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.

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CONTENTS

CHAPTER TITLE PAGE NO

Certificate iAcknowledgement iiDeclaration iiiAbstract ivContents vList of figures vii

CHAPTER 1 INTRODUCTION 1-5

1.1 General 11.2 About Expanded Poly Styrene (EPS) 21.3 Raw Materials of EPS 31.4 EPS Manufacturing Process 31.5 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 6Pre-cast sandwich composite panel & RC moment frame with brick infill

2.3 Use of advance plastic materials in Nigeria performance assessment 7EPS building technology system

2.4 Light weight expanded polystyrene beads concrete 72.5 Radiative properties of EPS foams 82.6 Modelling of heat transfer in low density EPS foams 82.7 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 buildings2.9 Partial replacement of coarse aggregates by EPS beads in concrete 102.10 Compressive creep test on EPS geo foam 10

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CHAPTER 3 METHODOLOGY 11-27

3.1 Properties of EPS 113.2 EPS technical details 153.3 EPS Wall insulation & EPS Roofing at Angul, Odisha 173.4 Benefits of EPS 183.5 Methodology of EPS panels installation for wall 193.6 Expanded polystyrene concrete 26

CHAPTER 5 A CASE STUDY 28-29

CHAPTER 4 CONCLUSION 30

REFERENCES 31-32

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LIST OF FIGURES

Figure No. Title Page No

1.1 Polystyrene Beads 31.2 Pre - Expansion of Polystyrene Beads 41.3 Manufacturing Process of EPS 53.1 Technical details of EPS 153.2 Procedure for installation of EPS panels for wall 193.3 Electrical drilling machine 193.4 Drilled holes in foundation 193.5 Erection of EPS panels 203.6 Alignment of EPS 203.7 EPS slab panel Erection 213.8 EPS slab & wall Erection with wire mesh arrangement 223.9 Opening of wall panel 223.10 Electrical conduiting and plumbing after installation of EPS 233.11 Shotcrete Pumping machine 243.12 Shotcreting all over the walls 243.13 Structure after shotcreting 253.14 Finished view of building 253.15 EPS concrete 273.16 EPS concrete sandwiched between calcium silcate Boards 27

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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.

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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.

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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.

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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).

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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.

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CHAPTER 2

LITERATURE REVIEW

2.1 THERMAL BEHAVIOUR AND ADMISSIBLE COMPRESSIVE STRENGTH OF EXPANDED POLYSTYRENE WALL PANELS OF VARYING THICKNESSAnthony 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 INFILLkaira 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

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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 CONCRETEAman 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

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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 FOAMSCoquard 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 FOAMSR. Coquard and D. Baillis Nov 04, 2005

ARTICLEREFERENCES

FIGURESTABLES

CITING 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.

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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.

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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.

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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

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on both material and labor. And for a given insulation performance, EPS itself costs less than these competing materials.

InsulationIn 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

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insulation material – waterlogged open-cell foams and mineral fibers are very 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

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

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spontaneously. When burning, EPS exhibits the normal characteristics of hydrocarbons such as wood, paper etc. Combustion products are mainly carbon monoxide and styrene.

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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.

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3.2 EPS TECHNICAL DATA

Fig 3.1 TECHNICAL DETAILS OF EPS

LongTermInsulationValueR-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.

MoistureResistanceWater 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-

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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.

TemperatureCyclingEPS 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.

StrengthCharateristicsFor 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.

CombustibilityLike 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

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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

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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 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

Compatible with fully adhered, ballasted or mechanically fastened systems

Compatible with common roof assembly components

Superior Performance

Dimensional stability

Moisture resistance

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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

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.

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Fig 3.3 Electrical Drilling Machine Fig 3.4 Drilled Holes in

Foundation

Fig 3.5 Erection of EPS Panels

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Fig 3.6 Alignment of EPS Panels

2) Wall panel erection

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.

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Fig 3.7 EPS Slab Panel Erection

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.

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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

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.

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Fig 3.10 Electrical Conduiting and Plumbing after Installation of EPS Panels

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 1 st layer being a rough layer and 2nd layer as a finishing layer.

SITE PICTURES AT ANGUL, ODISHA

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Fig 3.11 Shotcrete Pumping Machine

Fig 3.12 Shotcreting all over the walls

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Fig 3.13 Building after shotcreting

Fig 3.14 Finished view of a Building

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

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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.

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

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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

Fig 3.16 EPS concrete sandwiched between Calcium Silcate BoardsCHAPTER 4

A CASE STUDY

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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 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.

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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.

CHAPTER 5

CONCLUSIONS

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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.

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