DIY polystyrene concrete – proportions, manufacturing method, application

An innovative material that’s becoming more and more popular in the construction industry is polystyrene concrete. It’s a lightweight, insulating concrete that combines the qualities of polystyrene beads for insulation with the strength of conventional concrete. This makes it a great option for a variety of construction projects, particularly those where thermal insulation is important, like wall to floor projects.

Having the proper ingredients and measurements to make polystyrene concrete at home is one of its main benefits. Doing it yourself will allow you to cut costs and tailor the mixture to your own requirements. To improve the qualities of the finished product, a mixture of cement, water, and polystyrene beads is sometimes added.

We’ll walk you through the entire process of creating polystyrene concrete in this article. We’ll go over the required amounts, how to mix them, and the range of uses for this adaptable substance. This guide will give you all the knowledge you need to successfully create and use polystyrene concrete in your projects, regardless of your level of experience with do-it-yourself projects.

Proportions	Details
Ingredients	Mix cement, sand, water, and polystyrene beads in a ratio of 1:2:3:6.
Mixing	Blend the cement, sand, and water first, then slowly add the polystyrene beads while continuously stirring.
Consistency	Ensure the mixture is even and the polystyrene beads are well-distributed.
Application	Pour the mixture into molds or use it directly for walls, floors, and insulation.
Curing	Allow the concrete to cure for at least 7 days to achieve optimal strength.

What is needed to make a working solution

Granular polystyrene foam is added to the mixture for polystyrene concrete along with cement. or balls of polystyrene foam. Its capacity to conserve heat is very high. You can get a material with good thermal insulation qualities by substituting sand into the solution.

Depending on the proportions of polystyrene concrete selected, they will either be higher or lower. Furthermore, the final solution’s application domain dictates this decision.

We will discuss this topic in more detail later on, but for now, take a look at the recipe for polystyrene concrete to see what proportions each ingredient is used in.

Further details about every element:

• If you take a higher grade cement instead of M400, then sand can be added to the solution in a ratio of 2:1 (2 parts cement and 1 part sand).
• Polistyle foam can be bought in construction stores, it is sold in plastic bags up to 1 cubic meter.

• SDO is a special additive that draws air into the mixture and forms air bubbles, the presence of which increases the thermal insulation properties of the material.

As a point of reference. The recipe for polystyrene concrete does not always require SDO, but it will not be as warm in this instance.

• Plasticizers. They are not included in the table, since their concentration may vary depending on the manufacturer. They should be added in accordance with the recommendations on the packaging.

Kindly take note. Liquid soap or dishwashing detergent work well as a replacement for this part. The amount added to water is 20 milliliters for every ten liters.

How to do it

Now that we are aware of the ingredients in DIY polystyrene concrete, let’s examine the production process.

Recalculation of volumes

The recipe for making large volumes of polystyrene concrete is provided above, and each ingredient is "tied" to one cubic meter of filler. Such a volume cannot be mixed at one time in individual production conditions.

Furthermore, all other components are indicated in volume units, and the consumption of cement is stated in kilograms. We must convert them all to the same unit of measurement for convenience.

• A 10-liter bucket contains 12 kg of cement.
• Let"s say we need to make a solution of D300 polystyrene concrete.
• For a cubic meter of filler, you need 240 kg or 20 portions (240: 12 = 20).
• We also divide all other values ​​from this column of the table by 20 to find out the volume of each for one batch.
• 1000 l: 20 = 50 l or 5 buckets of polystyrene.
• 120 l: 20 = 6 l of water.
• 650 ml: 20 = 32.5 ml of SDO.

We learned that five buckets of filler and slightly more than half a bucket of water are needed for every bucket of cement. In a similar manner, you can figure out the volumetric makeup of any other brand of polystyrene concrete.

Mixing sequence

The directions for the sequence in which to add the components to the solution must be followed for the handcrafted material to be robust and uniform.

• First, you need to pour the entire volume of polystyrene into the drum of the concrete mixer.

• Then dissolve the plasticizer or detergent in water and pour about a third into the concrete mixer.

• Wait until all the granules are wetted with the solution. This is necessary so that they adhere well to the cement.
• Pour all the cement into the rotating drum and pour out the remaining water.

• Pour in the air-entraining additive and mix the mixture for 2-3 minutes.

Suggestions. Before adding to the solution, reserve a small amount of water from the total volume to dissolve the resin in it.

With the aid of this technology, you can obtain a superior building solution with a variety of applications. However, there is an alternative.

Polystyrene concrete that is ready to use can be purchased in bags, all you need to do is add water. It comes in sets, each of which is intended to create a specific density of solution.

You won’t need any additions because the polystyrene granules are pre-sophisticated and the dry mixtures already contain plasticizers.

Properties and purpose

Its application range is determined by its unique properties, and it is utilized as blocks or as a fresh solution in the construction of polystyrene concrete.

Characteristics of the material

This material can be placed in a row with aerated concrete and foam. It is lightweight and has a slight density. Additionally, regular concrete with sand or crushed stone as a base has strong heat-shielding qualities.

Gives these characteristics to the mixture’s composition and the material known as polystyrene concrete. More accurately, the kind of filler. Polystyrene is, after all, regarded as one of the lightest and most efficient heaters.

I’ll go over some of its other characteristics so you can see why it’s used in construction so frequently. These are the following:

• High tensile and compressive strength, which allows it to be used to build load-bearing walls;
• Non-flammability;
• Low water absorption, allowing it to maintain low thermal conductivity even when wet;
• Frost resistance, reaching 100 cycles;
• Excellent adhesion (adhesion) to other building materials;
• Higher elasticity than cellular concrete;
• Ease of processing and finishing;
• Resistance to atmospheric and biological influences, such as precipitation, sunlight, fungi and mold.

Application area

The density that polystyrene concrete can have was explained above using the following information: technology + compositions + recipe. This parameter primarily establishes the material’s area of application.

The application of the solution varies depending on the goal:

• For floor screeding or installation and insulation of floors – in liquid form;
• To build walls, blocks are made from the solution by pouring it into molds. They can be of any size;
• A monolithic house can also be built from polystyrene concrete by pouring the solution into the formwork with reinforcement installed in it.

Concrete containing a light filler places less strain on building foundations and other structural components than cement-sand mixtures. Furthermore, vapor barrier materials are not needed when installing screeds or ceilings, but they are necessary when insulating floors with mineral wool.

Because of all of this, building is less expensive and the homes end up being sturdy and warm.

A simple and adaptable material that you can easily make at home is polystyrene concrete. The proper ratios of cement, water, sand, and polystyrene beads combine to form a resilient and insulating concrete that can be used for a variety of construction tasks. This tutorial will show you how to make polystyrene concrete at home, including how to mix and pour it and what uses work best for it. Examples of uses include insulation and wall panels.

Concrete volume calculator

For those who enjoy do-it-yourself projects, making their own polystyrene concrete opens up endless possibilities. You can create a multipurpose building material that is lightweight, insulating, and durable with the correct proportions and a thorough understanding of the manufacturing process. Polystyrene concrete can be customized to your exact specifications, whether you’re using it for walls, floors, or other construction projects.

Cement, water, polystyrene beads, and a foaming agent are the only essential ingredients needed for the simple manufacturing process. To get the right consistency and qualities, measure and combine these ingredients carefully. To guarantee that the polystyrene beads are dispersed equally throughout the concrete, it’s critical to adhere to the suggested ratios and mix thoroughly.

Applying polystyrene concrete is easy once you have it. Use it creatively around your construction site by spreading it out for flooring, pouring it into molds or forms, or in other inventive ways. Its low weight makes it manageable, and its insulating qualities offer additional advantages for controlling sound and temperature.

In conclusion, DIY polystyrene concrete is a useful and affordable solution for a variety of construction tasks. You can create a dependable and effective material that satisfies your building needs by perfecting the ratios and production process. For your next project, polystyrene concrete offers an inventive and reasonably priced solution, regardless of your level of experience as a builder or do-it-yourself enthusiast.

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