Keeping the Look of Cast Concrete Without the Weight
One of our clients approached us seeking a heavy-duty concrete look specifically, a finish that resembled cast concrete wall panels. After a brief consultation, we understood their vision and recommended using Modcon Lightweight Concrete (MLC).
MLC proved to be the perfect solution. It delivered the aesthetic of shuttered concrete, capturing the raw, industrial look they wanted, but with none of the challenges of handling traditional precast panels.
The lightweight nature of MLC meant that a single person could lift and position a panel with ease. Better still, installation required no heavy machinery and caused no disruption to the finished floors making it ideal for office fit-outs or interior refurbishments.
The end result? A beautifully executed concrete look that combines design impact with practical efficiency.
Introduction
Developed in 1999, MLC (Modcon Lightweight Concrete) is a polymer-modified, fibre-reinforced cementitious composite. It combines the strength and durability of concrete with the advantages of lightweight construction. Over time, MLC gains strength through exposure to moisture and environmental conditions, making it ideal for both interior and exterior applications.
MLC has been widely used in iconic South African developments such as Montecasino, Gold Reef City, and Emperors Palace, among many others.
Key Benefits
- Lightweight with high impact resistance
- Excellent fire performance
- When installing in high areas, no need for heavy machinery and scaffolding
- less labour needed for installation
- Strong dimensional stability
- Easy to machine and finish
- Non-toxic and UV-stable
- Can be painted, sealed, or left raw
- Comparable strength to traditional concrete with reduced weight
- Big advantage being fully waterproof
- Can be used for signage, which makes it look like Concrete and cladding
Weathering and UV Performance
MLC is unaffected by UV exposure. However, some external finishes may fade due to high pigment concentration. For best long-term results, we recommend using integrated MLC-compatible additives such as granules, pigments, or metal effects. External sealers are optional, not required.
Material Characteristics
| Property | Description |
| Appearance | Natural grey finish |
| Compressive Strength | >30 MPa |
| Flammability Rating | SABS 0177 Part 3 – Class 1 (Not formally tested) |
| Dimensional Stability | <0.5% shrinkage on cure |
| Working Temperature Range | -10°C to 150°C |
| Fire Resistance | Non-flammable; testing pending with CSIR |
| Impact Resistance | Charpy Impact ~30kJ/m² |
| Hail Resistance | 6–8 mm laminate withstands standard 10-year hail tests |
Chemical Resistance
| Substance Type | Resistance Level |
| Alkalis & Acids | Excellent |
| Solvents & Hydrocarbons | Not recommended |
| Water & Saltwater (non-immersed) | Good |
| Immersion in Water | Fair – sealer recommended |
Fixing & Installation
- MLC products can be fixed using traditional or bracketed systems.
- Consultation with a structural engineer is recommended for large elements.
Trademark & Disclaimer
MODCON can assist with technical advice or professional referrals.
MODCON is a registered trademark (2004/09270).
All data and recommendations provided are based on internal testing and believed to be accurate. End users are responsible for determining product suitability for their specific application. MODCON assumes no liability for use beyond standard specifications.
