification document is generated from the CLAD Materials Atlas Database. Information is for general guidance only and does not constitute professional engineering advice. Values are typical and may vary by batch, manufacturer, and production run. Verify suitability for specific project applications independently.