Lightweight concrete has a history of more than two-thousand years and its technical development is still proceeding. This review starts with a retrospective that gives an idea of the wide range of applications covered by lightweight concrete during the last century. Although lightweight concrete is well known and has proven its technical potential in a wide range of applications over the past decades, there are still hesitations and uncertainties in practice. For that reason, lightweight aggregate properties and the various types of lightweight concrete are discussed in detail with a special focus on current standards. The review is based on a background of 25 years of practical and theoretical experience in this field. One of the main challenges in designing lightweight concrete is to adapt most of design, production and execution rules since they often deviate from normal weight concrete. Therefore, aspects are highlighted that often are the cause of misunderstandings, such as nomenclature or the informational value of certain tests. Frequently occurring problems regarding the mix design and production of lightweight concrete are addressed and the unintended consequences are described. A critical view is provided on some information given in existing European concrete standards regarding the mechanical properties of structural lightweight concrete. Finally, the latest stage of development of very light lightweight concretes is presented. Infra-lightweight concrete is introduced as an innovative approach for further extending the range of applications of lightweight concrete by providing background knowledge and experiences from case records.

This study presents a novel construction method for prefabricated wall elements by integrating a framework made of thin-walled sheet steel profiles into an optimized thermally insulating lightweight aggregate concrete (LAC) building envelope. The load-bearing function of the framework is provided by cold-formed Sigma-profiles, which are spot-welded to non-load-bearing U-profiles at the vertical ends. The LAC shapes the wall and stabilizes the thin-walled steel profiles against buckling, but has no further load-bearing function, thus allowing the reduction of its necessary compressive strength and subsequently minimizing its density. As a result, the LAC exhibits strength and density values well beyond existing standards, providing highly competitive thermal conductivity values that meet today’s energy requirements without the need for additional insulation materials. Tailored composite specimens verify the stabilization of load-bearing sheet steel profiles by the LAC, which not only prevents buckling but also increases the load-bearing capacity of the overall system. The feasibility of this approach is validated by the production of two prototypes, each comprising a full-sized wall, in two different precast plants using distinct process technologies.