Autoclaved Lightweight Concrete Panels for Stronger, Smarter, Sustainable Builds

ALC panels excel in both hot and cold climates due to their thermal mass and insulation. In winter, they help retain indoor heat, reducing heating demand. In summer, the thermal mass slows heat transfer, keeping interiors cooler and cutting HVAC loads significantly. With R-values ranging from R 0.95–1.25 per inch, an 8” ALC wall performs similarly to a wood stud wall with R-20 batt insulation when accounting for mass effects. This makes Caldera Panels ideal for Canadian regions with wide seasonal temperature swings, helping buildings remain energy-efficient year-round.

Yes. One of the most significant advantages of Caldera Panels is their multi-hour fire resistance. Being non-combustible and inorganic, ALC does not produce toxic gases under high heat and maintains its structural integrity far longer than traditional materials. Depending on panel thickness and assembly, fire resistance can reach up to 4 hours, meeting or exceeding most commercial and residential fire code requirements. This makes ALC an ideal choice for multi-storey buildings, firewalls, and high-occupancy structures where safety is paramount.

Cost savings with ALC come from several areas:

• Faster Installation: Panels are pre-manufactured and arrive on site ready to install, reducing labor hours.

• Elimination of Wet Trades: No need for masonry or plastering drastically shortens construction timelines.

• Lighter Weight: ALC reduces foundation and framing requirements, cutting structural costs.

• Energy Efficiency: The built-in insulation helps reduce operational energy costs over the building’s lifetime.
  When these factors are combined, projects often see not only lower upfront costs but better lifecycle value compared to conventional methods.

Yes. Caldera Panels can serve as exterior wall systems, interior partitions, floor slabs, roof panels, and decorative cladding. While they are typically used as non-load-bearing infill or curtain wall elements, they can be structurally integrated in certain configurations when designed accordingly. Their steel reinforcement and panel strength make them suitable for a wide range of architectural and structural applications, from residential homes to high-rise commercial projects.

For architects, Caldera Panels offer greater design flexibility with large-span panels that reduce the need for interior load-bearing walls. This increases usable floor area by up to 6% and allows for open layouts without compromising performance. For engineers, the panels’ predictable performance values (R/RSI, fire ratings, weight) simplify modeling for code compliance and energy efficiency, particularly within Canadian standards. This clarity reduces guesswork, streamlines approvals, and speeds up the overall design process.

ALC panels are made from durable silicate materials that do not corrode, rot, or degrade over time. They are resistant to weathering, pests, and freeze-thaw cycles. With proper detailing and finishing, their service life matches or exceeds that of traditional concrete structures, often lasting several decades with minimal maintenance. Because panels are factory-produced, quality is consistent, and any required maintenance typically involves surface finishes rather than the panels themselves.

Yes. Caldera Panels are certified as new wall materials by multiple municipal authorities and are recognized for their contribution to low-carbon construction. Manufacturing requires less energy than traditional concrete production, and their lightweight design reduces embodied carbon by minimizing structural demands. Additionally, their long service life and high thermal efficiency contribute to lower operational energy use, making them a strong fit for green building certifications such as LEED and Step Code compliance in Canada.

Installation is typically carried out using mechanical lifting equipment and standardized connection details, which ensures precision and speed. Panels are anchored to steel or concrete framing using hook bolts, angle steel, and sealing methods designed for airtight and watertight performance. Because panels are manufactured to exact dimensions, on-site cutting is minimized. This approach leads to cleaner worksites, shorter schedules, and reduced reliance on specialized trades—ideal for both new construction and retrofits.

Yes. Caldera Panels are excellent for retrofits and additions where weight, speed, and thermal performance are critical. Their lightweight structure allows them to be added to existing frames without significant reinforcement, and their thin profile with high R-values enables envelope upgrades without major loss of interior space. This makes them particularly suitable for energy retrofits, seismic upgrades, and commercial façade modernizations where minimizing downtime and preserving usable space are priorities.