This document provides a technical seminar report on the use of expanded polystyrene technology in construction. It begins with an abstract that discusses how construction techniques have improved over time to use lighter materials and faster construction methods. One such technique is the use of expanded polystyrene (EPS) in construction, which provides benefits like less weight, cost effectiveness, faster construction, insulation, and more sustainable use of resources. The document then provides a table of contents and list of figures before diving into chapters that discuss EPS properties, applications, installation methodology, case studies, and conclusions.

1. A TECHNICAL SEMINAR REPORT
ON
EXPANDED POLYSTRENE
TECHNOLOGY IN CONSTRUCTION
ABSTRACT
With increase in demand for construction materials, man has improved a lot in
construction techniques of structures. In earlier ages structures were constructed
with heavy materials and followed conventional materials and methods which were
time consuming, costly and maintenance would be more. But this modern era is
following the latest techniques in construction which have lot of advantages so the
use of light weight materials and faster construction has been are started. Thus one
of latest techniques being adopted at present is use of Expanded polystyrene
(Thermocol) in construction of walls, slabs etc., i.e used for non structural
elements which imparts less weight, economic , faster construction , acts as
insulator and by which results in a sustainable future as the resources can be saved
to some extent.
iii

2. iv

3. CONTENTS
CHAPTER TITLE PAGE NO
Certificate i
Acknowledgement ii
Declaration iii
Abstract iv
Contents v
List of figures vii
CHAPTER 1 INTRODUCTION 1-5
1.1 General 1
1.2 About Expanded Poly Styrene (EPS) 2
1.3 Raw Materials of EPS 3
1.4 EPS Manufacturing Process 3
1.5 EPS Storage 5
CHAPTER 2 LITERATURE REVIEW 6-10
2.1 Thermal behaviour and admissible compressive strength of 6
Expanded Polystyrene of varying thickness
2.2 A comparative study on of construction using Schnell concrete wall 6
Pre-cast sandwich composite panel & RC moment frame with brick
infill
2.3 Use of advance plastic materials in Nigeria performance assessment 7
EPS building technology system
2.4 Light weight expanded polystyrene beads concrete 7
2.5 Radiative properties of EPS foams 8
2.6 Modelling of heat transfer in low density EPS foams 8
2.7 Behaviour of unreinforced EPS light weight concrete (EPS-LWC) 9
Wall panel enhanced with steel fibre
2.8 Environmental, health & safety concerns of decorative mouldings 9
made of EPS in buildings
2.9 Partial replacement of coarse aggregates by EPS beads in concrete 10
2.1
0 Compressive creep test on EPS geo foam 10
METHODOLOGY 11-27
v

4. CHAPTER 3
3.1 Properties of EPS 11
3.2 EPS technical details 15
3.3 EPS Wall insulation & EPS Roofing at Angul, Odisha 17
3.4 Benefits of EPS 18
3.5 Methodology of EPS panels installation for wall 19
3.6 Expanded polystyrene concrete 26
CHAPTER 5 A CASE STUDY 28-29
CHAPTER 4 CONCLUSION 30
REFERENCES 31-32
vi

5. LIST OF FIGURES
Figure No. Title Page No
1.1 Polystyrene Beads 3
1.2 Pre - Expansion of Polystyrene Beads 4
1.3 Manufacturing Process of EPS 5
3.1 Technical details of EPS 15
3.2 Procedure for installation of EPS panels for wall 19
3.3 Electrical drilling machine 19
3.4 Drilled holes in foundation 19
3.5 Erection of EPS panels 20
3.6 Alignment of EPS 20
3.7 EPS slab panel Erection 21
3.8 EPS slab & wall Erection with wire mesh arrangement 22
3.9 Opening of wall panel 22
3.10 Electrical conduiting and plumbing after installation of EPS 23
3.11 Shotcrete Pumping machine 24
3.12 Shotcreting all over the walls 24
3.13 Structure after shotcreting 25
3.14 Finished view of building 25
3.15 EPS concrete 27
3.16 EPS concrete sandwiched between calcium silcate Boards 27
vii

6. CHAPTER 1
INTRODUCTION
1.1 GENERAL
Over the ages, the world has experienced a continuous growth and improvement in
every area of human endeavor and the built environment is not left in the process as
shelter have remained one of the most vital needs of man. The evolution of the built
environment in any nation determines the nature and pace of national development
and the citizen’s quality of life.
Construction materials have evolved over the years till the real breakthroughs in the
construction industries of the 21st century due to the development of versatile, easy to
construct, thermally insulating materials that can be used worldwide to build
sustainable homes. A building material that meets the safety standards (including
seismic resistance) and the dweller‘s comfort requirements must also be thermally
insulating, light weight and in expensive.
As the world‘s population increases, the demand for energy and raw materials is
growing at a greater pace and has led to the greenhouse gas effect that is responsible
to the global climate change. The need for new ecological equilibrium has led to
researches into the embracing of materials that are more environmentally friendly and
this has brought about greater adoption of plastic based materials in the construction
industry. Expanded polystyrene (EPS) represents one of such materials that have
found their way into the previously conservative construction industry.
Also, the world is becoming more concerned about the environment, and measures
are being taken in every nation of the earth to reduce the impact of activities on
environment .For the building and construction industries worldwide, these concerns
are being addressed by the careful choice of building materials, and in particular, the
selection of insulation (EPSASA, 2006). Therefore, the use of environmentally
friendly material such as EPS for new and improved building technology system will
go a long way to enhance the environmental quality.
Plastics are typically polymers of high molecular mass, and may contain other
substances to improve performance and/or reduce production costs. Monomers of
plastic are either natural or synthetic organic compounds. With the proven strengths
of plastic materials, its use in commercial and residential construction has
dramatically increased in the last 30 years due to improved material performance,
efficient use of technologies in new applications, and the need for lightweight, durable
materials for insulating and construction purposes.
1

7. Polystyrene is one of the most widely used plastics, the scale being several billion
kilograms per year. The polystyrene foam is a thermoplastic material obtained by
polymerization of styrene. The use of expanded polystyrene in construction has lot of
advantages compare with the use of conventional materials which results in
sustainable future.
1.2 ABOUT EXPANDED POLYSTRENE
Expanded Polystyrene (EPS) is a lightweight rigid foam material that is made by the
polymerization of styrene, an oil derivative also found naturally in foods such as
strawberries, nuts and beans. The blowing agent employed is pentane which is neither
a CFC nor an HCFC.
EPS is a versatile durable material that offers excellent insulation properties. As the
structure of EPS consists of 98% air its initial thermal properties are maintained
throughout its working life. It can be manufactured in a wide range of shapes and
sizes. It is non- toxic , moisture resistant and rot proof.
EPS is primarily used as an effective thermal insulation material for walls, roofs and
floors in a wide range of buildings. It also used as a packaging material and has
applications avoid-forming fill material in civil engineering projects, as lightweight
fill in road and railway construction, and as flotation material in the construction of
floating pontoons in yachting marinas.
Expanded Polystyrene (Thermocol) offers a non hydroscopic and does not readily
absorb moisture from the atmosphere. Its closed-cell structure reduces absorption
and/or migration of moisture it is odorless, rigid, closed cell Expanded Polystyrene
containing 98% by its volume still air entrapped in its cell and is the major reason for
its excellent insulation properties.
Because of its closed cell structure, it offers a remarkable resistance to unwanted heat,
chill and moisture to penetrate through it and also gives a rigid, structurally strong
product to withstand various kinds of loads and vibrations. It does not decay or age
with the time and gives permanent lifelong insulation without regular maintenance.
Perfect, even and plain surface makes its suitable to opt it for false roofing and easy to
install, carry and plastering on it.
2

8. 1.3 EPS RAW MATERIALS
EPS Resin
The EPS resin in used for the molding of EPS products. It is manufactured in the form
of very small polystyrene beads with a weight – average molecular weight between
160,000 and 260,000 and contains 4 to 7% blowing agent, usually pentanes or butane.
The bead diameter can vary between 0.007 – inches (0.2mm) to 0.11 – inches (3.0
mm).
Fig 1.1 Polystyrene Beads
1.4 EPS MANUFACTURING PROCESS
• 1st Stage Pre-Expansion
The raw material is heated in special machines called pre-expanders with steam at
temperatures of between 80-100°C. The density of the material falls from some
630kg/m3 to values of between 10 and 35kg/m3. During this process of pre-
expansion the raw material’s compact beads turn into cellular plastic beads with
small closed cells that hold air in their interior.
3

9. Fig 1.2 Pre –Expansion of Polystyrene Beads
• 2nd Stage Intermediate Maturing And Stabilization
On cooling, the recently expanded particles from a vacuum in their interior and
this must be compensated for by air diffusion. This process is carried out during
the material’s intermediate maturing in aerated silos. The beads are dried at the
same time. This is how the beads achieve greater mechanical elasticity and
improve expansion capacity — very important in the following transformation
stage.
• 3rd Stage Expansion And Final Moulding
During this stage, the stabilized pre-expanded beads are transported to moulds
where they are again subjected to steam so that the beads bind together. In this
way moulded shapes or large blocks are obtained (that are later sectioned to the
required shape like boards, panels, cylinders etc).
4

10. Fig 1.3 EPS manufacturing process
1.5 EPS STORAGE
Store EPS boards under cover, protected from high winds and out of direct sunlight.
Care should be taken in storage not to bring the boards into contact with highly
flammable materials such as paint, solvent or petroleum products. Smoking should be
prohibited in the storage area and the products must not be exposed to flame or other
ignition source.
5

11. CHAPTER 2
LITERATURE REVIEW
2.1 THERMAL BEHAVIOUR AND ADMISSIBLE COMPRESSIVE
STRENGTH OF EXPANDED POLYSTYRENE WALL PANELS OF
VARYING THICKNESS
Anthony Nkem Ede (Ph.D)
Over the years, clay bricks, concrete hollow blocks and other conventional
construction materials have been in use and they have stood the test of time. However,
in the recent times, modern building materials that conform to the standards of
international regulations, meet up with the basic needs of safety, economy, good
aesthetics and constructability desired for engineered structures and satisfies the
contemporary expectations of sustainability and durability have been introduced to the
construction industry in the more advanced nations. In the developing nations such as
Nigeria such is not the case as the building industry is faced with shortage of
affordable building and the masses have difficulties building houses of their own
because of the excessive costs of building materials such as reinforced concrete and
sand-crate blocks and the high cost of labor. As a way of finding solution to these
housing challenges, this research considers EPS wall panel as a possible substitute to
the conventional concrete-sand crate blocks normally used in Nigeria for walls. This
research seeks to investigate the thermal behaviour and the compression strength of
3-D wall panel with insulation core of polystyrene and concrete shell. The thickness
of the expanded polystyrene and of the concrete shell was varied for this research.
The thermal transmittance and reactance of these various wall panels was obtained
with the aid of a computer program in Microsoft Excel developed according to
ENISO 6946. The results obtained on the admissible axial loads and thermal
resistance demonstrate that the application of this innovative construction system is
feasible and will be a good substitute for traditional concrete hollow blocks that are
predominantly used in Nigeria.
2.2 A COMPARATIVE STUDY OF CONSTRUCTION USING SCHNELL
CONCRETE WALL PRE-CAST SANDWICH COMPOSITE PANEL AND
RC MOMENT FRAME WITH BRICK INFILL
kaira Sneha, T.P.Tezeswi
Developing countries especially those in Asia (India), are facing the challenge
of a growing middle class with greater demand for housing facilities. Faster and more
affordable methods of construction are being sought after it, more than ever before as
the action of emergency response. Increased innovation aimed at reducing the cost of
construction, and creating affordable housing, is being integrated into methods of
building and construction. This has led to introduction of components pre-fabricated
using assembly line methods, in the construction process, which reduces the negative
aspects of in-situ construction such as theft, unreliable supply of labor, unpredictable
6

12. weather conditions, un predected fluctuations in prices of materials and plenty of
energy consumption. A comparative analysis is conducted based on Discrete event
Simulation and Scheduling integration methodology in order to calculate duration of
each activity of construction process by EZ Strobe and determine the resource utility,
productivity of resources for Schnell Concrete wall and RC moment frame with brick
infill construction technologies. This research paper will utilize time study method to
determine the time taken by manpower and equipment to perform each task and show
advances in technology that are making management of productivity, resource utility,
cost, time which are more predictable.
2.3 USE OF ADVANCED PLASTIC MATERIALS IN NIGERIA:
PERFORMANCE ASSESSMENT OF EXPANDED POLYSTYRENE
BUILDING TECHNOLOGY SYSTEM
Anthony Nkem Ede1 (Phd), Valentine Alegiuno and Paul Oluwaseuna woyera, 2015
The provision of affordable residential houses for the masses in the
developing nations has been a mirage over the years and the future does not portend
good as the cost of adopting conventional concrete material technologies is
escalating while so many environmental issues like climate change are being raised
in the recent times. To circumvent this poor housing provision trend, some
innovative construction materials and technologies are being introduced to facilitate
unique modular designs, reduction of labor, decline in the depletion of exhaustible
materials, savings of time and fund. One of such materials is the expanded
polystyrene. The introduction of advanced plastic materials and in particular the
expanded polystyrene building technologies in the Nigerian construction industry
will be a very useful and brilliant initiative that will aid the reduction of cost of
construction and facilitate access to affordable houses for the masses. This research
aims at studying the applications of this innovative plastic material in the Nigerian
building industry with special regard to the performance perception by the clients
and the end users. A building estate where expanded polystyrene building
technology has been predominantly used in Abuja is considered as a case study.
Questionnaires were distributed among clients and residents of the building estate
and statistical tools were used to analyze the data collected. Great satisfaction
verified among the clients and residents and the high ranking performance confirmed
for recyclability, reliability, versatility and moisture resistance of EPS building
products all herald a great future for the applications of this advanced building
products in the Nigerian building industry.
2.4 LIGHT WEIGHT EXPANDED POLYSTYRENE BEADS CONCRETE
Aman Mulla, Amol Shelake, 19 March 2016
With increase in demand for construction materials, man has improved a lot in
construction techniques of structures. In earlier ages structures were constructed with
heavy materials, but in this modern era of construction old techniques are being more
costly due to heavy loading. So the uses of lightweight materials are started. The
7

13. Expanded polystyrene beads are the material which substitutes in the place of coarse
aggregate. The main objective of this investigation is to find a concrete mix
proportion which gives better results than the Burnt Brick (compressive strength and
density), and to study the properties, such as density, compressive strength and
splitting tensile strength of lightweight Expanded Polystyrene (EPS) beads concrete.
Then its properties are compared withM20 grade conventional concrete
2.5 RADIATIVE PROPERTIES OF EXPANDED POLYSTYRENE FOAMS
Coquard Rémi, Baillis Dominique and Quenard Daniel Oct 22, 2008
Expanded polystyrene foams are one of the most widely used materials for a
building’s thermal insulation. Owing to their very low density, a substantial
proportion of the heat transfer is due to thermal radiation propagating through their
porous structure. In order to envisage an optimization of their thermal performances,
an accurate modeling of their radiative behavior is required. However, the previous
studies on this subject used several drastic simplifications regarding their radiative
behavior (optically thick material) or their porous morphology (homogeneous cellular
material, dodecahedral cells). In this study, we propose a more accurate model based
on a detailed representation of their complex morphology allowing us to predict their
entire monochromatic radiative properties. We investigated the influence of the
different structural parameters on these properties. We checked the validity of our
model by comparing the spectral hemispherical reflectance and transmittance
measured on slabs of foam samples with values predicted by our model. A good
accordance was found globally.
2.6 MODELING OF HEAT TRANSFER IN LOW-DENSITY EPS FOAMS
R. Coquard and D. Baillis Nov 04, 2005
ARTICLEREFERENCESFIGURESTABLESCITING ARTICLESExpanded polystyrene (EPS) foams are one of the most widely used thermal
insulators in the building industry. Owing to their very low density, both conductive
and radiative heat transfers are significant. However, only few studies have already
been conducted in the modeling of heat transfer in this kind of medium. This is due to
their complex porous structure characterized by a double-scale porosity which has
always been ignored by the previous works. In this study, we present a model of one-
dimensional steady state heat transfer in these foams based on a numerical resolution
of the radiation-conduction coupling. The modeling of the conductive and radiative
properties of the foams takes into account their structural characteristics such as foam
density or cell diameter and permits us to study the evolution of their equivalent
thermal conductivity with these characteristics. The theoretical results have been
compared to equivalent thermal conductivity measurements made on several EPS
foams using a flux-meter apparatus and show a good agreement.
8

14. 2.7 BEHAVIOUR OF UNREINFORCED EXPANDED POLYSTYRENE
LIGHTWEIGHT CONCRETE (EPS-LWC) WALL PANEL ENHANCED
WITH STEEL FIBRE
Rohana Mamat, Jamilah , June 2015
This study used steel fiber as reinforcement while enhancing the EPS-LWC
strength. In line with architectural demand and ventilation requirement, opening
within wall panel was also taken into account. Experimental tests were conducted for
reinforced and unreinforced EPS-LWC wall panel. Two samples with size of 1500
mm (height) x 1000 mm (length) x 75 mm (thickness) for each group of wall panel
were prepared. Samples in each group had opening size of 600 mm (height) x 400 mm
(length) located at 350 mm and 550 mm from upper end respectively. EPS-LWC wall
panel had fcu of 20.87 N/mm2 and a density of 1900 kg/m3 . The loading capacity,
displacement profiles and crack pattern of each sample was analyzed and discussed.
Unreinforced EPS-LWC enhanced with steel fiber resist almost similar loading as
reinforced EPS-LWC wall panel. The presence of steel fiber as the only reinforcement
creates higher lateral displacement. Wall panel experience shear failure at the side of
opening. The number of micro cracks reduces significantly due to presence of steel
fibre.
2.8 ENVIRONMENTAL, HEALTH AND SAFETY CONCERNS OF
DECORATIVE MOULDINGS MADE OF EXPANDED POLYSTYRENE
IN BUILDINGS
S. Doroudiani,H. Omidian , March 2009
Decorative tiles and mouldings made of polymeric foams are getting more
popular in buildings. There are health, safety and environmental concerns on these
products and their use in the buildings. In this paper, we report the results of the study
and discuss about concerns of decorative mouldings made of expanded polystyrene
(EPS). Physical damage to the structure of the building, potential harms to residents
and health hazards were found as main concerns in this regard. The use of decorative
mouldings made of EPS in the buildings is the subject to some considerations. The
climate conditions play significant role in the feasibility of usage of decorative
mouldings in the buildings. Although these products may add some aesthetic effects
to the building's exterior view, the observations and results of this study do not
support the use of the products in the buildings. Decorative mouldings bring
significant safety and health risks, and it is recommended that for usage in buildings,
particularly residential ones, the decorative moulding to be made of non-flammable
light-weight materials or to be completely excluded from the buildings.
9

15. 2.9 PARTIAL REPLACEMENT OF COARSE AGGREGATES BY
EXPANDED POLYSTYRENE BEADS IN CONCRETE
Thomas Tamut, Rajendra Prabh ,Feb-2014
With the increase in demand for construction materials, there is a strong need
to utilize alternative materials for sustainable development. The main objective of this
investigation is to study the properties, such as compressive strength and tensile
strengths of lightweight concrete containing Expanded Polystyrene (EPS) beads. Its
properties are compared with those of the normal concrete i.e., without EPS beads.
EPS beads are used as partial replacement to coarse aggregates. The results showed
that the amount of polystyrene beads incorporated in concrete influences the
properties of hardened concrete. At 28 days, it was found that compressive strength of
5%, 10%, 15%, 20%, 25% and 30% EPS incorporated concrete strengths were 91%,
77 %, 71%, 63%, 57%, and 45%, respectively when compared to concrete with no
EPS case.
2.10 COMPRESSION CREEP TEST ON EXPANDED POLYSTYRENE (EPS)
GEOFOAM
Y. Z. Beju & J. N. Mandal ,27 Apr 2016
Expanded polystyrene (EPS) geo foam is vulnerable to time-dependent creep
deformation when a constant magnitude stress level is applied. In the present study,
an attempt has been made to understand the behavior of compression creep of EPS
geo foam using stress controlled loading frames. The test has been carried out on EPS
geo foam samples of three different densities, 12, 15, and 20 kg m−3
under the applied
pressure of 65% of the compressive strength. Cube samples of 50 and 100 mm sizes
were tested for the investigation. The test results showed that with the increase in
density of EPS geo foam, creep deformation value decreases, whereas on low density
of EPS geo foam, the effects of creep deformations were more pronounced. Small size
samples tend to overestimate creep deformations of EPS geo foam because of end
effects and more noticeable seating error.
10

16. CHAPTER 3
METHODOLOGY
3.1 PROPERTIES OF EXPANDED POLYSTYRENE
Recommended safety practices and mechanical/chemical properties of expanded
polystyrene are found in the appropriate EPS Technical Bulletins. Expanded
polystyrene exhibits a number of outstanding properties meeting the needs of a
number of general applications including but not necessarily limited to building
insulation, packaging, flotation, geo technology, product displays, stage settings, etc.
• Light Weight
EPS offers an exceptionally lightweight solution to so many applications in
construction. This is not surprising when you consider that, as a result of advanced
manufacturing technologies, EPS is effectively98% air captured within a 2% cellular
matrix. The advantages in on-site handling and transportation bring significant
economic benefits whilst considerably reducing health and safety risks associated
with the lifting of heavier materials. It is therefore an excellent substitute for infill
materials and ballast where it also brings load and fill times down in time-critical
build projects.
• High Strength and Structural Stability
In spite of its light weight, the unique matrix structure of EPS brings the benefits of
exceptional compressive strength and block rigidity. This means it is ideal for use in
many construction and civil engineering applications, particularly as a structural base
infill, for example in road, railway and bridge infrastructures. Strength tests
performed on EPS which was firs placed in the ground almost 30 years ago show that
it is just as strong today the tested strength routinely exceeding the original minimum
design strength of 100kPa. EPS bridge foundations, which have been subject to many
years of sustained loading, show ‘creep’ deformation of less that 1.3% -only half as
much as had been theoretically predicted. Most importantly, EPS stability does not
deteriorate with age.
• Economy
EPS is a well-established material for the construction industry and offers a proven
and economic solution which helps specifies maintain build costs and insulation
budgets. Far from incurring a cost premium, the new build cost of insulating a
building withes, rather than polyurethane, polyisocyanurate or mineral wool, is
typically 20% less. Floor construction with EPS requires only one waterproof
membrane to be installed, not the two needed for mineral wool or PU foam– saving
on both material and labor. And for a given insulation performance, EPS itself costs
less than these competing materials.
11

17. • Insulation
In the construction sector, EPS has a long established reputation for its exceptionally
high insulation qualities. Its BRE ‘A-plus’ rating means it is the perfect choice for
use in under-floor,-floor, walling and roofing applications where it is able to give a
constant insulation value across the full service life of the building. Thermal
conductivity testing of EPS to DIN52612, under the auspices of th Forschungsinstitut
für Wärmeschutz in Munich, confirmed that its insulation efficiency at0.0345W/my
was well within the originally specified standard requirement of 0.04W/mK.For those
seeking higher performance material for the Code For Sustainable Homes (CSH),low
lambda material is available – which is typically grey in color. The thickness of high-
performance, low lambda EPS can be as little as 70mm, making possible a total floor
thickness of 135mm.
• Design Versatility
Ease of cutting or molding allows the factory production or on-site preparation of
complex shapes to match the most demanding architectural and design requirements –
usually without the need for specialist cutting tools or skills. This means the breathing
masks, goggles and protective gloves needed for working with mineral wool and other
materials are not required with EPS.
• Accredited Performance
EPS has a long and proven track record and has-been tested to some of the world’s
most demanding performance standards. EPS has BBA Approval, BRE Certification
and many wider industry accreditations. Its light weight, high compressive and impact
strength, insulation, safety and eco-credentials combine to make it the preferred
option for so many architectural and construction applications.
• Resistance to Water ingress
After almost 30 years in the ground, samples of EPS retrieved from locations as little
as200mm above the groundwater level all have less than 1% water content by
volume ,submerged show less than 4% water content – performance notably superior
to other foamed plastic materials.
• Safety in installation and use
EPS is non-toxic, chemically inert, non-irritant and rot-proof. Fungi and bacteria
cannot grow on EPS and it is insoluble and non-hygroscopic.EPS is also rodent-proof
and offers no nutrient attraction to vermin. Nor is it affected by water, thus ensuring
that moisture contact will not lead to deterioration of the product or its performance.
In fact, the reinstatement of flood damage buildings is a much quicker, more
practical and less costly procedure if building structures feature non-water-absorbing
insulation material – waterlogged open-cell foams and mineral fibers are very
12

18. vulnerable to flood damage, are very hard to dry out and may never recover their
insulation performance. Cement, lime, gypsum, anhydrite and mortar modified by
plastics dispersions have no effect on EPS, so it can confidently be used in
conjunction with all conventional types of mortar, plaster and concrete encountered in
building construction. All of this makes it entirely safe in use across all of its
construction applications including subterranean and marine environments.
• Sustainability Credentials
At every stage of its life cycle, from production to recovery or recycling, Proffers
exceptional eco-credentials and is therefore ideally suited to the new generation of
eco-friendly building projects. All manufacturing processes comply with current
environmental regulation. EPS uses no greenhouse gas producing materials. It is
chemically and environmentally non-aggressive and it can be – and is –easily recycled
into long-life products through an expanding nationwide network of collection points.
• Low Thermal Conductivity
According to the Thermal Insulation Technical Background Report, thermal
conductivity measured in W/mK describes how well a material conducts heat. It is the
amount of heat (in watts) transferred through a square area of material of given
thickness (in meters) due to a difference in temperature (in degrees Kelvin) either side
of the material. The lower the thermal conductivity of
the material, the greater the material’s ability to resist heat transfer, and hence, the
greater its insulation’s effectiveness.
Thermal insulation in buildings helps to regulate internal temperature by reducing the
flow of heat through the exterior surfaces of the building. The choice of insulation
product is usually guided by its application, and the amount of insulation required will
depend on the climate of the location, latitude and altitude at which the building is
constructed. EPS due to its closed air-filled cell structure inhibits the passage of heat
or cold, and a high capacity for thermal insulation is achieved. Thermal insulation of
ceiling, floors and walls is essential
• Fire Performance
According to the European Manufacturers of EPS (EUMEPS, 2002), the vital factors to
be considered when determining the potential fire hazard of EPS are:
1. The foams’ density and shape
2. Its configuration relative to an ignition source
3. The location of the product
4. The availability of oxygen
13

19. At the initial stage of a fire, ignition energy comes in contact with the flammable material
which will give off flammable gases above a temperature of 200⁰C combusting
spontaneously. When burning, EPS exhibits the normal characteristics of hydrocarbons
such as wood, paper etc. Combustion products are mainly carbon monoxide and styrene.
14

20. The latter may be further decomposed, giving off oxides of carbon, water and a certain
amount of soot. Even with the fire risk with EPS, the presence of fire retardant additives
provides a relief. Hexa bromo cyclododecan (HBCD), the additive, enables the foam to
shrink rapidly away from the heat source, thus reducing the likelihood of ignition. The
additive also the enables self-extinguishing characteristic such that when the ignition
source is put out, EPS seizes to burn.
• Water Absorption
EPS has a closed-cell structure that limit water absorption. When used in well-drained
conditions, no change in weight is expected over time. However, when subjected to
submerged application, a slight increase in the weight is expected over time.
• Ageing Resistance
During a monitory program by Frydenlund and Aaboe, (2001), no material decay should
be expected from EPS when placed in the ground. The first road insulation project with
EPS in 1965 and lightweight embankment in 1972 provides viable evidences to depict
EPS’s resistance to adverse condition with respect to time. The study concluded that no
deficiency are to be expected from EPS fills placed in the ground for a normal life cycle
of 100 years.
All of the properties listed above are retained over the whole of the material’s life and
will last as long as the building itself. EPS is not altered by external agents such as fungi
or parasites as they find no nutritional value in the material. It can be reground, recycled
and reused in many composite applications such as lightweight concrete.
• Recyclability
Recycling has been an area of concern with eco-efficiency . EPS being an eco friendly
polymer, recycling is encouraged and it can be recycled infinity times. The process can
take various forms; it can be reused in non-foam applications such as lightweight
concrete. The recycling process of EPS is carried out such that it transforms into
polystyrene plastic after the process.
EPS is 100% recyclable. There are two main types of plastic resins mainly thermoplastics
and thermo sets. Thermo sets cannot be re-melted but thermoplastics can be recycled and
changed into various types. Polystyrene is a thermoplastic family and is suitable for
recycling.
15

21. 3.2 EPS TECHNICAL DATA
Fig 3.1 TECHNICAL DETAILS OF EPS
 LongTermInsulationValue
R-value means the resistance to heat flow. The higher the R-value, the greater
the resistance to heat flow. EPS insulation (0.90 pcf) provides atypical R-value
of 3.60 per inch at a mean temperature of 75 degrees F and atypical R-value of
4.00 per inch at a mean temperature of 40° degrees F. When properly installed
and protected from moisture, the R-value of EPS insulation remains constant.
This is because the closed cell structure of EPS contains only air. The R-value of
EPS will not decrease with age. As a result, the thermal resistance or R-value, of
EPS may be used without any adjustment for age.
 MoistureResistance
Water vapor transmission through insulation materials is the passage of water
through the material in the vapor phase. In comparison to other common
building materials, EPS insulation has moderate water vapor permeability per
unit of thickness. Recommended design practices for wall sand foundations
should be followed in the selection of vapor and moisture
barriersforsevereexposures.
A study by the Energy Materials Testing Lab (EMTL) has shown that EPS insu-
16

22. lation installed in well-constructed roofs does not absorb appreciable moisture,
even under conditions characteristic of prolonged, cold, damp winters. The small
amount of moisture has little or no effect on the compressive or flexural
strength,andtheEPSinsulationretainsbetween 95%and97%ofitsthermalefficiency.
Each roof application should be studied to determine the need for a vapor
retarder to control internal condensation. Based on NRCA/MRCA-sponsored
studies, vapor retarder placement for EPS insulated roof systems is less critical
than for other types of roof insulations.
 TemperatureCycling
EPS is able to withstand the rigorous of temperature cycling, assuring long-term
performance. In a series of tests conducted by the Dyna tech Research and
Development Co., Cambridge, MA, core specimens removed from existing
freezer walls, some as old as 16 years, demonstrate EPS withstands freeze-thaw
cycling without loss of structural integrity or other physical properties.
 StrengthCharateristics
For foundation and wall applications in which EPS bears a minimal load, ASTM
C578 Type I EPS material is adequate. The resilience of EPS insulation board
provides reasonable absorption of building movement without transferring stress
to the outer skins at the joints. In most roofing applications, Type 1 EPS
insulation material provides the dimensional stability and compressive strength
necessary to withstand normal roof traffic and equipment weight. If greater
rigidity and strength are needed, as a result of design loads, higher density EPS
insulation products are available. Please contact Insulation Technology for
recommendations regarding your particular application.
 Combustibility
Like many construction materials, EPS is combustible. EPS products are
manufactured with a flame retardant; however, EPS insulation will burn upon
exposure to flame or heat sources, including, but not limited to, open flames,
welder's torches, or other sources of heat. EPS insulation should be covered with
a thermal barrier or otherwise installed in accordance with applicable building
code requirements. It is the responsibility of the purchaser to ensure that EPS
insulation is properly handled and stored on the jobsite.
 SolventAttack
EPS is subject to attack by some petroleum-based solvents. Care should be taken
17

23. to prevent contact between EPS and these solvents and their vapors.
 ApplicationTemperatures
In roof construction requiring hot asphalt, temperatures should not exceed 250
degrees F at the time of direct contact with EPS insulation. Avoid contact
between EPS and high-temperature equipment, such as asphalt Kettles and flame
sealers.
 InstallationExposure
prolonged exposure to sunlight will cause slight discoloration and surface
dusting of EPS insulation. The insulating properties will not be significantly
affected under normal usage. EPS stored outside should be protected with a
light-colored opaque material.
3.2 EPS APPLICATION IN CONSTRUCTION
EPS has for decades been the architect’s No.1 choice for economy, performance and
sustainability in a wide range of applications. It is the leading 21st century solution
for many construction and civil engineering tasks including:
 Roof, floor and wall insulation
 Sub-structures and void-fill blocks for civil engineering
 Foundation systems
 Clay Heave protection
 Bridge, rail and road widening schemes
 Underground heating system support
 Interior and exterior decorative mouldings
 EPS Concrete In Non Structural elements
3.3 EPS WALL INSULATION AND EPS ROOFING AT ANGUL, ODISHA
EPS panels, tailored for specific projects are used as walls panels for partitioning and
for floor slabs. These are normally finished on-site by applying concrete/sand crate
18

24. with pneumatic devices. On durability issues, strength tests performed on EPS which
was first placed in the ground almost 30 years ago show that it is still strong today
(BPF, 2009).
The benefits of expanded polystyrene (EPS) in the building industry worldwide can
be summed up as lifetime durability, moisture resistance, proven acoustic and
excellent thermal insulation, design versatility, cost-effective, easy installation leading
to record time completion, flexible mechanical properties, good strength and
structural stability. Specifically on the cost of production and time of construction,
EPS material has an edge over conventional building materials.
Panels can be assembled on site and in situ poured concrete (double panel, floors,
stairs) and shotcreted concrete (single panel) to realise the different elements of the
system like
 Vertical structural walls
 Horizontal structural elements
 Cladding element
 Internal walls
3.4 BENEFITS OF EPS ROOFING
Consistent R‐value (thermal resistance)
 Consistent over Life of Roof
 Measurable Energy Savings
 Lower cost per R‐value than many other insulation products
Design Attributes
 Design flexibility and versatility in meeting project specific applications
19

25.  Compatible with fully adhered, ballasted or mechanically fastened systems
 Compatible with common roof assembly components
Superior Performance
 Dimensional stability
 Moisture resistance
 Compressive strength
Environmental Benefits
 Recycled EPS incorporated in many insulation products
 Never manufacturer with ozone‐depleting gases, such as CFCs or HCFCs
 Lightweight, less material required to meet R‐value standards
3.5 METHODOLGY OF EPS PANELS INSTALLATION FOR WALL
20

26. Fix vertical anchors on the
grade slab
Erect Wall panel (anchoring)
Checking the alignment
Tie the weld meshes, corner
mesh etc
Erect floor panels & Shotcrete
o
f
B
a
s
e
P
r
e
p
a
r
a
t
i
o
n
ConstructionSequence
Fix vertical anchors on the
grade slab
Erect Wall panel (anchoring)
Checking the alignment
Tie the weld meshes, corner
mesh etc
Erect floor panels & Shotcrete
o
f
B
a
s
e
P
r
e
p
a
r
a
t
i
o
n
Fig 3.2 Procedure for installation of EPS Panels for Wall
1) Foundation/ preparation of base
- Foundations for the Concrete wall system whether strip or slab are conventional.
-Preparation of base is first step for of panels.
Fig 3.3 Electrical Drilling Machine Fig 3.4 Drilled Holes in
Foundation
21

27. Fig 3.5 Erection of EPS Panels
Fig 3.6 Alignment of EPS Panels
2) Wall panel erection
22

28. • Anchoring rebar’s to foundation
• Mark out and profile line wall positions
• Starter bars should be either φ6mm or φ8mm,500mm long with 100mm drilled
into the foundation sand 400mm above.
• All corners and wall joins must be reinforced with right angled wire mesh to
the full height of the walls
• Once the panels are plastered on one side the wall braces can be removed 24
hours later. The panels are now sufficiently ‘stiff’ that plastering on the other
side can be done without bracing.
3) Single panel roof installation
When the vertical panels are assembled on site, the verticality of the walls checked
and the bending meshes positioned on all the corners, it’s time to put the horizontal
bending meshes to connect the floor/roof to the vertical panels. The bending meshes
must be fixed in whole the perimeter of the floor/roof, at level of the intrados.
The concrete casting on the floor/roofing panels
(after placing the additional reinforcing bars, if needed) must to be done after the
walls are plastered and it requires a series of props to limit the deformation of the
panel.
Fig 3.7 EPS Slab Panel Erection
23

29. Fig 3.8 EPS Slab and wall Erection with Wire Mesh arrangement
4) Window and door fitting
• To cut panels to fit and for door and window openings the wire must first be
cut with a wire cutter or angle grinder.
• Reinforcement around wall openings added steel mesh reinforcement is
needed around window and door openings to ensure no plaster cracks form in
these areas. Mesh reinforcement strips of must be wire tied diagonally (45°)
around openings before plastering.
• Fix a metal angle iron or hollow tube sub frame into the openings before
plastering. Fix and plaster these in place and then secure the frames to the sub
frame.
Fig 3.9 Opening of Wall Panel
24

30. 4) Electrical and Plumbing Installations
• A hot air gun or torch is used to create channels in the polystyrene for the
placement of switch boxes, electrical conduits, cables or pipes.
Fig 3.10 Electrical Conduiting and Plumbing after Installation of EPS Panels
25

31. 5) Application of shotcrete
• Application of shotcrete is done on both sides of the single or double panel till
a thickness of 17-20mm is achieved. After about 30 minutes, mortar of
15mmthickness is applied.
• Shotcreting involves placing a mix of 1:3 (Cement, Sand and crusher dust)
cement mortar to create a structural wall. Shotcreting is being done using
pumps at pressure of 2kg/cm2
• To ensure the structural behaviour of the panels, min 35mm thick shotcreting
is done on the panels.
• To save on plastering costs, the shotcreting is done in 2 layers, the 1st
layer
being a rough layer and 2nd
layer as a finishing layer.
SITE PICTURES AT ANGUL, ODISHA
Fig 3.11 Shotcrete Pumping Machine
26

32. Fig 3.12 Shotcreting all over the walls
Fig 3.13 Building after shotcreting
Fig 3.14 Finished view of a Building
27

33. 3.6 EXPANDED POLY STYRENE CONCRETE
Expanded polystyrene (EPS) concrete (also it known as EPS-CRETE, EPS concrete
or lightweight concrete) is a form of concrete known for its light weight made from
cement and EPS (Expanded Polystyrene). It is a popular material for use in
environmentally "green" homes. It has been used as road bedding, in soil or geo-
stabilization projects and as sub-grading for railroad track
.
It is created by using small lightweight Styrofoam or EPS balls as an aggregate
instead of the crushed stone that is used in regular concrete. It is not as strong as
stone-based concrete mixes, but has other advantages such as increased thermal and
sound insulation properties, easy shaping and formed by hand with sculpturing and
construction tools. EPS concrete combines the construction ease of concrete with the
thermal and hydro insulation properties of EPS and can be used for a very wide range
of application where lighter loads or thermal insulation or both are desired.
According to Kuhail, (2001); Park and Chisolm, (1999), one of the essential
properties of lightweight concrete is its porosity; this quality results in a low apparent
specific gravity (ratio of mass of substance to that of an equal volume of water at
4ºC). The use of lightweight concrete for construction has advantages such as lighter
load during construction, reduced self-weight in structures and increased thermal
resistance. In concrete structures, self-load takes a large percentage of the total load
on the structure; hence, there is consideration to reduce the density of concrete. The
use of lightweight concrete enhances construction and handling techniques as well as
easing up rigors of transportation and on-site handling. Lightweight concrete reduces
the cost of formwork and steel coupled with increased productivity.
According to Park and Chisolm, (1999), lightweight concrete has better thermal
insulation than ordinary concrete with density ranging from 300 – 1850 kg/m³. The
study further stated that concrete weight can be lightened by:
1. Introduction of air to form air bubbles of coarse size; also known as aerated
concrete.
2. Introduction of air by using a special agent; also known as air-entrained concrete.
3. Use of lightweight aggregate as substitute to normal aggregate.
The production process of lightweight concrete is cost-intensive due to complex
machinery, chemicals and lightweight aggregate to be used. The idea of using
polystyrene as a substitute for the expensive lightweight aggregate (or the air bubbles)
was introduced. This is due to the low density of polystyrene ranging from 16 - 27
kg/m³ as compared to that of normal aggregate 1700 - 2000 kg/m³.
28

34. Poly-concrete is a lightweight concrete made with cellular polystyrene beads
“particles” as aggregate. It can be used for both in-situ and precast components. The
aggregate is made from raw polystyrene which consists of spherical beads that are
non-absorbent since their cells are closed and contains expanding agent. Their main
function is to act as a filter in the concrete mix and also increase thermal resistivity
along with enhancement of desirable properties. After a careful investigation of the
characteristics of polystyrene, Kuhail, (2001) concluded that all forms of cement and
sand can be used for poly-concrete. The sands include natural sand, crushed rock and
both dense and lightweight mineral aggregates.
Fig 3.15 EPS Concrete
29

35. Fig 3.16 EPS concrete sandwiched between Calcium Silcate Boards
CHAPTER 4
A CASE STUDY
SITE DESCRIPTION
Sharad Institute of Technology College of Maharashtra, India
ABSTRACT
With increase in demand for construction materials, man has improved a lot in
construction techniques of structures. In earlier ages structures were constructed with
heavy materials, but in this modern era of construction old techniques are being more
costly due to heavy loading. So the uses of lightweight materials are started. The
Expanded polystyrene beads are the material which substitutes in the place of coarse
aggregate. The main objective of this investigation is to find a concrete mix
proportion which gives better results than the Burnt Brick (compressive strength and
density), and to study the properties, such as density, compressive strength and
splitting tensile strength of lightweight Expanded Polystyrene (EPS) beads concrete.
Then its properties are compared with M20 grade conventional concrete.
INTRODUCTION
In this work, an attempt is made to make the concrete mix design as replacement to
the Burnt Brick with more benefits as high strength and low density. In this study the
partial replacement of coarse aggregate was done by Expanded Polystyrene (EPS)
beads to reduce its density. The Expanded Polystyrene is a stable, low density Foam,
which consists of 98% of air and 2% of polystyrene material. It has closed structure
and cannot absorb water. It has good impact resistance. Polystyrene is packaging
material in medical industry. Polystyrene is non-biodegradable material, so it creates
disposal problems.
Utilizing crushed polystyrene in concrete is good waste disposal method. The
polystyrene beads can be easily merged into mortar or concrete to produce lightweight
concrete with a wide range of density. An application of polystyrene concrete
includes walls, cladding panels, tilt up panels and composite flooring. Polystyrene
concrete was used to produce load bearing concrete wall, also as the material of
construction for floating marine structures. Expanded polystyrene beads concrete was
popular through the ages.
One of the main problems associated with the use of conventional lightweight
aggregates produced from clay, slate and shale in concrete is that these porous
aggregates absorb very large amount of the water mixed in concrete. This is affecting
the performance of the concrete, apart from the fact that it is difficult to maintain
30

36. specific water content during the casting. Also, this absorption of water by the
aggregates will mean that the additional water will be required to maintain the slump
at acceptable levels. These increased water contents requires higher cement contents,
even without any benefit.
CONCRETE MIX OF M20 GRADE USING EPS BEADS
• The Expanded Polystyrene beads used in this project was spherical in shape
and size varying between 1.18 to 2.36 mm in diameter.
• The physical properties of ingredients are determined individually. The mix
proportion for conventional M20 grade concrete is arrived as per IS: 10262-
2009.
• Assumed w/c ratio = 0.50, the proportion of concrete mix is,
W C FA CA
160 320 797.5 1169.87
0.50 1 2.49 3.66
• Different densities of EPS beads were considered
• After mixing different tests were performed on the concrete with EPS beads
• Concluded that EPS with higher density gave higher compressive strength and
thus concluded that natural resources can be saved up to some extent.
31

37. CHAPTER 5
CONCLUSIONS
• Compare to the conventional materials and conventional methods,
construction using EPS technology has lot of benefits as mentioned earlier.
• The development of this lightweight concrete panel with EPS foam cores and
a steel mesh frame will brings great innovation.
• As the material is light in weight it imparts less weight to the structure and
can be moulded in any shape , versatile in nature.
• Expanded polystyrene as an efficient and effective thermal insulation material
can play its part in reducing carbon dioxide emissions and make a very
positive contribution to the alleviation of global warming. No CFCs or HCFCs
foaming agents are used in its manufacture, so EPS causes no damage to the
ozone layer.
• The energy used in its manufacture (embodied energy) is recovered within six
months by the energy saved in the buildings in which it is installed. For the
remainder of the life of the building, the EPS reduces its energy requirement
thereby requiring the combustion of less fossil fuel which results in less CO2
being generated.
• At the end of its useful life it can be recycled or the thermal energy contained
within can be recovered by incineration in suitably designed Waste to Energy
Plants to provide energy for district heating or the generation of electricity.
EPS can therefore make a positive contribution to the overall world
environment.
• The construction using EPS technology is cost effective, high performance,
less maintainence, recyclable, decreases the use of natural resources , rapid
construction with less duration and leads to sustainable future.
32

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