Aerofill. What is it?

Aerofill is a composite material that combines 100% recycled EPS, cement and an advanced binder to create a lightweight, high-performance insulating screed and void filler. Aerofill is ideal for projects that require superior thermal efficiency, reduced carbon impact and enhanced structural integrity.

“Aerofill uses a polymer-modified binder that boosts the performance of EPS-based insulation. Developed in-house, this binder enhances binding strength, durability and environmental resistance while reducing the need for cement. The result is a high-performance, sustainable insulation solution that minimizes carbon emissions and supports green building standards.”
— Wouter - Director

  • The polystyrene in Aerofill is 100% recycled, making it an eco-friendly aggregate that significantly reduces the material’s weight while enhancing its insulating properties. As a key component, EPS provides superior thermal performance and helps lower the carbon footprint, contributing to a more sustainable construction solution.


  • The binder in Aerofill is a cutting-edge component designed to enhance the cohesion between EPS and cement. It improves the workability, boosts insulation properties and reduces the overall cement usage, resulting in a more sustainable, lightweight and high-performance material. This innovative binder sets Aerofill apart, delivering exceptional thermal efficiency and environmental benefits.

  • The cement in Aerofill plays a crucial role in enhancing its structural integrity and durability. By optimizing the cement content, Aerofill achieves the perfect balance between strength and thermal insulation, while significantly reducing the carbon footprint compared to traditional cement-heavy solutions. This thoughtful composition ensures long-lasting performance with minimal environmental impact.

Polybinder

Aerofill’s polymer-modified binder is a cutting-edge innovation specifically engineered to enhance the performance of EPS-based insulation systems.

Developed through extensive research, this binder combined advanced polymers with traditional binders to deliver superior binding strength, flexibility and resistance to environmental factors such as moisture and temperature fluctuations.

Key features of our Polybinder include:

  • Enhanced binding strength: The unique polymer formulation increases adhesion between EPS particles, ensuring greater structural integrity and reduction of the need for additional cement.

  • Durability and flexibility: Unlike traditional binders, the polymer-modified version offers enhanced elasticity, allowing it to better withstand stresses from thermal expansion and contraction over time.

  • Eco-friendly: By reducing the reliance on cement, this binder contributes to a lower carbon footprint and supports sustainable building practices, making it ideal for projects that prioritize green building standards.

  • Thermal and compressive performance: When combined with EPS, the binder significantly improves the overall thermal insulation properties and ensures the required compressive strength for various construction applications including under-slab insulation and lightweight bulk fill.

Sustainability

Made from 100% recycled EPS, Aerofill promotes circular economy by repurposing materials that would otherwise end up in landfills.

Low Carbon

With up to 50% less cement usage, Aerofill reduces CO2 emissions, making it a truly eco-friendly alternative to traditional cementitious products.

Thermal efficiency

Aerofill offers exceptional thermal insulation, minimizing heat transfer and significantly improving energy efficiency.

Lightweight

Aerofill’s composition makes it much lighter than traditional materials, reducing installation cost and labor time.

Key features

Versatile

Aerofill is suitable for a wide range of applications, including under-slab insulation flat roofs and void filling in civil engineering projects.

Compliance

Aerofill meets Australian building standards for thermal efficiency and environmental impact, ensuring it’s suitable for both residential and commercial projects.