ICF forms have steel or polypropylene webs that hold two leaves of an insulating board that is made from Neopor. Originally ICF incorporated EPS. This post identifies the differences between the current insulation materials that are used in the building industry.
EPS
EPS is short for expanded polystyrene and all the early ICF forms were made from it. BASF the German chemical company recognised that if the insulation value of EPS could be improved and developed Styropor and then the Neopor
EPS is still used widely for insulation and packaging.
How is it made
• EPS begins with small polystyrene beads, often around 0.5-1.5mm in diameter.
• These beads contain a blowing agent, typically pentane, which is a hydrocarbon that evaporates easily.
• The polystyrene beads are fed into a pre-expander, a machine that uses steam to heat them.
• The steam causes the pentane inside the beads to vaporize and expand, increasing the bead’s volume.
• This pre-expansion stage can increase the bead size up to 40 times its original volume.
• The beads are then allowed to mature and stabilize in silos, allowing the pressure inside to equalize.
• The pre-expanded beads are then fed into molds, which are shaped to the desired final product.
• Steam is introduced into the mold, causing the beads to expand further and fuse together.
• This molding process creates a rigid, lightweight, and closed-cell foam structure.
• The final EPS product is typically 98% air and 2% polystyrene.
• EPS is known for its excellent insulation properties, lightweight nature, and cushioning abilities.
XPS
XPS is a type of polystyrene foam that is manufactured through extrusion, resulting in a more uniform and dense structure. This makes XPS an excellent choice for applications requiring both thermal insulation and moisture protection, such as below-grade foundations, roofs, and walls.
How is it made
• Polystyrene beads are melted into a liquid state.
• The molten polystyrene is forced through a die to create a continuous sheet of foam.
• Blowing agents and additives are mixed with the polystyrene, and as the mixture cools, it expands, forming the closed-cell structure
Advantages of XPS
- Effective insulation: Reduces heat transfer, leading to energy savings and improved temperature regulation.
- Moisture resistance: Protects against water damage and mold growth in various applications.
- Durability and strength: Withstands heavy loads and compressive forces.
- Long lifespan: XPS can last for many years, providing long-term insulation benefits.
Disadvantages of XPS:
- Higher cost: Generally more expensive than EPS insulation.
- Heavier and more difficult to handle: Can be more challenging to cut and install compared to some other insulation types.
Styropor and Styrofoam
In 1951 the German compny, BASF AG introduced Styropor, the world’s first EPS raw material for thermal insulation. Styropor is a registered trademark of BASF AG and is EPS, while Styrofoam is a registered trademark of the Dow Chemical Company and is XPS
Neopor
Neopor is an innovative thermal insulation raw material that was developed from Styropor® by BASF in 1998. It is a general purpose thermal insulation material that contains special graphite particles which give it a unique silver-grey color, compared to the white Styropor. Neopor consists of granular raw materials and improves insulation performance by 20 percent over conventional insulation materials. It is widely used by processors for various applications such as building insulation (insulation boards for façades, roofs, and floors), sound absorption and various packaging materials.and of course ICF.
BASF has continued to innovate by replacing the flame retardant HBCD (hexabromocyclododecane) with the eco-efficient flame retardant Polymeric FR, throughout its entire thermal insulation product line (HBCD is listed as a POP (Persistent Organic Pollutant).and is banned in the EU, Canada and China).
Polymeric FR greatly reduces flame spread and furthermore Neopor will self-extinguish once the source of fire is removed.