Spheres of application of extruded polystyrene foam

Selecting the appropriate insulation materials is essential for maintaining our homes’ comfort and energy efficiency. Extruded polystyrene foam (XPS) is a standout choice due to its excellent performance and wide range of applications. XPS is now a popular option for both builders and homeowners, serving as a barrier against moisture in below-grade applications and insulating exterior walls.

Extruded polystyrene foam performs exceptionally well in insulating basements and foundations. Because of its closed-cell structure, which greatly resists moisture, it is perfect for below-grade installations where there may be a risk of water intrusion. By successfully keeping moisture out, XPS ensures a healthier indoor environment and increases energy efficiency by thwarting the growth of mold and mildew.

Extruded polystyrene foam is also frequently used as an insulator for floors, especially in places like bathrooms and kitchens where there is a lot of foot traffic or where moisture resistance is crucial. It’s a dependable option for keeping floors warm and cozy all year round due to its durability and capacity to retain thermal performance even in damp environments.

The insulation of external walls is another typical use for XPS. Homeowners can dramatically increase the thermal efficiency of their buildings, minimizing heat loss in the winter and cutting energy costs, by placing XPS panels under siding or cladding. Furthermore, XPS contributes to the development of a continuous insulation barrier, reducing thermal bridging and raising indoor comfort levels generally.

Extruded polystyrene foam is used in commercial and industrial settings in addition to residential construction. XPS provides adaptable solutions for a range of construction and insulation requirements, from insulating roofs and refrigeration units to offering thermal protection for piping systems.

Building Insulation	Used to insulate walls, floors, and roofs in residential and commercial buildings.
Foundation Insulation	Provides thermal insulation for building foundations, helping to prevent heat loss and moisture intrusion.

Comparison of foam and extrusion polystyrene foam

Although they have a similar composition, insulators are produced using entirely different technologies, which causes a significant difference in their technical properties.

Merely 2% polymer makes up Styrofoam. The air inside the hermetically sealed capsules occupies the remaining space, staying still as a result.

It is well known that this type of immobile air layer offers effective thermal insulation. Polystyrene foam has a significantly lower thermal conductivity than brick (by a factor of 17) and wood (by a factor of 3). Owing to this peculiarity, walls that are 21 cm thick will require the insulation of a board that is 12 cm thick.

Penoplex has better heat conductivity than polystyrene foam because of its higher density, though the difference is not very great. Therefore, the corresponding parameter of foamlex is 0.032 W/mK if the thermal conductivity of foam plastic is 0.04 W/mK. In terms of materials, a 20 cm thick foam board can be used for thermal insulation in place of a 25 cm thick polystyrene foam board, with the same effect. These indications, however, might change based on the producer and a specific material brand.

Sound permeability is one more benefit of the material. To attain complete soundproofing, a 3 cm thin board is required.

Water resistance is an undeniable benefit of traditional polystyrene foam. The maximum amount of moisture that can be absorbed by a material is 3% of its total weight. The properties of foam plastic remain unchanged, though, even at maximum absorption of moisture.

Better outcomes could be obtained if the polymer is extruded. For instance, expanded polystyrene has a maximum moisture absorption rate of 0.4%. Consequently, it is acceptable to overlook the vapor barrier when using extrusion polystyrene foam to insulate the facade. Even if Styrofoam was chosen, vapor barrier installation is still preferable.

When it comes to strength, foamplex triumphs as a more dense material. Over time, foam plastic’s resistance to different influences inevitably decreases because of its large micropores.

The extruded polystyrene foam has a compressive strength of 0.5 MPa, whereas the foam plastic has only 0.2 MPa. The foam plastic is four times less strong than the other slab when comparing their compressive strengths of the same thickness.

Advantages, disadvantages and features of the popular material

Method for joining plywood and polystyrene foam: Gluing on smooth fuga (a), microship (b), toothed spike (10 mm) (c), "tongue and groove" (d), and inserted spike ("key") are the possible methods.

The process of extrusion Made of organic polymers, polystyrene foam is a porous plastic material with a consistent closed structure of tiny cells, or pores. Foaming agents, such as freons and carbon dioxide, are injected into the material during its production in the extrusion unit along with high pressure and temperature. The mass is extruded from the machinery after passing through all manufacturing processes. Consequently, EPPS boards are created, which must be dried before being used. The extrudate’s homogeneous composition, unique cellular structure, and high performance attributes are all made possible by the technological process of extrusion, which also accounts for its broad application.

Among EPPS’s benefits are:

• low water absorption;
• low thermal conductivity;
• frost resistance;
• high compression resistance;
• resistance to rotting processes, biological decomposition;
• resistance to chemical agents
• environmental friendliness;
• small weight;
• resistance to temperature fluctuations;
• low vapor permeability;
• the material does not change its working characteristics when exposed to temperature fluctuations;
• easy to install, easy to process;
• work with the material can be carried out at temperatures from -50° to +70°;
• good combination with other materials;
• durability;
• durability.

Configuring the mesh for later overlapping and joining.

• phenols are emitted when the material burns;
• low flammability;
• high cost;
• When exposed to organic solvents, complex hydrocarbons, ultraviolet rays, the material is destroyed;
• There are restrictions in the use of thermal insulation of pitched roofs, saunas, baths.

The industry uses unique additives called flame retardants to produce EPPP. These additives help the material resist ignition, which is important when using it in areas where there is a higher risk of fire.

Returning to the contents table

Advantages of extruded polystyrene foam

The majority of the technical qualities this material possesses take the shape of benefits, the most notable of which are as follows:

• Resistance to critically low temperatures and neutrality to rotting processes allow EPP to withstand the difficult operating conditions of the Russian climate.
• Due to insensitivity to temperature fluctuations, extruded polystyrene foam can be placed for storage outside without protective shelters.
• EPP is characterized by a long service life, thanks to which it can not lose its properties for 50 years.
• The boards of this material are characterized by the absence of difficulties in installation.
• Material has an affordable price, that allows to use it for solving various tasks by the overwhelming majority of the population of our country.
• In this material found manifestations of unique properties that determine its popularity. Such plastic is able to replace conventional hydro- and thermal insulation, as well as various objects and structures.
• EPP is not harmful to health, which also has a positive impact on its use.
• The slabs of this material have a very small thickness (about 20 mm), which compares favorably with foam and mineral wool, whose values are 30 m and 40 mm, respectively.

Peculiarities of use and choice of material

Despite the numerous benefits of extruded polystyrene foam, it is still advised to use it properly and consider a few key factors related to its operation.

• EPP boards are able to demonstrate high durability in the temperature range – 50 degrees to + 75 degrees. After all, only in such a temperature range polystyrene foam keeps its physical and thermal characteristics unchanged.
• Sheets of the material can be installed immediately at the stage of construction of the object or on its basis can be created an additional layer of thermal insulation during finishing works.
• There are also peculiarities regarding storage: when placed outdoors, it is desirable not to remove it from the "native" package, and it should be kept in places where it will not be exposed to direct sunlight.
• Careful attention should be paid to the choice of adhesive composition. It is important to make sure that the latter does not harm the plastic.

Every owner is required to adhere to the EPP’s usage guidelines. If you ignore them and select the incorrect kind of adhesive, you may experience the unpleasant phenomenon known as board shrinkage. Extruded polystyrene foam should not be used in conjunction with the following materials:

• Paint thinners;
• Coal tar;
• Acetone;
• Petroleum toluene;
• Ethyl acetate;
• Water-based materials that are used to treat wood to protect it, as well as those containing solvents.

To avoid making a mistake when selecting extruded polystyrene foam, start by familiarizing yourself with the product’s quality certificates rather than focusing on the price. If there are no supporting documents, you might be presented with low-cost alternatives, whose use could be harmful to your health in addition to negatively affecting the structure’s or object’s performance.

In the USA, foam plastic has been phased out for a number of years when tasks that formerly required it are completed. Extruded polystyrene foam is replacing less effective materials in an increasing number of countries. Gradually, this trend is also seen in our nation.

Production technology and composition

The material’s chemical makeup is comparable to that of Styrofoam. Granules of polystyrene foam make up its main ingredient. They are combined with materials that strengthen and enhance the properties of polystyrene foam, as well as flame retardants that lessen combustibility, and they are melted at high temperatures. Once the molten mass is homogeneous, it is injected under high pressure with carbon dioxide, a foaming agent.

After that, the material goes through the extrusion procedure. The hot mass that results is pushed through the extruder’s rectangular opening. The mass foams due to the expansion of carbon dioxide when the pressure returns to normal. The final strip’s thickness and width are managed by the extruder opening’s dimensions. XPS strip is sawed into boards with predetermined measurements.

Extruded polystyrene foam satisfies SNiP 21-01-97 "Fire Safety of Buildings and Structures" requirements. The combustion products’ toxicity index is governed by Federal Law No. 123. An indicator T2 designates moderately hazardous insulators in high-quality EPPS. Parquet and other wood materials have the same index. GOST 32310-2012 regulates the extrusion polystyrene foam production process, testing procedures, and labeling.

Foam vs Extruded Polystyrene Foam

Regarding the debate over foam plastic vs foamplex, there are a lot of contradicting sources of information on the Internet. Since polystyrene is the same component used in both materials, there are some similarities between them. However, extruded polystyrene foam and Styrofoam share a lot of similarities despite these distinctions.

• Styrofoam is not characterized by durability.
• Manufacturing technology.

Polystyrene, the material that makes up Styrofoam, is granular in nature and melts at high temperatures. Consequently, one cohesive structure is created that serves as both soundproofing and insulation.

Dry steam is applied to the material to create foam plastic. Because of this, the granules just stick to one another rather than forming a solid mass.

• Extruded polystyrene foam is made by extrusion, thanks to which it has a lower value of moisture absorption compared to the . As for the foam plastic, water can seep through its cells, albeit slowly, but can seep through the pipes. Water access is only possible in the cells that are on the side surfaces. That is, the entire board of the material does not absorb vapor and moisture from the outside.
• With noise insulation is the same.
• Extruded polystyrene foam has a density that is 4 times higher than that of Styrofoam. Styrofoam is slightly heavier than expanded polystyrene, which means that it can support a greater load.

It has already become commonplace throughout the world to gradually replace old foam with more modern extruded polystyrene foam. For instance, extruded polystyrene foam is now mass produced in the United States, where its use is prohibited.

Technical characteristics

Any material’s qualities and properties are taken into consideration when using it. Extruded polystyrene foam’s technical qualities enable it to be used in a variety of operating environments.

The material has a small weight limit because of its density, which ranges from 25 to 45 kg/m³. However, high thermal insulation qualities are ensured by low thermal conductivity (0,029–0,034). Its low water absorption (beyond 0.2-0.4%) permits use of the material in high humidity and temperature swing environments.

Another drawback of the material is that EPS is classified as G3–G4 in terms of combustibility. However, the capacity for self-extinguishing makes up for it. The insulation releases class T2 toxic substances when it burns. Since parquet belongs to the same class, extruded polystyrene is considered non-toxic.

The material’s density determines the ultimate compressive and deformation strength. Although insulation can be used in a wide range of temperatures, -75 degrees Celsius should be the highest temperature.

Where you can carry out insulation with extruded polystyrene foam

The size and type of extruded polystyrene foam determine its classification and price.

The marking on extruded polystyrene foam (XPS) indicates the purpose of the insulation and is dependent on the material’s density:

• Penoplex GEO – withstands heavy loads and is designed for insulation of buried, loaded structures. It acts as an effective thermal insulation under a layer of cement-sand screed or under another protective layer. It is used in the construction of residential houses and insulation of industrial buildings, as an insulator for structures with insignificant requirements for fire resistance.
• Penoplex Pitched roof – Insulation boards form a light and at the same time rigid layer of thermal insulation, resistant to moisture. The insulator carries loads well and has low thermal conductivity, is easy to install and does not form cold bridges during operation.
• Penoplex Facade – is an ideal insulator for walls, it is used for both external and internal insulation. Extruded polystyrene foam is resistant to moisture and mechanical damage and does not require a windproof film as part of the ventfasade. The milled surface of the insulation in the wet facade increases the adhesion of the plaster layer.
• Penoplex Base – is applicable for thermal insulation of not loaded constructions. Widely used in civil construction for basement insulation, foundation insulation, interior/exterior wall insulation, floor insulation. The material is popular for roof insulation.
• Penoplex 45 – a high density material that can withstand heavy loads of 50 tons/m.square. The insulator is used for thermal insulation of road pavement, in the construction of railroads, airfields, for the device of loaded inversion roofs.

There is no doubt that extruded polystyrene foam, the cost of which is listed in the price list, does not facilitate combustion. Because of the flame retardant additives, foam plastic’s primary drawback is eliminated.

Which polystyrene foam extrusion is superior? You get to make the decision! However, you can currently get extrusion polystyrene foam at a discount regardless of the material you select!

Technical characteristics of polystyrene foam

1. Thermal conductivity. Styrofoam is a kind of compacted foam. The air inside the bubbles of polystyrene is an excellent thermal insulator. The heat transfer coefficient of the material varies between 0.028-0.034 watts per meter per Kelvin. The higher the density, the higher this indicator. Extruded polystyrene foam has the best properties.
2. Vapor permeability. This indicator for insulation varies from 0.019 to 0.015 kilograms per meter-hour-Pascal. Unlike Styrofoam, which has zero vapor permeability, Styrofoam is molded by slicing. Steam enters through these cuts, penetrating inside the gas-filled cells.
3. Moisture permeability. When dense extruded polystyrene foam is immersed in water, it remains practically dry. It absorbs moisture only about 0.4%. The pressless material will absorb approximately 4% of water. In contact with liquids, the insulation is not damaged.
4. Strength. Medium and high density polystyrene foam has a strong bond between molecules. Its static bending strength is 0.4-1 kilograms per centimeter per square centimeter.
5. Chemical resistance. Polystyrene foam does not react with soda, soap, fertilizers, bitumen, gypsum, cement, asphalt emulsions, lime. Damage and even dissolve the insulation can such substances as acetone, turpentine, olive oil, some alcohols, varnishes, petroleum products.
6. Resistance to ultraviolet light. Direct sunlight is destructive to polystyrene foam of all varieties and grades. At first UV light makes the material less strong and elastic, and later completely destroys it.
7. Sound absorption ability. The insulation can muffle impact noise only if it is laid in a thick layer. Waves of air noise polystyrene foam is not able to absorb and isolate. This is due to the design of the insulator – the gas-filled cells are rigidly arranged and fully insulated.
8. Biological resistance. Polystyrene foam is unsuitable for the growth and spread of mold and fungi. But rodents and insects damage it easily. They do not use the material for food, but they make passages through it to sources of heat and food.
9. Environmental friendliness. In the open air, the material is subject to oxidation processes. At the same time a lot of harmful substances are emitted into the air: toluene, benzene, methyl alcohol, formaldehyde, acetophenone. When burning, it also produces many toxic components: phosgene, hydrogen bromide, hydrocyanic acid. If the material is not exposed to atmospheric influences, it does not produce any dangerous compounds.
10. Fire resistance. Styrofoam is a combustible material. When exposed to fire, it emits a large amount of acrid smoke. For a material that does not include flame retardants, the smoke factor is 1048 meters square per kilogram. For fire retardant polystyrene foam, the rate is even higher – 1219 squares per kilogram. For example, this coefficient is 850 for rubber, and 23 for wood. Insulation, which contains fire retardant in its composition, is labeled with the letter C. It is worse to ignite and has a class G2. However, over time, the properties of fire retardant become weaker and the material receives reduced fire safety classes – G3 and G4. The fire temperature of polystyrene foam is 450 degrees Celsius.
11. Service life. With proper installation and use of polystyrene foam insulation, it is guaranteed to serve at least 30 years. To preserve the qualities and properties it is necessary to protect it with a decorative finishing layer on the walls.

types and technical characteristics of extruded polystyrene foam

The color of Penoplex is carrot.

The technical properties of extruded polystyrene foam vary slightly amongst manufacturers. Three brands are the best-selling in the home market:

Aside from a few subtle differences, they are all similar. For instance, Technoplex is strengthened with the addition of graphite. Unlike Ursa, a light beige shade, or carrot-colored Penoplex, the insulation turns gray due to graphite. Let’s examine each brand in isolation.

It is not allowed to get direct sunlight and solvent on extruded polystyrene foam.

Penoplex is a product made in the United States that is utilized in industrial and civil construction. Ten positions correspond to the insulation line. Principal attributes:

• Extruded polystyrene foam thickness: 2, 3, 4, 5, 5, 6, 8, 10, 12 and 15 cm;
• sheet sizes: 60×120 cm, 60×240 cm;
• thermal conductivity of extruded polystyrene foam is 0.03-0.032 W/m*C;
• compressive strength 0.2-0.5 MPa;
• water absorption not more than 0.4%;
• flammability group G4.

For pitched roofs, there is additional insulation in the form of a wedge. Slope ranges from 1.7% to 8.3%. Technoplex comes in standard sheet sizes of 60×120 cm and 58×118 cm, with thicknesses of 3, 4, 5, and 10 cm. With a higher coefficient of thermal conductivity of 0.002 W/m*C, it transmits heat more effectively than Penoplex. Because of the graphite in its composition, it has a 0.2% lower moisture absorption rate and a higher compressive strength. As a result, the material performs better when applied to basement walls or foundation insulation.

The multinational corporation Ursa maintains representative offices throughout Russia. It ranks among the top producers of building supplies. Three varieties of extruded polystyrene foam are produced. general traits

• Thermal conductivity 0.032-0.034 W/m*C;
• compressive strength 0,25-0,5 MPa;
• moisture absorption of 0.3%;
• combustibility group G4, except Ursa XPS N-III, which has combustibility group G3.

Extruded polystyrene foam Ursa dimensions: standard 60×125 cm in length and width, and thicknesses of 3, 4, 5, 6, 8, and 10 cm.

The first step in installing high-quality insulation in a log home is caulking the corners and interstitial spaces. For walls, only breathable insulation materials are permitted.

Learn about winterizing a well with insulation.

Interior and exterior insulation

Selecting the insulation method is essential before beginning to insulate the walls. to install external insulation or, depending on personal preference. Every approach has benefits and drawbacks. Studying the characteristics of each insulation technique is important when designing a building.

Insulation from the inside

The qualities listed below define internal wall insulation:

• The cost of insulation from the inside is less than for external insulation;
• Season and weather does not affect the choice of time for the work;
• there is no need to build additional scaffolding for insulation work.

Factors that negatively impact internal insulation include:

• significant reduction of living space;
• the outer wall is isolated from heating from the room;
• the probability of fungus formation inside the wall increases, since the dew point is formed exactly in the inner part of the structure;
• when turning off the heating, the walls cool down quickly due to the low inertia of the insulation;
• the place of adjoining the floor to the outer wall can not be equipped with insulation, which leads to the formation of cold bridges.

Although the cost of labor and materials to complete the work is significantly higher than the method of internal insulation, the external wall insulation method is more common.

Insulating from the outside

Insulating the walls from the outside has the following benefits:

• During winter and cold weather, the heat is retained in the wall for a long time;
• the designed area of the room is preserved;
• external thermal insulation protects the internal walls from dampness.

Furthermore, the external walls are further shielded from atmospheric phenomena, extending the structure’s service life considerably.

The following are the primary drawbacks of the structure’s external insulation:

• limitation of the execution of work according to weather conditions;
• Increase in the cost of materials used.

On which side of the wall to insulate with expanded polystyrene

Since polystyrene foam is not air-permeable and can cause condensation to form inside walls during internal insulation, it is best to insulate walls outside. Additionally, indoors, the material may release a distinct odor.

Pros and cons

These days, extruded polystyrene is regarded as a trustworthy, useful, and dependable material. Its importance stems from a number of advantageous aspects, all of which merit further discussion.

• This material is waterproof. In case of unfavorable contact with liquid, the polystyrene foam floors are filled – no further advancement of moisture in this case.
• Extruded polystyrene foam is characterized by a low level of thermal conductivity. If we compare it with other insulating coatings, we can conclude that the thermal conductivity coefficient of EPPS is less or equal (only polyurethane foam is an exception to the rule).
• A characteristic feature of EPPS is its low vapor permeability. The coefficient of this parameter is considered to be the minimum among the insulating components.
• Styrofoam is not subject to deformation even after a very long time.

• This material is not afraid of temperature fluctuations. In such conditions it does not lose its useful qualities and remains as practical/effective. Its operating temperature is from -100 to +75 degrees Celsius.
• Installation, as well as the dismantling of polystyrene foam – it is not difficult, and it does not take as much time as many people think.
• This material can boast a long service life, during which it does not deform and does not lose its qualities.
• In the course of operation extruded polystyrene is not subject to destruction.
• Extruded polystyrene foam is not afraid of inorganic solvents.
• Working with this material is very easy and simple, since it has a low weight and a small thickness.

• This material is relatively inexpensive. Many consumers will be able to afford it. In this case, the price-quality ratio can not fail to please.
• When laying EPPS, you can do without the use of additional waterproofing and heat-insulating coatings, which will significantly save money.
• According to experts, EPPS is not dangerous to human health. Moreover, when working with it the master will not have allergic reactions.
• Such a material is not afraid of low temperatures, so it is ideal for being in the harsh and changeable Russian climate.
• The durability of extruded polystyrene is confirmed by the fact that it is not subject to rot – this quality can boast not every building and finishing material.

As you can see, EPPS has a ton of benefits. For this reason, it currently holds a prominent position in the insulation materials market. Before making a purchase, you should be aware of the drawbacks of this useful and trustworthy coating.

• This material is subject to combustion.
• Being in conditions of temperature over 75 degrees, expanded polystyrene can emit harmful substances dangerous to human health.
• According to experts, this material is afraid of contact with infrared rays.
• Mice can get into EPPS, although many manufacturers deny this fact.
• When interacting with various solvents, this material can degrade.

You can confidently proceed with the purchase of this contemporary material if the aforementioned drawbacks don’t terrify you—it is utilized in numerous applications.

3 Sphere of application where materials based on polystyrene are used

Even with the clear benefits of extruded polystyrene, a large number of consumers—particularly in our nation—preferred foam plastic. It has to do with price; foamplex is much more expensive, with the difference sometimes amounting to several times that. Typically, foam is chosen by regular customers since they are unaware of the differences between the products.

However, because Styrofoam releases toxic and hazardous substances when used as fire insulation, it is already illegal to use in some nations, including Western Europe and the US. Experts in this field advise purchasing trustworthy and superior extrusion polystyrene. However, it should be noted that it does not fall under the category of items that are entirely safe for the environment and free of toxins.

Penoplex is superior to foam plastic in many ways, but foam plastic is still a very high-quality, long-lasting insulator when compared to the majority of its competitors. Furthermore, it is possible to use only polystyrene foam in certain circumstances. Foam plastic, for instance, is used to finish building facades because it is perfect as an indicator of moisture absorption and air permeability. Because of the low adhesion level, finishing the walls with extruded polymer presents challenges.

This material’s excellent qualities make it perfect for insulating homes.

Penoplex works wonders for insulating loggias and balconies. It’s not just about high indicators here, either. Since most of these rooms are not very large, it is essential to use thin insulation sheets in order to preserve as much usable space as possible. Naturally, there isn’t much of a difference in the sheet thicknesses, but 5 cm on each wall will be required to win.

Extrusion polystyrene foam should also be used as insulation for foundations, ground floors, and basements. In large quantities here, foam plastic does not have the proper quality indicators to consistently protect these rooms from moisture and steam. If not, using extremely thick foam boards will be necessary to get the desired outcome. There are no specific requirements if you need to insulate the living area’s floor. Ultimately, both materials handle the insulation of the space admirably; even fairly dense foam plastic can easily support any weight for an extended period of time.

Consequently, there is still a noticeable and substantial difference between extruded polystyrene foam and regular foam foam. Both materials are made of polystyrene, but they are not the same in terms of affordability, dependability, resistance, or moisture absorption. Regardless of the products selected, the quality of the insulation is always very high.

Heat-insulating boards made of extruded polystyrene foam

The issue of insulation inevitably comes up during building and maintenance. A warm house offers a chance to reduce utility costs while also ensuring the health of your family. After asking yourself this question, you must make a decision regarding which material is the best option for an insulator. There are currently a number of insulation options available on the market, including foam plastic, extruded polystyrene foam, glass wool, and rock wool.

Depending on the characteristics of your house and the particular area that needs to be worked on—the floor, balcony, walls, etc.—you must select one of these materials. When selecting insulation, there are a few guidelines that need to be followed.

Extruded polystyrene foam boards are a material that is almost always used for external room and building insulation. Its favorable attributes include strength, resistance to moisture, excellent thermal protection, longevity, and safety for the health of the home’s occupants. Let’s examine in more detail why these material properties are significant.

WATER RESISTANCE.

The building’s insulation material needs to be able to keep out moisture from the outside and avoid allowing condensation to build up inside the insulated surface. Your home will be cold in the winter and hot in the summer if the insulation absorbs water while in use, losing its ability to block heat.

Moreover, mold will start to grow in the damp insulation, eventually destroying it and endangering the occupants’ health as they breathe in the fungus’s spores. Because it is moisture-resistant, polystyrene foam is perfect for insulating walls, floors, roofs, and foundations.

DURABILITY.

It is necessary to use an especially sturdy material that can tolerate high pressure when insulating floors, foundations, or plinths. These materials, which are made of extruded polystyrene foam plates, do not squirm, settle over time, or degrade over an extended period of time. The strength and resistance to shrinkage of walls can be enhanced and prevented by insulating them with these same qualities.

HEAT PROTECTION.

When selecting a material, our primary goal was to obtain thermal protection. The coefficient of thermal conductivity determines thermal protection. The manufacturer has always provided specifications for this part in the product’s supporting documentation. The insulating properties of an insulator increase with decreasing coefficient of thermal conductivity. Polystyrene foam has a heat conductivity coefficient that fluctuates between 0.030 and 0.03. This is a useful indicator that will let you determine the heat-insulating layer’s thickness with less material.

DURABILITY.

Extruded polystyrene boards are predicted to last 40 to 50 years.

HEALTH SAFETY.

The majority of brands that use extruded polystyrene foam for thermal insulation boards are also those that make disposable dishes, toys for kids, and medical supplies. As the temperature changes, this insulation does not release any harmful substances into the surrounding air.

However, polystyrene foam boards are not without their drawbacks. Since the walls don’t breathe, some people view this drawback as low vapor permeability. Nevertheless, since it offers dependable waterproofing, this same "disadvantage" is actually a huge benefit when it comes to insulating the floor and foundation. However, the application of extrusion polystyrene foam is somewhat limited due to its flammability.

It is still uncommon, even though some manufacturers have figured out how to add particular materials that make the material more fire resistant. Extruded polystyrene foam in the shape of a board with combustibility group G3–G4 is more frequently seen in sales. In any event, these boards will be inside the structure and you won’t use them without a protective covering. When fire safety standards are high, heat-insulating materials with flammability groups no lower than G3 may be used.

"PENOPLEX" is the largest producer of extruded polystyrene foam boards in Russia. High-quality materials are produced in the company’s factories, which are outfitted with contemporary European machinery. There is a wide selection of goods according to purpose. Boards are an option for foundations, walls, roofing, and other applications.

Consider the insulation’s function, features, and look when making your selection. A high-quality insulation will resist mechanical pressure, have an even and smooth edge, and have a homogeneous structure.

Use of extruded polystyrene in domestic and industrial construction

Firstly, it is important to note that the issue of insulating roadbed bases, basements, and foundations was drastically resolved in the construction industry with the introduction of EPPS. The intended result was not obtained with the use of cellular glass, expanded clay, or granulated clay. Furthermore, the extruded material’s high contact strength allowed it to withstand even the most severe cases of building settlement and ground swelling. Almost all subterranean and basement structures constructed today are insulated using extruded polystyrene foam.

Yet the insulation of walls and communications systems demonstrates the true benefits of extruded polystyrene. Mineral fibers and traditional glass wool have always had one serious drawback. Fiber mats with poor vapor barrier membranes quickly absorbed precipitation moisture and condensed, increasing the weight of the absorbed water by nearly twice, which frequently resulted in insulation breaking.

Even the majority of independent builders have long since come to the conclusion that it is simpler to use lightweight extruded polystyrene foam sheets for the walls and cement plaster for the insulation layer than it is to deal with basalt wool, which can be fickle and unpredictable.

Scope of application of extruded polystyrene foam

The production and consumption of expanded polystyrene (EPS) are increasing annually by 3-4%, even though its use is prohibited in the USA and certain European countries. The primary reason for the ban was the use of Freons and the manufacturing of EPPP, not its use. These days, the only countries using carbon dioxide and Freon to produce extruded materials are China and Russia.

The best material for insulating small and medium-sized buildings, as well as almost all communications and subterranean structures, is extruded polystyrene foam.

The technical and functional aspects of EPPS are what have led to its widespread use:

1. High thermal insulating qualities of EPPS, a 20 mm thick sheet of penoplex is equivalent to 40 mm of mineral fiber matting and 200 mm of wooden beam. The average thermal conductivity of EPPS is 0.03 W/m∙K;
2. Due to the increased density and partial ordering of the cell structure extruded material is able to withstand serious contact and bending loads, in the range of 0.4-1.0 kg/cm2. For expanded polystyrene, this indicator is 20 times less;
3. Resistance of extruded polystyrene foam to the destructive action of fungal and bacterial microflora, high acidity, pollution, temperature fluctuations.

Crucial! The effects of UV light and organic polar solvents, such as alcohol, acetone, dichloroethane, and liquid unsaturated and aromatic hydrocarbons, are the only things that polystyrene foam is concerned about.

Prominent manufacturers are aware of the drawbacks associated with EPS and are continuously striving to eliminate them. For example, an increasing number of materials for residential building insulation are made into sandwiches rather than "clean" sheets of extruded polystyrene foam. It is the identical EPPS, but sheets of non-flammable, water-resistant material are adhered to it.

Summary

You are always free to choose your insulation, but expanded polystyrene foam is a great option!

You are welcome to share your thoughts in the comments section regarding the material’s information.

September 6, 2016.

If you would like to thank the author, add a clarification, voice your objection, or ask a question, please do so by leaving a comment.

Disadvantages of polystyrene foam

• Low level of sound insulation. Styrofoam can only slightly muffle knocking and vibrations. But it does not absorb or reflect acoustic waves.
• Low level of resistance to many chemicals. Contact with solvents, acids, alkalis acts destructively on polystyrene foam, destroying its structure.
• Low resistance to fire. Modern quality material is self-extinguishing, but its ignition temperature is quite low and is 210-440 degrees Celsius. In addition, when burning polystyrene foam emits a whole "bouquet" of toxic substances into the air.
• Destruction under the influence of sunlight. Without proper protection in the form of a finishing layer, polystyrene foam open to ultraviolet light quickly becomes unusable.
• Exposure to rodents and insects. The softness of the material attracts many pests, which easily lay burrows and passages in it. To protect against them it is necessary to apply special means and methods.
• Low level of vapor permeability. In a low-density insulator, vapor passes through the pores and condenses in it. Thus, the thermal conductivity of polystyrene foam increases by 7-10%. When the temperature drops to zero, condensate will freeze and destroy the insulation.

Properties of foam plastic as insulation full list

Because of the name of the Finnish company that supplied polystyrene foam to the USSR, polystyrene foam (PPS) is commonly referred to as "penoplast." Similar to "Xerox," the company’s name eventually became the material’s name and a nominal designation.

Hundreds of businesses both domestically and internationally now make Styrofoam. Foam plastic production equipment is inexpensive and does not require skilled labor for upkeep and operation.

Now let’s look at Styrofoam’s primary characteristics as an insulator:

• Styrofoam is lightweight. This property of expanded polystyrene allows it to be used for insulation of lightweight structures, such as facades on lightweight foundations or floor slabs in residential buildings under screed. Styrofoam does not increase the weight of insulated structures at all and this puts it on the first place among all insulators, when it is necessary to leave the weight of the structure the same or to avoid loading of the structure.
• Styrofoam is combustible. This property negatively affects all applications of Styrofoam as an insulator. This is especially true for the use of PPS as insulation in ventilated facades. Where there is free access of air to the insulation, expanded polystyrene should not be used. However, in any closed construction, such as a wet facade system, it is possible and necessary to use foam plastic as an insulator – it belongs there.
• Foam is eaten by mice. What is true, is true. Rodents love to make their nests in the thickness of foam plastic. It is not uncommon to see during the dismantling of basement insulation entire mouse cities in the foam, with chambers for storage of supplies and long passages between them. It is necessary to close the foam plastic from mice with a metal mesh with a fine mesh to exclude this mishap.
• Styrofoam is cheap. This gives this insulation a big head start over other effective insulators. In the conditions of Russian reality, when an individual builder is forced to save every ruble, the cost of insulation sometimes comes first, overshadowing the requirements for fire safety or environmental friendliness.
• Styrofoam is warm. Thermal insulating properties of expanded polystyrene are really high. This is one of the most effective insulators with a thermal conductivity of 0.03-0.05 W (m*C), which allows you to do without a minimum layer of insulation for insulation of building envelopes. In order to achieve the required by the new SNiP index of heat resistance of building envelopes, for example, for Moscow, you need only 150 mm of foam on the walls and 200 mm of foam on the floor and ceiling.
• Styrofoam absorbs moisture. This property does not allow the use of foam plastic for insulation of pipes laid in the ground. There are other, more suitable, heat insulators for this purpose.

Let’s now discuss the use of expanded polystyrene in contemporary low-rise private building.

Extrusion polystyrene foam technical characteristics

We want to call particular attention to the fact that manufacturers frequently exaggerate a product’s ability to prevent fires. Naturally, the material won’t ignite from a cigarette that has been dropped carelessly or from a smoldering cigarette butt, but it will ignite from an electric welder that is sparking or from a match.

EPP burns as many people have seen time and time again. Everyone observes that thick, pungent clouds of black, acrid smoke form as the material burns.

Our domestic homeowner will always select a thicker sheet for insulation, according to the experience of EU citizens who have used extruded polystyrene foam in residential buildings with great success for many years. Europeans usually find that 3–4 mm is plenty. You’ll say, of course, that their winters aren’t as harsh, and you’ll be partially correct.

On the other hand, a thin layer of thermal insulation releases far fewer toxic substances into the room in the event of a fire. Families will be able to vacate the building before they have a chance to seriously harm someone’s health. Why don’t people give up on the hazardous content entirely? The salient point here is not so much the self-assurance of EU citizens as it is the fact that the advantages of the EPP are so great that fussy outsiders overlook small "deficits."

Using EPP for thermal insulation in buildings with high temperature regimes, like saunas or baths, is not worth it. Sunlight, or more specifically ultraviolet radiation, as we just discussed, is detrimental to EPP. Paint the thermal insulation or use a solid cement mortar covering it. Do not expose the material to sunlight, not even for a little while!

It should be mentioned that despite its thick layer, extruded polystyrene foam does not react well to sudden changes in temperature. Cracks are observed to occur in EPP when subjected to such drastic changes.

There’s a chance that eventually icy air will seep through the openings. However, it is an undeniable fact that our room will get warmer the thicker the expanded polystyrene we use. Video alert:

Marking

European and GOST standards are followed in the labeling of expanded polystyrene foam.

The following information should be labeled, per GOST:

• Name of the product
• Manufacturer"s name or trademark and address
• Working shift, date of manufacture, workshop of the manufacturing plant
• Fire safety class
• Thermal resistance
• Thermal conductivity
• Nominal thickness
• Marking code
• Type of cladding or coating, if any
• Length and width
• The number of products in the package and their total area, if necessary

The document EN 13164:2001 contains information on EPPS labeling standards used throughout Europe. Different manufacturers, however, have different names for these fundamental qualities. For instance, the following marking is present on products sold under the Penoplex brand:

• Indication of type – 30, 35, 45
• Fluted surface designation
• Indication of the selected quarter
• Board thickness in mm

This marking is in the format 35GS-30.

Advantages of polystyrene foam

1. Low thermal conductivity. A 120 millimeter thick polystyrene foam with its thermal insulation qualities corresponds to a brick masonry wall about 210 centimeters thick or a 45 centimeter thick wood wall.
2. Low weight. Insulation boards are light, as they are 98% composed of air. They are easy to transport and install even on your own without helpers. In addition, polystyrene foam does not exert any load on the foundation, floors and walls.
3. Water resistance. Extruded material practically does not pass and does not absorb moisture. It is a hydrophobic insulator, which can be used as a waterproofing material. In addition, moisture is not able to spoil polystyrene foam or deteriorate its qualities.
4. High resistance to deformation. The thermal insulator has high compressive strength values. It can be placed as insulation and waterproofing on the floor under the screed.
5. Wide permissible temperature range of operation. The material is not afraid of frost, withstands prolonged heating up to 80 degrees Celsius and short-term up to 95 degrees Celsius. When the temperature rises above this mark, polystyrene foam begins to soften.
6. Ease of installation. The technology of plate installation is simple and can be done even by a beginner. In addition, it is easy to handle the edges and cut polystyrene foam with an ordinary construction or assembly knife. No special equipment will not need to work with it.
7. Low cost and quick payback. The cost of this insulator is much lower than many other heat insulators. Moreover, the effect of installation of expanded polystyrene boards is felt immediately – heating and conditioning costs are reduced to a large extent (at least 3 times).

Extruded polystyrene foam characteristics

• Strength within 2-3.6 kgf/sqm. cm at 10% linear strain and 4-7.1 kgf/sq. cm at static bending. The strength index of EPPS directly depends on its thickness and density.
• Bulk weight – 15-29 kg/cubic meter. m and 30-36 kg/cubic meter. м. The first is used for insulation of houses and industrial buildings and is fixed on unloaded structures – walls, ceilings, interstorey ceilings. The second is used to insulate the foundation, floor, roof and other horizontal and inclined surfaces.
• Shrinkage The material is practically absent in any operating conditions.
• Thermal conductivity 0.026 w/mGrad at an average temperature of 10 C. As an insulator polystyrene foam is noticeably superior to other materials. For example, 50 mm thick foam insulation would be equivalent to 20-30 mm of EPPP.
• Frost resistance. The material loses only 5% of thermal resistance after 1000 cycles of freezing and thawing. Temperature range, in which it does not change the physical and thermal conductive parameters – from -50 to +75 C.
• Water absorption no more than 0.5% of the volume within 30 days. Low moisture absorption is due to the low capillarity of the material. This allows its use in high humidity conditions and for insulation of basements and roofs. Water absorption occurs only on the surface due to the fact that there are broken cells there.
• Vapor permeability depends on the thickness and density of EPPS. 20 mm thick boards have vapor permeability equivalent to one layer of roofing felt. Foam polystyrene brand Penoplex has a coefficient of vapor permeability 0,007-0,012 mg/(m-h-Pa).
• Class fire resistance of ordinary EPPS – G3-G4. Addition of flame retardants raises the class to G1. The material is not completely incombustible, but has sufficient resistance to fire for use in the construction of buildings and structures.
• Cost material is charged per square meter or cubic meter. Depending on the manufacturer and brand ranges from 55-80 rubles./sq. м. or from 3800 rubles./cubic meter. м.
• Sound insulation. Impact noise reduction index – 25 dB. XPS refers to materials used for insulation against impact noise.
• Environmental friendliness. Insulation refers to moderately hazardous and has a toxicity class T2. Not subject to decomposition in the environment, the appearance of fungi and molds.
• Service life extruded polystyrene foam is comparable to the service life of the building. Quality material serves more than 40 years if the installation technology is followed.

Extruded polystyrene foam, commonly known as XPS, finds versatile applications across various sectors, particularly in the realm of building construction and insulation. Its lightweight yet sturdy nature makes it an ideal choice for insulating walls, roofs, and floors in both residential and commercial buildings, effectively reducing heat loss and enhancing energy efficiency. Beyond construction, XPS is also utilized in packaging due to its excellent shock-absorbing properties, safeguarding fragile items during transit. Moreover, its moisture resistance makes it suitable for use in areas prone to dampness, such as basements and crawl spaces. Additionally, XPS is employed in crafting models and prototypes in the manufacturing industry, owing to its ease of shaping and durability. From improving thermal performance to providing protection and versatility in various applications, extruded polystyrene foam proves to be a valuable material in diverse spheres.

Important points

Since EPS boards are a costly material—as I’ve already indicated—low-quality knockoffs are frequently seen on the market. It’s not difficult to identify them. Usually, a quick glance at a new section of the board suffices.

A uniform layer characterizes high-quality material because 0.1 mm cells are hard to see with the naked eye. However, you can see the balls that make up the fake right away.

Additionally, if you have the time and the conditions permit, soak a piece of material in water for a day. Then, wipe it off, place it on a napkin, and attempt to squeeze it out. A few drops of real polystyrene foam will trickle out, while the imitation will completely wet the napkin underneath.

Putting the slabs down on asphalt.

In accordance with SNiP standards, plaster or a comparable material with a minimum thickness of 30 mm that can endure the effects of an open fire for 30 minutes should be placed on top of this insulating layer.

As I’ve already mentioned, burning polystyrene foam releases harmful smoke, so having this protection is necessary to give people at least thirty minutes in case of a fire before the fire reaches the insulation. However, this requirement is largely disregarded, to be honest.

I can also add, based on my own experience, that you should not skimp on the brand of boards you buy. If the number is less than 28, it is best to pass on the better deal.

Arranging tiles using mounting glue.

Pros and Cons of Extruded Polystyrene Foam

One type of insulating material with a consistent structure is extruded polystyrene foam. It is made up of tiny, closed-type cells. Granules of polystyrene are combined under intense pressure to create an EPP board. The foaming agent is gradually added.

The image displays extruded polystyrene foam.

The following can be linked to the material’s benefits:

1. High indicators of heat preservation. The thermal conductivity coefficient is 0.031-0.042. Since it is high, it manages to reduce the consumption of polystyrene foam several times.
2. It is not exposed to moisture. The material is based on such a component as polystyrene. In the process of processing, it forms cells that are filled with air. Thanks to this insulation does not absorb water. Thus, extruded polystyrene foam can be used for foundations, swimming pools and flat roofs. Due to water resistance, the material is characterized by high heat-saving properties, which remain unchanged throughout its service life.
3. Thermal insulation material is not subject to the influence of rot, mold and fungi. Thus, its structure remains unchanged.
4. High compressive strength. When the polystyrene foam is affected by mechanical or temperature factors, it remains in the same state.
5. High noise insulation. Since the cells of polystyrene foam are filled with air during the manufacturing process, this increases its sound insulation. Using the material for thermal insulation of the house, it is possible to improve its noise insulation by 35 dB.
6. High fire safety. The considered insulator does not contribute to the spread and support of the hearth of fire. In addition, polystyrene foam is a self-extinguishing thermal insulator. Thus, it can even be used to put out a fire.
7. Affordable price. Due to its low cost, many people will be able to buy this kind of insulator.
8. Does not react chemically. The insulator is unaffected by lime, salt, gypsum, roofing felt, cement, concrete, soda, alcohol. In addition, it will be able to withstand short contact with food and machine drains.
9. Ecological purity. By using extruded polystyrene foam, you do not have to worry about your health.
10. Long service life. Since extrusion method was used for polystyrene production, it guarantees high performance characteristics of the material. Its properties remain unchanged for 50 years. Therefore, you will not have to change the old insulation for a new one often.

Extruded polystyrene foam in the video:

The disadvantages of extruded polystyrene are not zero. It crumbles when it comes into contact with complex carbons. When exposed directly to UV radiation, it suffers negative effects. One cubic meter of insulation will contain 104 micrograms of styrene when heated to 25 degrees. It won’t be utilized for thermal insulation on a highly exploited facade because a denser material will be required.

This article will explain what foam ceiling tiles are and where they are used.

This article explains how to adhere foam to concrete and what adhesive material is worth using.

It will be easier to comprehend the following information if you know how and with what material the exterior of the foam is plastered: /sypuchie-materialy/shtukaturka/po-penopleksu.html

And this article goes into detail about how to plaster a facade on foam and how challenging it is to do.

Production of extruded polystyrene foam boards

Chemical extrusion on specialized lines produces EPPS. The basic line can be composed of the following equipment:

• tandem extruder systems with automatic filter change;
• single unit extrusion plant;
• mixers;
• molds;
• forming platforms;
• product removal device;
• pulling device;
• trimming machine;
• calibrators;
• flat-slot heads (dies) with adjustable profile of the forming channel;
• auxiliary devices and equipment.

Polystyrene foam insulation scheme for the "wet facade" system.

The most common types of extrusion plants are single-unit systems with one or two worm extruders and double-unit (tandem) systems, where extruders are installed one after the other. A continuous processing machine for polymer raw materials, an extrusion plant shapes the materials by forcing them through an extruder and a dedicated calibration section. Pure polystyrene granules are used as the raw material in the production of EPS, and they are manually or automatically loaded into the extrusion unit’s hopper using a loader that is mechanical. The raw material enters the auger’s feed section through a funnel from the hopper volume, travels through the cylinder for plasticization, and then exits.

The plasticizing cylinder consists of a rotating auger, and is driven by hydraulic or electric motors. screw moves to the mouthpiece during injection and then takes the initial position. Axial displacement of the piston is made by the work of the plunger with a hydraulic cylinder. Plastic cylinder is designed for loading, feeding the extrudate to the mouthpiece, special processing of raw materials (plasticization), in the process of which the extrudate (mass) gets the necessary working properties, dosage, injection. As a result of the system, heating, squeezing, mixing, the extrudate melts, acquiring a homogeneous composition. The following extruder devices are required to produce finished EPPS: blowers, extrudate transport system, oil cooling, mixing of the main raw material with modifying additives, stabilizers and gases, dosing units, various nozzles, devices for transporting the belt to the devices for cutting plates, supplying products to the warehouse and others. There is a conveyor production.

Returning to the contents table

Technology of insulation of the wall with polystyrene from the outside

It is essential to remove gutters and ornamental elements, clean the wall, and apply primer to it before beginning to insulate the wall with expanded polystyrene. Moreover, to create window jamb and eaves thermal insulation.

Let’s now discuss polystyrene foam thickness.

REMEMBER THIS: When installing extruded polystyrene sheets for wall insulation, make sure the sheets are at least 80 to 100 mm thick.

You can use thinner sheets 30-40 mm thick, if they are laid in two layers.

Let’s move on to using our hands to install insulation on the walls:

• in the lower part of the wall is installed profile to hold polystyrene foam;
• the adhesive mixture is applied to the wall on the entire area pointwise and on the sheet of insulation (abundantly on the center and edges of the sheet);
• tightly attach the sheet to be glued to the wall;
• Use dowels to fix the panel so that the dowel enters the wall at least 50 mm. Dowels are placed in the center of the panel and at the joints. It is recommended to use plastic nails;
• If gaps are formed (up to 2 cm), they are sealed with mounting foamfoam, if the gaps are larger, they are first sealed with pieces of insulation and then foamed. Excess foam is cut off;
• The plastic nail heads are cleaned and puttyed.

A reinforcing mesh is applied to the facade following the installation of the insulation. On slopes and corners, mesh strips must be cut to the appropriate length and glued with an adhesive-containing trowel. Adhere the wall grid to the polystyrene foam by allowing the adhesive to seep 0.1 centimeters through the grid. Separate mesh strips are overlapped and glued extra if an overlap forms.

Gadget in a cut

Using dowels to secure the boards

Using the adhesive for installation

Once the surface has completely dried, fine-grit sandpaper is used to level it.

Next, putty and a final decorative coating are applied to the wall surfaces. External insulation with polystyrene foam with proper installation will provide coziness and warmth in the house.

Extruded polystyrene foam, or XPS, has shown to be a useful material with a range of uses in home insulation and heating. Because of its special qualities, it’s the best material for a variety of applications, including underfloor heating systems and wall and roof insulation.

Insulating exterior walls is one of the main applications for XPS. It can withstand the weather and maintain thermal efficiency thanks to its high compressive strength and moisture resistance. Homeowners can greatly reduce heat loss through walls by installing XPS insulation, which will improve indoor comfort and result in lower energy bills.

Additionally, XPS is used to insulate attics and roofs. A layer of XPS insulation placed between the outer roofing material and the roof sheathing allows homeowners to stop heat from escaping through the roof, which helps to keep the interior temperature consistent all year long. This improves comfort and helps save energy at the same time.

XPS is also frequently utilized in underfloor heating systems. Because of its superior thermal conductivity, the floor distributes heat effectively, giving the living area a consistent temperature. Underfloor heating with XPS insulation provides an opulent and economical heating option, and can be combined with new construction or retrofitted into an existing house.

To sum up, extruded polystyrene foam finds use in a multitude of heating and insulation applications for residential buildings. Both builders and homeowners favor it because of its strength, longevity, and thermal efficiency. XPS is a dependable solution for increasing comfort, lowering energy use, and boosting overall sustainability in home environments, whether it is used to insulate walls, roofs, or floors.

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