Battle of the Titans: which is better foam concrete or polystyrene concrete

The selection of building materials can be quite confusing. Polystyrene and foam concrete are two common options for insulated and lightweight construction. Both are employed in different construction projects and each has a unique set of benefits, but which one really sticks out? The main distinctions between foam concrete and polystyrene concrete will be covered in this article to help you choose wisely for your upcoming project.

Air bubbles are added to the concrete mixture to produce foam concrete, also referred to as cellular concrete, which is lighter and more insulating than regular concrete. It is a favorite for a variety of applications, from blocks and panels to void filling and insulation, and is frequently commended for being simple to use and adaptable.

Conversely, tiny polystyrene beads are mixed into the mixture to create polystyrene concrete. This addition makes the concrete lighter and improves its ability to insulate against heat. Because of its superior thermal insulation, polystyrene concrete is highly prized and perfect for projects that prioritize energy efficiency.

While there are many advantages to both materials, depending on the particular requirements of your construction project, one may be more appropriate than the other due to differences in composition and performance. Knowing these two materials will give you the knowledge to select the one that best suits your needs, regardless of whether handling simplicity, thermal efficiency, or some other consideration is more important to you.

Feature	Foam Concrete	Polystyrene Concrete
Thermal Insulation	Good insulation properties	Excellent insulation, better than foam concrete
Weight	Lightweight	Lightweight, but heavier than foam concrete
Strength	Moderate strength	Higher strength compared to foam concrete
Cost	Generally cheaper	Usually more expensive
Ease of Use	Easy to work with	Easy to handle but requires more care

Both foam concrete and polystyrene concrete have advantages over the other that make them suitable for varying construction applications. This is the subject of an ongoing debate. Foam concrete is preferred due to its versatility and ease of use, as well as its excellent insulation qualities and lightweight nature. In contrast, polystyrene concrete has embedded polystyrene beads that provide increased strength and improved thermal insulation. Comprehending the distinct benefits and uses of every material can assist constructors in making well-informed choices regarding the most appropriate choice for their projects, guaranteeing maximum efficiency and economy.

A little about the most important

Before delving into a thorough analysis and determining which is superior, expanded polystyrene concrete or foam blocks, let’s first make clear how each is made. Products from the plant will cost more, but if you have to choose between purchasing goods from a small manufacturer or those manufactured in a factory, don’t hesitate to purchase goods from the plant.

There are two clear advantages to making this decision:

Reasons	Large manufacturing enterprises	Small and medium-sized organizations
Technological efficiency	Most factories and plants are equipped with a set of professional equipment. Products from such lines are of the best quality. Although, there is always a certain percentage of defects. This should not be forgotten either.

These are the two primary factors that affect the blocks’ quality. Not buying what I’m saying? Purchase foam and polystyrene concrete blocks, bring them to a separate construction laboratory (do not name the manufacturers to ensure experiment integrity), and obtain a comparison of quality markers.

Characteristics of blocks

Comparing polystyrene and foam concrete on similar-looking blocks is the best way to make comparisons. Let’s look at high-quality, permanently dry polystyrene blocks D600 and foam block products D600–D800.

Density

Both materials meet the requirements of GOST R 51263 – 2012 "Polystyrene concrete" and GOST 25485-89 "Cellular concrete." Three categories of "technical conditions" exist: structural, heat-insulating, and structural-heat-insulating.

Our blocks are included in the third group. This implies that they can be utilized to construct two-story houses’ load-bearing walls.

Polystyrene concrete D600 is permitted for use in the construction of three-story houses, and higher density foam concrete is used instead. Polystyrene concrete blocks of the relevant grade are a perfect choice for superstructures.

However, it’s important to keep in mind that low-density wall material crumbles when drilled, making repairs impossible.

Strength

When compared to foam blocks of the same brand density, the strength properties of polystyrene concrete are 1.5 times higher. Hence, with D600, polystyrene concrete has a stable strength class of B2.5, whereas standards indicate that it should be B2, but its foamed relative consistently displays class B1.

Actually, it hardly ever gets to this amount. Consequently, load-bearing structures are constructed using polystyrene concrete of the appropriate density, whereas interior partitions are made of D600 foam concrete blocks.

Two factors are directly linked to this gap:

• Structure.If you look at foam concrete in cross-section, you will notice significant differences – its body is all dotted with homogeneous bubbles. They provide lightness, volume and heat capacity. But, at the same time, this reduces the strength indicators. The higher the strength indicator, the higher the density and the lower the thermal conductivity.

Concrete made of polystyrene is another story. Polystyrene filler contributes warmth, lightness, and volume; it also has strength data. Regarding air-filled microbubbles, nothing can be said.

• Supplements.The strength of concrete is simply “eaten up” by foaming agents, which during hardening reduce the activity of cement at the chemical level. But, it is worth keeping in mind that if the filler in polystyrene concrete has poor adhesion, then the balls will begin to crumble out of the concrete body. The quality of the products will suffer greatly as a result.

Another weakness of foam concrete is its fragility. Cracks under dynamic load, chips at the corners, and dents where the packing tape is used are all signs of the material’s ongoing "disease." In the picture, she is clearly reflected. When using polystyrene foam, this is not seen.

Thermal conductivity

Cellular concrete’s ability to retain heat is the primary factor contributing to its growing popularity. They are the same for both types when we take the D600 brand into account: 0.14 W (m * o C). However, when considering the strength indicators, concrete blocks made of polystyrene win out.

For instance, polystyrene concrete D600 is appropriate for building load-bearing walls, and D800 is required if foam concrete is to be used as a wall material. Furthermore, this brand’s 0.21 W (m * o C) thermal conductivity is an order of magnitude worse.

Thus, as the wall thickens, the following consequences result:

• additional costs for the purchase of blocks, masonry mortar, reinforcement cages;
• an increase in the load on the foundation, respectively, work is carried out to strengthen it;
• the need for a more reliable insulation of the facade and heating system.

Frost resistance

Another factor that will help decide whether polystyrene concrete blocks or foam blocks are more durable is frost resistance. A product’s ability to withstand multiple freeze-thaw cycles without breaking down is known as its frost resistance.

Residents in areas with a harsh continental climate in particular should be aware of this parameter. Polystyrene blocks can withstand up to 45 cycles of frost, but foam concrete can only tolerate up to 35 cycles.

Vapor permeability

Currently, building homes with "breathing walls" is in style. Sounds good. However, let me explain what it means and how beneficial it is for the house’s microclimate. The ability of a material to pass steam and air is known as its vapor permeability.

Additionally, the indicator’s capacity to pass air flows through itself increases with its height. On the one hand, there are a number of advantages to this:

• the walls will not get damp;
• there is no condensation on the windows;
• you can say goodbye to stuffiness in the rooms.

On the other hand, all of the cold will enter the house during windy and icy conditions.

An increase in the vapor permeability coefficient indicates that the material can hold onto more moisture. Wet walls are uninviting and have a short lifespan. Technical documentation states that an indicator of the same kind for foam concrete is 2.25, and for polystyrene concrete it is 0.068.

There are two ways to solve the problem with such values:

• In polystyrene houses, it is necessary to arrange powerful ventilation, choose only plaster mixtures with a high level of vapor permeability, both for the facade and for interior work. Or use a facade ventilation system as a finish.
• Foam concrete walls require a reliable and competent device of an insulated ventilated facade.

Combustibility

These two wall materials are classified as G1 flammable. In other words, they are not fire resistant but they also do not burn. For instance, foam blocks crack and polystyrene balls in concrete gradually collapse. But a fire that lasted for several hours produced these.

Environmental friendliness

Concrete made of foam and polystyrene is completely safe for the environment and poses no health risks. However, there are a few minor variations. Insects and rodents are not drawn to foam concrete on sand, nor is it prone to the growth of fungi. when insects can sharpen blocks of polystyrene.

Adhesion with plaster solutions

Foam concrete adheres to plaster and gypsum mixtures very well. When the adherence of polystyrene concrete blocks is poor, finishing work will cost more.

Manufacturability

Indicators such as manufacturability of production are crucial for individuals who choose to fabricate wall materials by hand. As demonstrated in the video in this article, the production of polystyrene concrete blocks is characterized by easily accessible production instructions and the utilization of basic equipment.

When producing foam concrete, specific tools, forms, humidity levels, and expertise regarding the impact of foam concentrate on product characteristics are needed. Another characteristic that sets foam concrete production apart is the high percentage of flaws that make the material unfit for construction. The biggest challenge is producing foam of high quality. It determines how long-lasting future products will be.

Both foam concrete and polystyrene concrete have advantages over one another and serve different purposes in the ongoing construction industry debate. Foam concrete is renowned for its superior thermal insulation, low weight, and simplicity of use. It is a well-liked option for filling gaps, insulating layers, and non-load-bearing walls because of these characteristics. Additionally, because of its lower density, the structure as a whole is not as stressed.

Conversely, polystyrene concrete offers a special blend of strength and lightness. Its thermal and acoustic insulation qualities are improved by the addition of polystyrene beads, which makes it appropriate for a range of uses, including in certain circumstances load-bearing structures. Its ability to withstand water absorption also adds a layer of durability, particularly in moist environments.

The particular needs of your project will ultimately determine which type of concrete—foam or polystyrene. Foam concrete might be a preferable choice in situations where thermal insulation and lightweight material are essential. However, polystyrene concrete might be a better option if strength and moisture resistance are more crucial considerations. Both materials give builders a variety of options to satisfy contemporary building standards while also supporting more sustainable and effective construction methods.

To sum up, foam concrete and polystyrene concrete are both useful in the construction sector, though they have distinct advantages. Builders can select materials that best suit the objectives and constraints of the project by being aware of their qualities and advantages. The application of these cutting-edge materials will develop further as construction technology progresses, offering even more specialized solutions for a range of building requirements.

Video on the topic

What is better Aerated concrete or Polystyrene concrete ? // Water absorption // Gleb Grinfeld

Foam concrete D600 and polystyrene concrete D500

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