How to make polystyrene concrete with your own hands: manufacturing technology, characteristics, step-by-step plan

The strength of conventional concrete and the insulating qualities of polystyrene are combined to create polystyrene concrete, a lightweight, adaptable building material. With features like lighter weight, better thermal insulation, and ease of handling, it’s a great option for both building and remodeling projects. One inexpensive way to benefit from these advantages is to make polystyrene concrete yourself.

We’ll walk you through the steps of making polystyrene concrete at home in this article. You will gain knowledge about the necessary materials, appropriate ratios for mixing, and procedures in the manufacturing process. This guide will give you the information you need to get started, regardless of whether you’re a professional builder or a do-it-yourself enthusiast wanting to try out new materials.

We will also examine the features of polystyrene concrete, including its strength, ability to insulate against heat, and ease of use. You can use this innovative material in your projects with more knowledge if you are aware of these qualities. You can create polystyrene concrete that suits your unique requirements and improves your construction projects by following our easy-to-follow guide.

The simple method for creating polystyrene concrete at home is to combine polystyrene beads with cement, water, and a few additional ingredients. This special kind of concrete is adaptable, lightweight, and insulating, which makes it perfect for a range of building projects. This post will walk you through the process of making polystyrene concrete, go over its advantages, and offer a straightforward, step-by-step plan to make sure your do-it-yourself projects turn out perfectly.

Making a solution

Many developers wonder about the possibility of making polystyrene concrete by hand, particularly when creating products for wall arrangement and insulation.

Granulated polystyrene foam, or foam balls, and a cement mixture make up the solution’s composition. They offer a high level of thermal protection and are distinguished by their strong thermal insulation qualities. Additionally, plasticizers are added to the mixture to help improve the finished product’s strength and dependability.

Additionally, there are many benefits to producing polystyrene concrete on your own, including the opportunity to save costs and obtain valuable experience in the construction industry.

Properties and purpose

Polystyrene concrete’s properties consider how lightweight and useful it is. With little financial outlay and basic technology, this type of composite material is created.

Characteristics

The class of composite building materials that includes polystyrene concrete is composed of silica filler, Portland cement or one of its variants, and a porous component.

The following raw materials are uniformly mixed during the manufacturing process:

1. Cement mixture.
2. Sand.
3. Water.
4. Granulated polystyrene.

At the construction site, the solution is poured into forms that have been prepared or formwork. You can use basic mixers to produce a material of superior quality.

1. Long service life – more than 100 years.
2. Compliance with environmental safety standards.
3. High degree of vapor permeability.
4. Resistance to fires.
5. High moisture and frost-resistant properties.
6. Good soundproofing parameters.

1. Technological efficiency – due to the low weight and correct geometry of the blocks, it is quite simple and quick to create walls and ceilings on their basis.
2. Thermal insulation properties – a wall structure 30 cm thick can retain as much heat as a 180 cm brick wall. Thermal conductivity values ​​vary from 0.7 to 0.1 W / mC. This helps to reduce thermal energy costs by 5 times.
3. Vapor permeability. Due to good moisture and air permeability, polystyrene concrete walls can "breathe", which ensures stable humidity regulation.
4. Durability – as they are used, polystyrene concrete blocks acquire additional strength. The declared service life exceeds 100 years.
5. The temperature range at which the use of the material is permitted varies within the range of -60 … + 70 ° C.
6. Affordable cost – 1 kV. m walls made of polystyrene concrete will cost much less than another option.
7. Thermal inertia – buildings are effectively heated, while their cooling takes a long time.
8. Environmental friendliness – since cement, water, wood resin and safe polystyrene are used to produce the material, the final product meets all environmental requirements.
9. Combustibility class – according to fire safety indicators, polystyrene concrete belongs to class NG1 (non-combustible). The material is not afraid of the effects of open fire, since when ignited, the surface granules begin to evaporate.
10. Weight – blocks measuring 200x300x600 mm weigh no more than 18 kg. This characteristic ensures high masonry speed and reduced labor costs.
11. Strength indicators – a wall of 30 cm thick can withstand a distributed load up to 35 tons per soup. m.
12. Waterproofing properties – the material absorbs no more than 4% of the moisture, which is 4 times less than brick or wood. The probability of fungi formation is practically excluded.
13. Soundproofing – a 30 cm wall can absorb more than 70 dB of sound.

Application area

Prior to beginning the manual production of polystyrene concrete blocks, you should think about the primary applications for them. These designs are needed for setting up screeds or interior partitions, building walls, and insulating structures for different uses.

The substance is also utilized in the creation of liquid solutions for pouring monolithic objects or facade panels.

Advantages

The following are some benefits of polystyrene concrete products:

1. Products made of polystyrene concrete do not need additional insulation with foam or mineral wool, since they are characterized by high thermal insulation properties.
2. Sound and thermal insulation are included in the list of key advantages, due to which people choose polystyrene concrete- the thermal conductivity of the material is low, since the seams are practically not arranged when laying it. The declared noise insulation is 37 dB for a wall with a thickness of 100 mm. Connection of elements requires the use of special glue.
3. Processing the material is quite easy and comfortable. At the same time, independent production is characterized by low material consumption and reduces the need for mortar by 70%.
4. Installation work does not require special skills and is carried out in a short time. Due to the small weight and dimensions, transportation, fastening and other actions with blocks are simplified.
5. Improved resistance to negative environmental influences. Products are not afraid of moisture, low temperatures, mold or mildew.
6. The service life of the material can exceed 100 years. Thanks to this advantage, it is very popular and is used in various areas of human activity.
7. Designs based on polystyrene concrete blocks comply with modern standards of environmental and sanitary and hygienic safety.
8. Surface treatment of products does not require special efforts or skills.

Disadvantages

However, expanded polystyrene concrete can have significant drawbacks in addition to benefits. Among them are:

1. Low strength of fastening. For the installation of dowels and anchor fasteners, you will need to use a concrete mixture of grade M150. If you miss this moment, the element can be removed by hand. Special anchors and dowels for polystyrene concrete are available for sale.
2. Deteriorated density. Such a characteristic complicates the process of installing windows and doors, due to which the material can deform, and the fittings can sag. If the installation technology is not followed, the fasteners will become very loose during operation.
3. Poor adhesion of elements with an insignificant content of polystyrene granules in the composition.
4. Need for finishing work both outside and inside the building. All surfaces from blocks need additional plastering, however, many owners say that such a material is poorly applied to the plaster and the wall processing has to be treated. For the best result, it is recommended to make a plaster layer of 1.5 cm outside and 2 cm inside.
5. Vulnerability to fire. Without proper treatment, the blocks become a brittle material that quickly ignites.
6. Insufficient vapor permeability. In this indicator, the material is inferior to aerated concrete or foam concrete blocks, due to which the microclimate and humidity are maintained inside the building, and the walls stop “breathing”. To prevent negative consequences, it is necessary to arrange a functional ventilation system.

Materials for production

Granulated polystyrene (which can be substituted with foam) and a cement mixture are needed to prepare polystyrene concrete. These raw materials have strong thermal insulation qualities, which help to dependable prevent the building from freezing. The primary additives and the density of the concrete mixture determine the frost resistance indicators.

1. Cement mixture grade M400. If you use a composition of the highest grade, the solution must be diluted with sand in proportions of 2:1.
2. Expanded polystyrene. The component is sold in construction hypermarkets.
3. SDO is a special additive that adds air to the mixture and promotes the appearance of air bubbles that improve thermal insulation.
4. Plasticizers. The concentration of these additives in the composition is determined by the characteristics of the mixture.

Equipment

Special equipment needs to be prepared in order to produce polystyrene concrete blocks on your own. The quantity of goods that must be produced determines its type.

1. Conveyor line. Characterized by full automation and practically does not require the involvement of human power. Finished parts are characterized by correct geometry and high performance properties.
2. Fixed line. Refers to budget equipment, but requires the intervention of workers.
3. Compact units. Designed for private business development. Their productivity reaches 30 m³ per day.

A set of raw materials, a concrete mixer, and molds to hold the mixed mixture are the least expensive options.

If you need to produce more than 25–30 m³ blocks a day, you will need to buy a steam generator so that the mixture can be loaded continuously.

Cement proportions

The following ratios are used per 1 m3 in the manufacturing of polystyrene concrete:

1. 840 l of foamed and treated granules.
2. 200 kg cement mixture.
3. 100 liters of water.

The ratios used determine the final weight of the polystyrene concrete. Utilizing this mass-to-proportion ratio is standard practice in the majority of situations.

Making polystyrene concrete at home can be a useful and satisfying endeavor. You can create a versatile and lightweight building material with a few simple materials and cautious procedures. To create an insulating and long-lasting concrete, cement, water, and polystyrene beads are mixed together.

First, assemble the following supplies: a mixing container, polystyrene beads, water, and cement. To guarantee a homogenous mixture, precisely measure each ingredient. Mix the cement and water together first, then add the polystyrene beads little by little, stirring well to create a smooth mixture.

Pour your mixture into the molds or forms of your choosing once it’s ready. In this step, you can mold the concrete to the exact specifications of your project. Allow the concrete to cure properly; depending on the circumstances, this could take a few days. The secret to getting good and consistent results is patience.

Particular advantages of polystyrene concrete include its low weight and effective thermal insulation. It can be applied to a range of construction tasks and is also fairly simple to handle. You can create high-quality polystyrene concrete for your construction projects by carefully following the steps.

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