Ecosphere technology for manufacture of infra-
lightweight concrete
Concrete meets glass technology: The Maxit Group (Azendorf) is setting new standards with a special product innovation in the concrete industry. The Group has succeeded in transferring the award-winning Ecosphere technology – based on the use of hollow glass microspheres as aggregate – to concrete. The result is a new infra-lightweight concrete which, in addition to high compressive strength, possesses very low thermal conductance and can therefore fulfill both loadbearing and insulating functions for monolithic walls. “Simple and robust wall constructions with low maintenance costs in fair-faced concrete quality can now be implemented,” explains Johannes Eberlein, Head of Product Management at Maxit. Both for residential buildings and commercial structures: this infra-lightweight concrete, is suitable as a pumpable and mechanically stable mix, for production of concrete components of any kind in automated in-plant processes.
Concrete is known as a highly versatile construction material that is available in a wide range of variations – depending on the requirements that must be satisfied. Lightweight concrete, for example, has relatively low density and therefore provides good thermal protection. The reason for this is the high proportion of air entrainment that provides the concrete mass with a porous structure. The Maxit Group is now taking one step further by bringing new infra-lightweight concrete to the market.
This concrete is based on award-winning Ecosphere technology, which features a binder-system technology with microscopically small hollow-glass microspheres (HGMs) as lightweight aggregate. This technology was used for the first time for manufacture of the mineral spray insulation of the same name, with which Maxit, in 2029, revolutionized the inner and outer insulation of masonry. For this innovation, the developers were nominated for the 2020 German Future Prize – the German “Oscar for Tinkerers.” These developers were additionally distinguished with several specialist prizes, such as the “Architects’ Darling Award” in gold. “Then we were able to apply the successful Ecosphere technology to the manufacture of highly effective insulation in the form of infra-lightweight concrete. In this way, high-tech construction material was created, which combines the potential of weight with the advantages of lightness,” explains Johannes Eberlein.
Concrete with a glass bonus
Its development was not an easy task. In the search for a suitable lightweight filler for optimizing the existing binder system, the microscopically small hollow glass spheres, however, were entirely convincing. They provide the infra-lightweight concrete with closed porosity and enable dense, low-maintenance surfaces as well as high thermal protection. The mechanical stability and pumpability of the mix are ensured thanks to the enormous strength of the hollow glass spheres – to the benefit of uniform quality and high reproducibility.
At its low dry density, from 500 to just under 800 kg/m3,infra- lightweight concrete moreover differs from the lightweight concretes as defined in DIN EN 206, whose dry densities range from 800 kg/m3 to 2, 00 kg/m3 . And, not least, it demonstrates reduced cracking and shrinkage behavior, ensures high fire protection and is frost-resistant.
Versatile and ecological
With immediate effect, the Maxit Group makes available three new infra-lightweight concrete product lines for in-plant prefabrication. The first line, called Maxit Ecomold ILB, serves for manufacture of thermally insulating sandwich elements for monolithic residential buildings. For these applications, the infra-lightweight concrete is designed for structural use in loadbearing and insulating function. With the pumpable Maxit Ecoflow ILB, mechanical production of concrete elements of any type can be implemented if these are intended to have low weight and high thermal insulation. Maxit Ecoprint ILB, on the other hand, was developed for erection of individual objects with 3D printing processes. These applications clearly demonstrate multiple areas of utilization. Such uses allow adjustment of the various densities and strength classes as well as the degrees of flowability and stability in the respective systems.
The erection of energy-efficient buildings is not the only contribution of infra-lightweight concrete from Maxit to the environment. Its low weight optimizes the eco-balance both during production and during transport of the construction material. Since, thanks to the new aggregate, less scarce construction sand must be added, and valuable resources can be preserved. Mix that is not completely used can be stored in silos. No segregation is required. The purely mineral material can be completely recycled. “Currently, we are planning to erect a complete building with infra-lightweight concrete and will soon be able to prove its efficiency with data from practice,” says Eberlein.
These three new infra-lightweight product lines were for the first time presented to the trade world at the leading trade fair BAU 2025 (13 to 17 January) in Munich. Further details on the new monolithic fair-faced concrete solution are available to the interested trade directly from the manufacturer.
