Construction from polystyrene concrete – a step-by-step analysis of the work

A novel building material known as polystyrene concrete combines the strength of concrete with the insulating qualities of polystyrene. Because of this combination, it’s a great option for contemporary building projects that want to be sustainable and energy-efficient. Gaining an understanding of the procedure for working with polystyrene concrete can help you, as a professional builder or a do-it-yourself enthusiast, create new possibilities for your construction projects.

We’ll go over every step of using polystyrene concrete in this guide, from preparing your supplies to adding the finishing touches. You’ll discover the proper methods for combining the ingredients, pouring the mixture, and watching it cure to create a sturdy, insulated building. Assuring you have all the information you require, we’ll go over each step in detail because it’s essential to getting the best results.

Compared to traditional concrete, polystyrene concrete is lightweight, which facilitates handling and transportation. This is one of its main advantages. It is also an environmentally friendly choice due to its exceptional thermal insulation qualities, which can drastically lower heating and cooling expenses. After reading this guide, you’ll have the know-how to use polystyrene concrete with confidence in construction projects, increasing the sustainability and efficiency of your builds.

Step Description
1. Planning Determine the project scope, budget, and timeline.
2. Site Preparation Clear the site and set up the foundation layout.
3. Foundation Pour the concrete foundation and allow it to cure.
4. Mixing Prepare the polystyrene concrete mix as per specifications.
5. Pouring Pour the polystyrene concrete into the forms.
6. Curing Let the concrete cure properly to gain strength.
7. Formwork Removal Remove the forms once the concrete has cured.
8. Finishing Smooth and finish the surface as needed.
9. Insulation Apply any additional insulation if required.
10. Final Inspection Inspect the completed structure for any defects.

What is polystyrene concrete

The challenge for the engineers developing this material was to make flammable foam plastic safe in this sense while also developing a wall-building material with a limited thickness that wouldn’t require extra insulation. We got what we have as a result.

Expanded polystyrene granules, also known as foam plastic, quartz sand, plasticizing additives to lessen stratification and boost the mixture’s elasticity, and water make up polystyrene concrete. Together, these endow the material with the following favorable and unfavorable qualities (let’s start with the favorable ones):

  • The material can be used at a very high temperature range. If we take into account possible temperature fluctuations all over the planet, we can say that it has no limitations at all. Polystyrene concrete tolerates sharp temperature fluctuations well, which is important.
  • Humidity is also not a problem for polystyrene concrete. The presence of polymer granules in the structure reduces the degree of absorption of the blocks many times, which is especially good for regions with high humidity.
  • Due to the fact that moisture practically does not penetrate into the material, its frost resistance also increases. Manufacturers claim that the material can withstand 150 to 300 defrosting cycles, which, as you understand, is a lot. And what is important, this does not affect its thermal insulation characteristics.

  • The thermal insulation and sound insulation characteristics of expanded polystyrene concrete are at a very high level. What can I say, the creators managed to achieve the desired effect.
  • Polystyrene concrete is lightweight, due to which a lightweight foundation can be laid under walls and ceilings made of it, which is important for private low-rise construction, since it allows you to significantly reduce material costs.
  • The material can be purchased in liquid form or prepared by yourself to pour into the desired forms. In this way, you can make ceilings and lintels over door and window openings – we will talk about this a little later.
  • If desired, the building box can be made monolithic, using the same liquid mixture – this construction technology is also gaining popularity today.
  • Construction from such blocks is much faster than from bricks, since they have large dimensions. We also remind you that the material is lightweight, which means you can do without large lifting equipment.
  • The material is easy to cut with a regular hacksaw, which allows you to adjust the parts quickly and accurately.

Although the material has many benefits, it also has drawbacks.

It is worthwhile to draw attention to the most significant ones among all of them:

  • Polystyrene itself is moisture- and vapor-impermeable. It also imparts this property to walls and ceilings made from it. For this reason, moisture gradually begins to accumulate inside buildings, since it simply has nowhere to go. High humidity means a decrease in thermal insulation characteristics, a violation of the microclimate, and the possibility of mold appearing on the finish over time.

Counseling! Frequent ventilation of the room and appropriate system organization are the only ways to address the issue.

  • Polystyrene concrete blocks are not as strong as expanded clay concrete and similar materials. However, in this regard, it is much better than gas blocks, which do not have filler at all. You can hang weights on polystyrene concrete walls, but it is still recommended to use special fasteners.

  • Polystyrene concrete is a new material, and, despite all the assurances of manufacturers, we can only judge its durability using certain forecasting systems. That is, there are no real examples, and there cannot be.
  • There are no accurate toxicity studies either, since styrene is harmful and can be released into the surrounding air.
  • Fire safety polystyrene foam blocks has been installed, but it is also known for certain that when heated strongly, the polymers in the composition begin to release toxic substances. At the same time, the strength of the material itself is greatly reduced, which means that if a fire occurs, but the building survives, it will still have to be dismantled.

That’s interesting to know! Even when polystyrene concrete is heated to a temperature of 1000 degrees Celsius during testing, the material is not completely destroyed. Although the strength declines—as we have already mentioned—the structure is maintained.

Step-by-step construction of a polystyrene concrete house

It is likely that you have already determined whether or not this material is appropriate for you. If you answered "yes," you can anticipate that the building will be constructed in about three to four weeks (not including the foundation), provided that you work as a cooperative team without interruptions.

Foundation device

Laying the foundation is the first step in any construction, and as we’ve already mentioned, it can be lightweight for a house made of polystyrene concrete.

Among the following options, you can select one that works best for you:

  • Pile foundation – both reinforced concrete and metal options will do;

  • Columnar foundation;

  • Strip foundation – the most material-intensive solution.

The qualities of the soil on which you plan to build as well as the local climate must be considered when selecting the type of foundation.

  • The most universal solution in this case is the use of a pile foundation, since it can be used on almost any type of soil. It is especially advantageous to take the metal option, since it can be installed in just a couple of hours, welded with a grillage made of channel and immediately begin erecting the walls.
  • The second in speed and convenience will be a columnar foundation, and the most extended in time will be the strip version, since although the concrete in it may be of a low class, it still requires 28 days to gain its strength.

  • The installation speed of a columnar and pile foundation will also depend on the type of grillage used. In some cases, it is made of reinforced concrete, which similarly stretches the work for the already announced period.

Using that identical pile foundation as an example, let’s ascertain the installation sequence:

  • First of all, the site for future construction is cleared. It must be leveled and the turf – the plant layer – removed from it.

  • Next, precise marking is carried out using pegs and threads stretched between them. The main marking must repeat the outlines of the house. All angles are made right, unless otherwise planned by you, which can be achieved using the Pythagorean theorem about legs and hypotenuse, as well as checking the length of the diagonals, which must be equal.
  • According to the capacity of the future grillage and the piles themselves, we place marks under the places where the piles will be screwed in. It is difficult to make such a calculation without the necessary preparation, therefore, without a project, you have to be guided by common sense, more often playing it safe. A step of 1.5-2 meters is usually enough.

  • Then, according to the marked points, the piles are screwed in to the required depth, which depends on the depth of soil freezing in the region. Installation can be done manually, as shown in the photo above, or you can use the services of special equipment for an additional fee. The price for the work is not that high, so if you want to speed up as much as possible, we use such services.

  • Depending on the terrain features, the piles can be screwed in to different heights, so after installation they need to be cut to the same level. We mark it with a laser axis plotter or everyone"s favorite water level.
  • Cutting is done with a grinder.

Counseling! Make sure to use a level to check the position of each pile before screwing it in place because all piles must be installed strictly horizontally.

  • Next comes the turn to install the grillage. We have already attached a diagram with all possible options, so choose the best one for yourself – in our opinion, this is a metal channel, which is welded in the shortest possible time, and you can immediately continue working.

Is it possible to lay a plinth made of polystyrene concrete blocks, as many people frequently inquire? The answer will be no when it comes to building a house. The polystyrene concrete’s strength is insufficient for the plinth, which is the portion of the foundation that is above ground.

To accomplish these goals, you can use:

  • Heavy concrete (FBS blocks);
  • Expanded clay concrete blocks;
  • Red brick;
  • Rubble masonry;
  • Rubble concrete;
  • Reinforced concrete;

For the basement and foundation, polystyrene concrete blocks are still an option, but only as permanent formwork.

To be perfectly honest, you can use this kind of base for a very light structure—for instance, if you’re using polystyrene concrete to build a bathhouse.

The advantages of conventional concrete are combined with improved insulating qualities in polystyrene concrete, an innovative building material. It’s a great option for energy-efficient building projects because of this. Because of its lightweight design, which also makes handling easier and puts less strain on structures, it is a useful option for both residential and commercial buildings.

There are several important steps in the polystyrene concrete construction process. Every stage of the process, from foundation preparation and mixing the polystyrene concrete to material pouring and curing, calls for meticulous attention to detail. By taking these precautions, the completed structure will be stable and long-lasting, ensuring its dependability and safety.

Buildings can perform better thermally and builders can save a lot of money by using polystyrene concrete in their construction. This material promotes a more environmentally friendly building process in addition to offering superior insulation. Its adaptability in contemporary construction practices is demonstrated by its versatility, which allows for a variety of applications, from walls and floors to roof panels.

All things considered, polystyrene concrete offers a viable substitute for conventional building materials. It is a useful addition to any construction project because of its distinct qualities and simple application procedure. Builders can optimize the advantages of polystyrene concrete and ensure durable, energy-efficient structures by comprehending and applying the appropriate techniques.

The strength of conventional concrete and the insulating qualities of polystyrene are combined to create polystyrene concrete, a lightweight, adaptable building material. This post will walk you through every step of building with polystyrene concrete, from combining the ingredients to shaping and curing the framework. Regardless of your level of experience, from professional builders to do-it-yourself enthusiasts, our step-by-step analysis will give you the fundamental knowledge and useful advice you need to finish your project successfully.

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Dmitry Sokolov

Chief engineer in a large construction company. I have extensive experience in managing construction projects and implementing modern technologies.

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