CarbonCast: advanced insulated wall panels for durable and efficient structures

Looking for lightweight, highly insulated and structurally superior wall panels? CarbonCast is the answer.

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CarbonCast

CarbonCast at a glance.

CarbonCast are insulated sandwich panels and wall panels with carbon fiber grid or carbon fiber grid. They consist of two concrete layers (wythes) separated by continuous insulation. Between the layers, the grid provides full structural composite effect. The result: our sandwich panels are up to 75 percent lighter than standard concrete and achieve an insulation value of up to R-37. At the same time, you retain all the familiar benefits of concrete, such as excellent fire resistance and superior sound attenuation.

Technical basis: carbon fiber grid

CarbonCast wall panels use carbon fiber grid, a cross arrangement of resin-bonded carbon fibers that serves as a sliding connector.

Characteristics carbon fiber grid:

  • Resin bound

  • Epoxy coated

  • Non-corrosive (no corrosive effect)

  • Partition walls in industrial buildings

  • Non-thermal conductive

These properties provide a durable, inert joint that permanently retains its strength even in aggressive environments.

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Thermal and acoustic insulation

CarbonCast sandwich panels are fully thermally broken. The continuous insulation layer eliminates thermal bridges and provides:

  • Superior insulation values up to R-37, depending on panel thickness and foam insulation

  • Energy savings in heating and cooling, contributing to lower operating costs

  • Acoustic damping, as sound is barely transmitted

This combination creates a constant and comfortable indoor climate, free from cold and noise intrusion.

Did you know…

…CarbonCast sandwich panels are up to 75% lighter than standard sandwich panels: they use less concrete and more insulating foam to reduce energy consumption and make the panels lighter.

Finish and design freedom

Architectural flexibility is at the heart of CarbonCast. Choose from hundreds of pigments, aggregates, textures, surface treatments, etc. and integrated finishes to realize virtually any design.

Finishes of the panels

Finishes sandwich panels:

  • Colored concrete

  • Washed-out concrete

  • (Colored) blasted concrete

  • Polished concrete

  • Decorative concrete

  • Integrated finishes such as thin brick strips, medallions and tiles

  • Textured mats and stone strips for added texture

Finishes CarbonCast panels:

  • Smooth

  • Blasted

  • Inset

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Durability and structural composite workmanship

CarbonCast not only offers a favorable carbon footprint, but also delivers excellent wear performance:

  • Full structural composite action: a panel with 10 cm of insulation between two 6 cm concrete shells behaves structurally as if it were a solid 22 cm panel.

  • Dry, mold-free and non-combustible due to absence of voids and the inherent fire resistance of concrete.

  • Proven technology with more than 1 000 000 m² applied in international projects.

By combining lightweight construction, continuous insulation and corrosion-free carbon fiber grid, you are betting on a future-proof façade solution with minimal lifecycle costs.