CLC Lightweight Concrete
Cellular Lightweight Concrete (CLC) engineered for structural roof screeds, void filling, and acoustic/thermal floor leveling in Dubai. Precise density control from 600 to 1200 kg/m³.
Cellular Lightweight Concrete (CLC) Engineering
Cellular Lightweight Concrete (CLC) is a versatile cement-based material engineered by introducing a uniform matrix of micro-sized air cells into a cement-sand slurry. Unlike autoclaved aerated concrete (AAC) which requires high-pressure steam autoclaves, CLC is produced cast-in-situ at the jobsite using automated continuous foaming generators and pumped directly into place.
IZOMATE delivers engineered CLC formulations across Dubai, Sharjah, and Abu Dhabi for applications requiring moderate compressive strength combined with ultra-low density, excellent acoustic dampening, and exceptional thermal insulation.
Applications Across UAE Projects
- High-Rise Floor Leveling: Lightweight underlayment beneath parquet, marble, and ceramic tiles that provides acoustic dampening between floors.
- Sub-Floor Trench & Void Filling: Encapsulating plumbing pipes, HVAC ducts, and electrical conduits without adding excessive structural dead load.
- Roof Screed Substrates: Heavy-duty slope creation for roofs requiring higher point-load resistance under mechanical chiller platforms.
Structural Performance & Compressive Strength Ranges of CLC
Cellular Lightweight Concrete (CLC) spans the technical threshold between pure thermal insulation foams and standard structural concrete. By incorporating graded fine silica sand (0.1mm to 0.6mm) or pozzolanic micro-silica into the cellular cement matrix, CLC achieves high compressive strengths (3.0 to 7.5 N/mm²) while maintaining dry densities between 600 kg/m³ and 1200 kg/m³—less than half the weight of normal concrete (2,400 kg/m³).
This unique balance of structural strength and low dead-weight makes CLC the ideal material for high-rise residential towers and commercial developments in Dubai, where structural engineers seek to minimize seismic inertia loads and reduce column dimensions.
Acoustic Sound Transmission & Thermal Insulation
In addition to weight reduction, CLC delivers exceptional acoustic sound attenuation between building levels. The billions of non-interconnected microscopic air pockets disrupt airborne sound waves and foot-impact vibrations, achieving Sound Transmission Class (STC) ratings exceeding 48 dB when used as a sub-floor leveling screed beneath ceramic, marble, or parquet finishes.
Comprehensive Applications Across UAE Building Projects
- Inter-Floor Leveling Screeds: Encapsulates electrical conduits, HVAC drainage lines, and plumbing pipes without creating acoustic flanking paths.
- Subterranean Void & Trench Filling: Filling abandoned pipelines, basement sinkholes, and perimeter retaining wall trenches with zero settlement.
- Composite Decking Underlayment: Poured over profiled corrugated steel decking in mezzanine floors and commercial warehouses.
- Precast Wall Core Insulation: Cast as lightweight insulating cores inside sandwich architectural precast concrete panels.
Precision Quality Control & Density Testing Protocols
Because Cellular Lightweight Concrete relies on stable microscopic air cells, quality control during batching and placement is paramount. Ambient temperatures in the UAE exceeding 40°C can destabilize inferior organic foams, causing air bubble coalescence and density stratification where heavy cement settles to the bottom and foam rises to the top.
IZOMATE utilizes advanced protein-based foaming agents reinforced with synthetic stabilizing polymers that resist high-temperature bubble collapse. On every placement shift, site quality control technicians measure the wet density of the pumped slurry using calibrated steel mud balances. Test cylinders (150x300mm) are cast and water-cured per ASTM C495 to verify 7-day and 28-day dry density, compressive strength, and thermal conductivity before issuing structural signoff.
Mezzanine & Structural Steel Floor Leveling Applications
In modern commercial interiors, retail centers, and logistics offices, mezzanine floors constructed with corrugated galvanized steel decking require smooth, level floor screeds prior to installing luxury vinyl tiles (LVT), raised access floors, or carpet. Standard concrete is too heavy for lightweight steel joists, while timber underlayments present fire hazards. Poured CLC provides a lightweight, non-combustible (Class A1 fire rating), ultra-flat leveling screed that bonds seamlessly to profiled steel decking while dampening footfall impact noise.
Multi-Layer Application Detail
Continuous, monolithic barrier applied stage-by-stage with flood test verification.
Substrate Cleaning & Level Survey
Base concrete slab vacuum cleaned and survey datum marks established.
Bonding Agent Application
Polymer bonding slurry applied to ensure interlock with structural concrete.
CLC Automated Continuous Mixing & Pumping
Controlled proportioning of cement, fine fly-ash/sand, and pressurized pre-foam.
Surface Screeding & Curing
Troweled to level tolerance and cured with water mist or curing compound.
System Specifications & Standards
Verified physical and performance parameters per official manufacturer technical data sheets (TDS).
| Property / Parameter | Technical Value | Unit | Standard / Method |
|---|---|---|---|
| Density Range | 600 - 1200 | kg/m³ | ASTM C495 |
| Compressive Strength | 3.0 - 7.5 | N/mm² | ASTM C495 |
| Thermal Conductivity (λ) | 0.14 - 0.22 | W/m·K | ASTM C177 |
| Fire Resistance | 4 Hours Non-Combustible | Rating | BS 476 Part 20 |
| Drying Shrinkage | < 0.08 | % | ASTM C157 |
From first visit to warranty
Inspect
Site visit, moisture and surface checks, photos.
Propose
System, layer build-up, price per m² and programme.
Install
Trained crew, stage-by-stage checks, flood test.
Hand over
Completion report and written warranty.
12 to 17 Years System Warranty
Every completed project includes a signed handover certificate, inspection log, and written warranty backed by manufacturer technical data.
Frequently Asked Questions
Answers to common questions regarding specifications, installation timeline, and preparation.
What is the difference between CLC and Foam Concrete?
CLC (Cellular Lightweight Concrete) is generally engineered at higher density ranges (600–1200 kg/m³) incorporating fine sand or pozzolanic micro-fillers, delivering higher compressive strength (3–7.5 MPa) for floor underlayments and structural void filling. Foam concrete typically refers to lower density screeds (400–600 kg/m³) focused primarily on insulation and roof slopes.
Is CLC suitable for floor leveling between apartment units?
Yes. CLC provides an ideal acoustic sound-insulating and thermal leveling screed for multi-story residential towers, effortlessly encapsulating electrical conduits and plumbing lines without structural overload.
What tools are used to level CLC lightweight concrete on job sites?
CLC is placed using high-pressure progressive cavity pumps and leveled with laser screed bars and lightweight aluminum straightedges. It self-levels smoothly, requiring minimal hand troweling to achieve Level 4 floor flatness.
How does CLC compare to Autoclaved Aerated Concrete (AAC)?
AAC requires precast manufacturing in autoclaves under steam pressure, limiting it to blocks and preformed panels. CLC is mixed and poured cast-in-situ directly at the jobsite, adapting seamlessly to irregular floor geometries and conduit layouts.