Concrete products that are lighter weight are both easier to install and cheaper to create. If these products can be created without substantial loss to strength or longevity, then there is no reason not to use a concrete additive in all of your projects.
That’s what you get with CityMix.
CityMix provides an innovative lightweight aggregate made from recycled expanded polystyrene (EPS) foam. Designed for use in cement-based mixtures, this product replaces heavy natural aggregates such as sand and gravel, significantly reducing the overall weight of the concrete while maintaining strength and durability. It offers a balance of performance, sustainability, and practicality for a wide range of modern construction applications.
Material Description and Technology
CityMix aggregate consists of individual EPS particles that are fully encapsulated in a proprietary coating. This coating enables strong bonding with cement paste and eliminates the static and handling issues common with untreated EPS. The result is a lightweight, concrete-compatible aggregate that can be integrated directly into existing production processes.
Key material attributes include:
- Bulk unit weight of approximately 2.5 to 3.0 lb/ft³
- Uniform dispersion and bonding throughout the concrete matrix
- Ability to replace traditional aggregates by volume, not by weight
- Improved freeze-thaw resistance, flexural strength, and crack resistance
- Made from approximately 99% recycled EPS material
CityMix is well suited for applications where weight reduction offers performance or handling advantages. These include architectural, decorative, and precast concrete products, as well as retrofit or multi-story construction projects where structural load limits are a concern.
Common applications include:
- Architectural precast panels and façade components
- Veneer stone and thin cast stone products
- Lightweight flooring and underlayment systems
- Decorative concrete and cement-based claddings
- Cement boards, stucco, and other lightweight building materials
There are very few limitations, as this aggregate can even be used in foundation to make installation easier and more cost effective.
Benefits for Manufacturers and Designers
CityMix supports both design flexibility and efficient production. By reducing the weight of concrete products without compromising appearance or integrity, it offers measurable benefits to manufacturers, contractors, and architects.
- Reduced Structural Load – Lighter products ease structural design requirements and reduce framing needs.
- Simplified Handling and Installation – Components can be transported and installed more easily, saving time and labor.
- Design Versatility – Compatible with custom molds and complex shapes, enabling a wide range of aesthetic possibilities.
- Sustainability – Manufactured using nearly 100% recycled EPS waste, reducing landfill waste and reliance on mined aggregates.
- Enhanced Performance – Improved resistance to cracking, freeze-thaw damage, and thermal cycling for longer product life.
When substituting CityMix for natural aggregate, mix design adjustments are necessary. The material must be measured by volume rather than weight to ensure consistent results. Manufacturers should also test performance metrics such as compressive strength, density, and bonding to confirm that the mix meets the project’s specific requirements.
The degree of substitution will depend on the intended application. Structural concrete may require a partial replacement to maintain compressive strength, while non-structural or architectural products can utilize a higher percentage for maximum weight savings.
Overall, CityMix represents a major advancement in lightweight concrete technology. By combining recycled EPS with a proprietary bonding system, it delivers a stable, high-performance aggregate that meets the needs of modern construction without the drawbacks of heavy natural stone or gravel. It provides designers and manufacturers with the flexibility to reduce dead load, simplify installation, and achieve sustainable outcomes — all while maintaining the visual and functional quality of traditional concrete.