Lightweight and Sustainable Construction with Concrete (2025-12)¶

This article provides an overview of technologies developed at the Institute for Lightweight Structures and Conceptual Design (ILEK) in the field of lightweight concrete construction. It focuses on two research approaches: mesogradation of concrete components by means of mineral hollow bodies and zero-waste fabrication of geometrically complex concrete structures using recyclable sand formworks. Both processes allow for targeted optimisation of components, thereby reducing weight and enabling the implementation of circular production methods. The integration of digital design and manufacturing processes is crucial to this. Solutions to the challenges of technology transfer into practice are demonstrated using three full-scale (1:1) prototypes. Hereby, the entire process chain, from design and structural analysis to manufacturing and implementation, is considered. The demonstrators show how technology transfer can be successfully implemented and illustrate the potential of digital tools in promoting lightweight and sustainable concrete construction.