Dufaylite Clayboard in construction
Construction site using Dufaylite Clayboard

Just how strong is Dufaylite Clayboard in construction?


Clayboard is our revolutionary void former for concrete foundation construction. It’s 30% smaller than the polystyrene alternatives and requires significantly less ground work to prepare for foundations than the traditional beam and block method. But just how strong is it in construction?

Well, each square meter of Dufaylite Clayboard can support up to 90 tonnes (90,000kg). That’s a lot of weight. But why is Clayboard more effective than other void-forming alternatives?

Clayboard is lightweight

The most important benefit here is that, because it’s made out of paper honeycomb, Clayboard can be up to 30% thinner than polystyrene blocks. This means that you could not only save days of digging and ground prep time through not having to dig an extra 30% deeper but save an extra 30% in landfill taxes. 

Not to mention that you save on transport costs as you can get 30% more material in a shipment for the same job than you otherwise could.

Clayboard is sustainable

Then there’s the issue of sustainability. Using polystyrene as a void former doesn’t really form voids – polystyrene doesn’t biodegrade, so it’s like landfill under foundations. As a result, it stays underneath the poured concrete and has a much greater chance of exerting force on foundations in the event of ground movement.

With Clayboard, however, the void formed is a true void. It’s rigid and strong while dry, so is able to hold up the concrete foundation while it’s setting, but then quickly degrades when you add water through the voidpack pipes. Crucially, because it then has no strength, ground shift doesn’t affect the slabs above – so you’re able to have thinner slabs with less reinforcement steel.

This leaves a true void that is able to account for any ground shift while not introducing more non-biodegradable materials than necessary into the soil beneath a construction. Over time, the paper and water are absorbed naturally back into the soil – a more sustainable solution from start to finish.

Clayboard is effective

So let’s say that you’re on board with not wanting to put unnecessary plastics into the soil. You can use the beam and block method. It’ll work, but you’re then having to dig significantly deeper in preparation for your foundation laying. Not to mention that it takes a huge amount of time and resources to prefabricate the concrete beams, transport them, and be able to store them on-site if projects are held up at all.

We firmly believe that our Clayboard is the best solution for all of these problems of foundation laying. And we have accreditation to back us up.

Fewer deliveries, less storage space taken up on site, less prep work, and a more effective material all add up to make significant savings on builds while producing a significantly higher build quality.

If you have any questions about using Clayboard in construction, let’s talk!

18 December 2020

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