DIY polystyrene concrete: understanding the manufacturing technology

A lightweight and adaptable building material that is becoming more and more popular among do-it-yourselfers is polystyrene concrete. The material is created by combining cement, water, and expanded polystyrene beads, which gives it the strength of concrete and the insulating qualities of polystyrene. It is perfect for a variety of construction projects, including insulation panels and walls and floors, thanks to its special combination.

The simplicity of use of polystyrene concrete is one of its key benefits. With some basic tools and guidance, you can create this material even if you have little to no construction experience. To ensure a consistent and functional mixture, the ingredients must be mixed in the proper amounts during the process. It is a desirable choice for people who want to do DIY projects around the house without paying for expert assistance because of its accessibility.

Not only is polystyrene concrete easy to use, but it also has many useful advantages. Because of its light weight, the structure will bear less overall load during construction, making it easier to manage. Additionally, it offers superior thermal insulation, which keeps your house cool in the summer and warm in the winter. In addition, polystyrene concrete offers long-lasting durability by being resistant to mold, moisture, and pests.

We’ll go into detail about how to make polystyrene concrete at home in this article. Everything from assembling the required supplies to combining the components and applying the final product will be covered. You’ll find the instructions you need to make your own polystyrene concrete and improve your construction projects, regardless of experience level with do-it-yourself projects.

A cost-effective and environmentally responsible method of producing polystyrene concrete is to make your own. This adaptable building material combines the strength of concrete with the lightweight and insulating qualities of polystyrene, making it perfect for a range of construction projects, from walls to insulating panels. To ensure that you can successfully make and use polystyrene concrete for your do-it-yourself projects, this guide will walk you through the basic steps and materials needed.

Getting to know the polystyrene concrete block: characteristics of the material

We will start our review by looking at the compositional features and properties of the material. Ultimately, the aspiring producer must possess comprehensive knowledge about polystyrene concrete.

Composition and properties

Despite being relatively new to the market, this material has already managed to become well-known. One may wonder: what’s the foundation for this? It all comes down to a unique combination of product attributes that satisfy the majority of contemporary construction standards.

During the manufacturing process, these qualities are created and modified by varying the ratios of raw materials and adding specific chemical components.

The following are the primary components of polystyrene concrete:

• Sand;
• Water;
• Cement;
• Polystyrene chips;
• Special additives (saponified resin, for example).

The aforementioned elements are all subject to specific GOST-compliant requirements.

• It is recommended to use high-grade cement: M400-500. The higher the grade, the stronger the product will be.
• Quartz sand is usually used.
• Polystyrene chips can be of different fractions, which also affects the result.
• A plasticizer is often added to the mixture. Such an additive can increase the plasticity of the solution, and thereby prevent damage to products due to cracking at the stage of production – or rather, during the hardening and drying of products.

Kindly take note! Additional additives are unique to each unique situation. Manufacturers add different chemical components to the solution that can improve the final material’s performance in an attempt to modernize the recipe and set their products apart.

Let us now discuss the properties in brief.

For the reasons mentioned above, polystyrene concrete insulation is very popular among homeowners.

Only products used in the construction of a structure’s exterior walls are subject to this requirement.

Note: The material in question appears to be on the first line of the rating when compared to other lightweight concrete representatives. For instance, this percentage is 25% for aerated concrete, 15% for foam blocks, and 18% for expanded clay concrete.

Types and scope of their application

As we’ve already established, polystyrene concrete can have varying densities. This provided the framework for the development of a classification system based on the fields in which the material was applied in its different forms.

1. The most popular area of ​​application of polystyrene concrete is insulation. The material is used not only in the form of blocks, but also in liquid form. For example, monolithic polystyrene concrete is used in the construction of screeds, in the insulation of roofs, in filling frames.

In this instance, the material’s increased density is not required, but the thermal conductivity index is crucial. This explains the term "heat-insulating" applied to polystyrene concrete with a density of less than 400 kg/m3.

1. If the goal is to erect a lightweight building, for example, in the form of an outbuilding, then you can use heat-insulating structural products. Their density is quite sufficient for this. However, no heavy ceilings and complex roofs should be installed, the blocks will not withstand such a load.
2. You can build a one-story house with an attic using structural and thermal insulation products. Their density grade reaches D600.

Now, a little about the material’s functionality and purpose.

• Wall blocks are used in the construction of walls. Such products must be subjected to subsequent cladding (finishing).

• Products with a facing side will not need to be finished, but only from the outside.

• Wall panels are also produced from polystyrene concrete. They are used for the installation of internal partitions.

• Lintels (reinforced) are mounted above window and door openings.

• Ventilation products are a special type of blocks. They have special openings through which utility lines are installed.

Material production technology

To begin producing polystyrene concrete blocks, you will need to buy a minimum amount of equipment. The configuration will determine the price and, consequently, the profitability.

We’ll start by thinking through our options.

Necessary equipment

If you have the necessary tools, which include a standard concrete mixer and product molds if you intend to make blocks, you can create polystyrene concrete by hand.

• If you want to produce about 20-25 cubic meters of block per day, then you should additionally purchase a special generator capable of providing a constant supply of the mixture.
• Such a generator can also be used in the manufacture of monolithic polystyrene concrete, which is fed directly to the pouring site.
• For greater convenience and partial automation, polystyrene concrete can be prepared using mobile units. Their cost, of course, is more than the above set.
• But you will still have to dose the components manually, which is one of the main disadvantages of using such equipment.

It is important to note the existence of more recent, potent lines as a point of comparison. They are typically employed by big businesses.

1. These are conveyor-type lines. They are maximally automated, and production volumes can reach hundreds of cubic meters per day.

Blocks produced using such machinery have highly indicative primary technical characteristics and nearly unique geometry.

1. Stationary lines are more compact, and therefore their price category is lower. Polystyrene concrete is manufactured on such lines by enterprises that are representatives of small and medium businesses.

It will be worthwhile to keep an eye out for such equipment in the future if you choose to make polystyrene concrete by hand for sale. It can be positioned on a space of about 100 square meters. Not really, in theory. The output volume is capable of 80 m3 per day.

This article’s video, "How to make polystyrene concrete with your hands," will walk readers through the basic principles of using various tools.

Stages of work

The casting method allows you to create polystyrene concrete blocks by hand. This is a traditional production technique with very basic technology.

The guidelines are as follows:

• The components are measured out one by one in the right proportions and fed into the mixer;
• There the ingredients are mixed until a homogeneous mass is formed;
• The molds should be prepared in advance: they must be lubricated with a special compound, and, if it is not available, with diluted machine oil. This will facilitate easier removal of products during stripping;
• The finished mixture is poured into the molds;
• After hardening, after a few days, the blocks are removed from the molds;
• If the block massif was flooded, they are cut using a cutting complex, which is usually included in the kit of the equipment;
• At the last stage, the products are sent for drying. After a few more days, they can be fully stored on pallets;
• Blocks are used in construction only after 4 weeks, since only then can polystyrene concrete achieve its brand strength.

The following video will provide you with more detailed instructions if you still have questions about making expanded polystyrene concrete by hand.

What is the difference between factory-made and home-made blocks?

The degree of automation is the only difference between the casting method and other processes when it comes to production.

The vibration pressing method, which involves processing the mixture on a vibration press after it has been brought to a semi-dry state, can still be produced in a factory setting. The final step involves drying the products in a dedicated drying cabinet.

We compare blocks of different production methods since the high cost of equipment prevents us from using such a method at home.

You have undoubtedly already deduced that goods made at a large company will perform noticeably better than blocks that are produced independently. Now let’s identify the primary benefits of the products that have been purchased.

• The block geometry will be much better. As a result, the number of cold bridges and the thermal efficiency of the wall will decrease.
• Homemade blocks are not controlled by anyone other than the developer trying to make them. And it is completely unknown what indicators the products will actually have.
• As a rule, the ratio of density and thermal conductivity of factory-made products is better, since special chemical ingredients are added to the composition that can improve this ratio.
• It is impossible to obtain blocks of the highest possible strength at home.
• With independent production, labor costs are high, a lot of time will also be required and the pace of construction will be reduced.

If you’re still not sure if it’s worth it to start producing polystyrene concrete blocks at home, watch the video for a detailed explanation of the benefits and drawbacks.

Economic feasibility of the production process

Let’s consider the potential profitability of producing goods on our own. Will the cost difference offset the equipment costs and make the time and effort invested worthwhile?

Let’s first determine the conditions under which the potential savings may occur:

1. Costs of purchasing a set of equipment;
2. Cost of raw materials;
3. Number of defective blocks;
4. Use of additives and the cost of their purchase.

Let us assume that a cube of polystyrene concrete block costs approximately 3,200 rubles on average. The developer will have to pay 2,700 rubles for handmade goods. This indicates that the savings when creating a 95 m3 block will be: 47,500 rubles.

You can save 17,500 rubles on your expenses if you buy equipment for less than 30,000. As you can see, the savings are still present even though the amount is modest.

Concrete volume calculator

Why you should give preference to polystyrene concrete: the pros and cons of the products

The following are some benefits of polystyrene concrete:

• Thermal efficiency of the material is obvious;
• Good bending and compression strength, especially considering the low thermal conductivity coefficient;
• High frost resistance and durability;
• Environmental friendliness;
• Fire resistance;
• Low cost;
• Possibility of independent production;
• Wide range of products and choice of manufacturers;
• The scope of application is varied, from insulation to the construction of buildings;
• Ability to sound insulation and vapor permeability;
• Biological resistance;
• Ease of use;
• Large dimensions and, as a result, increased construction speed;
• Low hygroscopicity;
• Polystyrene concrete walls can be finished with almost any desired material.

• The need to purchase special fasteners;
• Ventilation systems will have to be designed in advance;
• Tendency to shrinkage;
• Relatively low density compared to other lightweight concrete products;
• You should not start finishing immediately, it is recommended to wait about 4 weeks;
• The need to coat with plaster;
• Costs for primers and other materials that can increase adhesion.

Step	Description
1. Gather materials	Collect polystyrene beads, cement, sand, water, and a foaming agent.
2. Prepare the mold	Ensure the mold is clean and properly assembled.
3. Mix the ingredients	Combine polystyrene beads, cement, and sand. Add water and the foaming agent, then mix thoroughly.
4. Pour the mixture	Pour the polystyrene concrete mixture into the mold evenly.
5. Let it cure	Allow the concrete to set and harden for at least 24 hours.
6. Demold	Carefully remove the cured concrete from the mold.
7. Finish the surface	Trim or sand any rough edges for a smooth finish.

Making your own polystyrene concrete is a doable and satisfying endeavor. You can create a flexible, lightweight building material with good durability and thermal insulation by comprehending the manufacturing technology.

Even though there are multiple steps in the process—mixing, casting, and curing—each can be completed with the correct equipment and careful attention. Using premium ingredients and adhering to a tried-and-true formula guarantees that your polystyrene concrete will function admirably in a range of construction settings.

With more practice, you’ll discover methods to hone your craft and raise the caliber of your mixes. Polystyrene concrete is a cutting-edge material that gives do-it-yourselfers new options and an affordable, environmentally friendly answer to a variety of building requirements.

You can utilize the advantages of polystyrene concrete in your projects and help create more resilient and energy-efficient structures by taking the time to learn and experiment. Take on the challenge and experience the fulfillment of making a contemporary building material by hand.

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