Description, characteristics and types of polystyrene concrete wall panels

Innovative wall panels made of polystyrene concrete combine the advantages of polystyrene’s lightweight qualities with the strengths of conventional concrete. Because of their adaptability and effectiveness in building projects, these panels are becoming more and more popular.

The superior thermal insulation of polystyrene concrete panels is one of their most notable qualities. Buildings with a polystyrene core are an excellent option for energy-efficient construction because it keeps them warm in the winter and cool in the summer. These panels are also renowned for their soundproofing capabilities, which can greatly improve interior comfort.

Polystyrene concrete wall panels come in a variety of forms, each intended to fulfill a particular purpose. While some panels can be customized on-site, others are prefabricated and ready for installation. Selecting the ideal option for your project can be made easier if you are aware of the traits of each type.

This post will discuss the different kinds of polystyrene concrete wall panels, their special qualities, and the benefits they provide. Understanding these panels can help you make wise decisions and get the best results for your construction needs, whether you’re working on a new build or a renovation.

Description Polystyrene concrete wall panels are pre-fabricated construction elements made from a mix of concrete and expanded polystyrene. They are used for walls in buildings due to their insulation properties and ease of installation.
Characteristics These panels are lightweight, offer excellent thermal insulation, and are resistant to moisture. They also have good sound insulation properties and are fire-resistant. Their surface can be easily finished or painted.
Types 1. Standard Panels: Basic panels used for general wall applications.
2. Reinforced Panels: Include additional reinforcement for higher load-bearing capacity.
3. Decorative Panels: Feature various textures and finishes for aesthetic purposes.

What is the material?

The completed panels are square or rectangular pieces of artificial stone, or polystyrene concrete, manufactured in compliance with GOST 33929-2016. High-quality Portland cement and foamed polystyrene granules, along with an air additive and water, make up the material’s distinctive composition.

Granule crumbs are readily apparent in the thickness interval on the cross-section of the products, which sets polystyrene concrete apart from other lightweight cellular concrete. Moreover, the material may contain wood residues, which gives it warmth in addition to strength.

The combination of the two primary components—the strength of concrete and the thermal insulation qualities of polystyrene concrete granules—makes the construction composition of the products unique. The thermal conductivity increases with density, indicated by the letter D. The thermal conductivity ranges from D150 to 600 kg/m^3.

Apart from its ability to conserve heat, the material possesses additional advantageous qualities that enable it to be employed in the construction of wall structures of any kind, whether they are prefabricated or self-assembly (high structural strength).

The slabs measure 1,500 x 6,000 x 250 (mm) in total (W x D x H). The thickness of the slabs is 250 (mm), which is their height as stated in the standards.

Polystyrene boards are perfect for adding extra heat and sound insulation, as well as for use as wall, floor, and ceiling insulation in place of monolithic ones.

Standards like these outline the necessary wall thickness requirements as well as the material’s technical specifications.

  • STO 00284807-001-2011;
  • SP 434.1325800.2018.

Products made from polystyrene concrete are made as smooth-edged, straight slabs without any internal reinforcement. They can also have metal grooves and an internal reinforced frame to boost the material’s strength. When installing a slab alongside another nearby, the product edges may have recesses that facilitate the speedy installation of the wall structure.

The technology of producing slabs on the construction site itself is employed in addition to finished goods. In many respects, pouring using formwork is similar to monolithic work.

Feasibility of buildings

Thanks to advantageous technical qualities, which are mainly defined by adequate density, strength, and durability, but also by low weight and quick installation.

Concrete slabs made of polystyrene allow you to construct any kind of building:

  1. private and apartment buildings;
  2. garages;
  3. baths;
  4. dachas;
  5. utility rooms;
  6. basements and cellars, etc.d.

Furthermore, the slabs can also be used to construct building envelopes.

Using concrete products equipped with polystyrene:

  • all types of load-bearing (external) walls;
  • partitions between rooms;
  • ceilings in the attic;
  • base surfaces;
  • any combined coatings;
  • ends of reinforced concrete floors;
  • ceilings in basements.

The material’s high thermal conductivity qualities enable it to be utilized as a double insulating layer for:

Polystyrene concrete used as a facing material will adorn any building’s exterior cladding.

Buildings made of polystyrene concrete are feasible because of the material’s excellent performance characteristics, broad range of applications, lack of spontaneous combustion, ability to reduce the overall distributing load on the foundation, and ability to support the entire weight of the roofing structure.

Polystyrene concrete floor slabs come in a range of products that are useful not only for initial construction but also for residential building repair and reconstruction projects where it’s important to reduce the weight on the foundation.

A common building material for walls, polystyrene concrete panels are lightweight and insulating. These panels are made of a material that is easy to handle and install and provides excellent soundproofing and thermal insulation thanks to the addition of polystyrene beads to concrete. This post will discuss the different kinds of polystyrene concrete wall panels, their special qualities, and how to use them in building to improve energy efficiency and lower noise levels.

Construction of a house wall made of polystyrene concrete

A wall composed of polystyrene concrete panels is designed by combining multiple products from the same brand that share similar features.

During installation, they are connected to one another and separated based on the intended use:

  • for the main (structural wall);
  • to form partitions between rooms;
  • to create a layer of thermal insulation or cladding on the street side.

An example of wall design could be this:

  • facing from the street side;
  • outer plaster layer made using reinforced mesh;
  • polystyrene concrete slab (with or without reinforcement);
  • waterproofing layer;
  • interior plaster.

A second layer of structural and thermal insulation, such as polystyrene boards, or any other chosen insulation, can be added to the main layers of construction that have been presented in cold climate regions.

Three layers of construction are sufficient to create partition walls:

  1. plate;
  2. plaster;
  3. selected type of finish.

Any wall pie should have a thickness of at least 60 (cm) in colder climates, 40 (cm) in temperate climates, and 25 (cm) in southern regions.

Built in compliance with all technological regulations, a wall structure is assembled from prefabricated slabs or poured into formwork, a detachable structure, with reinforcement consisting of rods or rods with a 5 mm diameter and associated construction wire.

Varieties

Expanded polystyrene concrete slabs have a grayish tint to them and can be found either way—as factory-made finished products or poured into formwork that has already been installed and reinforced.

  1. Structural. Used only for load-bearing (external walls). Evenly distributes the load on the foundation. They have a thermal conductivity of 0.14 – 0.17 (W*mS). Wall thickness according to regulatory requirements + density grade used is – 2.55-3.14 + D 500.
  2. Thermal insulation and structural. Used to create interior partitions. They have the following characteristics in terms of thickness and specified thermal conductivity – 0.08 – 0.13 (W*mS); 2.55-3 + D 300.
  3. Thermal insulation. Create additional insulation on the inside of any building. Thickness, grade and thermal conductivity are – 2.55 + D 150; 0.05 – 0.07 (W*mS).

The density grades of polystyrene concrete panels vary; D 150 is the lowest threshold and D 550 is the highest. By density, there are a total of 9 brands. Every brand has class B and M compressive strengths of its own.

M2.5 indicates the minimum strength, and B2.5 indicates the maximum. Markings on the stove itself and the packaging may be found on high-quality product manufacturers’ products. The purchaser additionally receives instructions for the products and a warranty.

Several construction companies in the Russian Federation provide wall structures with pre-made window and door openings that are composed of polystyrene concrete plates and a monolithic typical filling.

This practical method makes construction go more quickly and according to schedule. Construction equipment (such as an overhead crane) can be used to erect large structures.

Characteristics

Regulatory construction documents (see the sections above) list the products’ technical specifications.

This covers both the material quality and the overall dimensions, which are 1500 x 6000 x 250 (mm):

  1. Environmental friendliness. Made from natural materials that do not cause allergies and do not harm the environment.
  2. Light weight – 10-15 (kg), with a small standard of 900 x 600 x 100 (mm).
  3. Density – 200-600 (kg / m 3 ). Indicated in the marking. The higher the indicator, the more stable and durable the structure.
  4. Biological resistance. Does not react to the effects of pathogenic microflora (mold, fungi), is not prone to decay.
  5. Thermal conductivity coefficient is λ = 0.052-0.068 W/(m · ° C).
  6. The stroke strength for compression is defined as m2-m5.
  7. Resistance to fire. Does not apply to spontaneous products.
  8. High noise and sound insulation. Thanks to the porous structure and polystyrene granules, all unnecessary noises are reduced.
  9. Water resistance. Has average indicators – from 3.0 %, for the distribution of moisture in the material. It is considered resistant to water, but in climatic zones with high humidity, from the inside it is built with equipped waterproofing, which provides additional protection for the walls.
  10. Frost resistance. It has good indicators-F25-125. It is considered one of the best wall materials that protect the room from freezing.

The demand for the building material—which is regarded as robust, cozy, and long-lasting—was fueled by the abundance of favorable qualitative traits.

Calculation of the required volume

It is best to leave the computation of the appropriate number of panels to the experts. This is because the ideal wall thickness is directly impacted by the material’s thermal conductivity, which is indicated by the marking. Simultaneously, you will need to use λ indicators for each type of plate from the GOST tables in order to perform wall pie calculations.

Following a review of the tables, the thermal resistance of the structure is calculated using the thermal conductivity coefficient, or another K. Here’s the formula that’s employed:

The resultant value aids in figuring out wall thickness and energy efficiency; however, the indicator of these two factors must be adjusted based on the planned building’s area, where all wall types and regulations are taken into consideration.

Important values such as the length and width of the final products are used in the computations to determine the area in addition to the thickness. The services of an internet calculator are also available to you.

In particular It is important to consider how products are packaged based on their approximate cost. For ease of use, a lot of manufacturers list the approximate material consumption per 1 m 3 and 1 m 2 on packages (starting at 10 pieces). Due to the fact that only the primary indicators and the planned area will need to be multiplied together, this significantly streamlines the computations.

Wall construction technology

Only after the foundation is laid and the earthworks and pits are fully completed can walls made of polystyrene concrete be constructed. The following factors alone will determine when the construction period begins:

  1. house design;
  2. purchase of consumables and tools;
  3. shrinkage of the foundation base.

Building codes state that if a monolithic foundation is chosen for construction, shrinkage should be anticipated within exactly one year. A strip foundation will take three to six months to complete.

With the pile-screw type, shrinkage is not a problem; however, you will need to wait until the floor screed that is poured on top of it dries completely, the formwork for the concrete pour is taken down, and the surface is double-layered with waterproofing material.

The following features and technological procedures should be used in the construction of completed polystyrene foam panels:

  1. Monolithic or brick pillars are installed along the perimeter markings (on a strong sand-cement mortar with plasticizers). From them, along the corners of the fastenings, construction cords are stretched along which the installation will be carried out.
  2. There are 2 methods of fastening the slabs – frame, with the installation of a metal structure that is fixed to the poles, and the usual way – connecting the slabs using cement, construction adhesive, anchors. In the first method, the frame is welded using reinforced rods and anchors to the pillars along the entire perimeter – plates will be inserted into it and connected to each other with glue and welding of the reinforcement. Second – reinforcing parts are welded to the pillars, the laying of the slabs is carried out in a checkerboard pattern with ligation of layers and trimming of excess parts. A reinforcement grid can be additionally used here.
  3. The first layer of slabs and the last one, under the roof, are always arranged in the form of a reinforced belt. Floor slabs are laid between the floors, which are then filled with concrete.
  4. The lower part of the slabs can be additionally secured with anchors to an armored belt made of cement and metal rods with a diameter of up to 30 mm. Additionally, the higher slab is secured to the lower one.
  5. Only high-quality brands of construction adhesive are used in installation. It is best to work with adhesive and sealing materials for seams at above-zero temperatures, in a dry (no precipitation) period.
  6. Installation is controlled by the building level. Reinforcement mesh is laid horizontally. The repetition of floors follows the example of the construction of the first wall.
  7. It is advisable to calculate the locations for window and door openings in advance, according to the project, so that there are no problems with their formation when work begins.
  8. If desired, waterproofing a structural wall is carried out, then its plaster and finishing. In the same way, you can lay the second layer of slabs, which will perform a heat-insulating function (especially relevant for the northern regions).
  9. Partition walls are formed according to the drawing. Installation follows the principle of constructing structural products, only here you will need anchoring to the load-bearing wall (3 times along the length of the floor), and there will be no need for waterproofing. After installation, the wall is completely ready for finishing.
  10. After this, all other work on the construction of the building from panels (windows, doors, roofing, communications) is carried out).

Polystyrene concrete can further be shielded from outside environmental influences by facade finishing. The future owners’ preferences will determine the choice of facing material.

Advantages and disadvantages

The following benefits are listed by experts on panel polystyrene concrete materials:

  1. High thermal insulation and vapor barrier properties. The houses are warm and cozy, maintaining a good microclimate both in winter and summer.
  2. No freezing or mold on the walls. The qualitative composition of polystyrene concrete eliminates the appearance of condensation on the wall structure and the formation of pathogenic microflora.
  3. High installation speed. Ensured due to the low weight of the finished slabs.
  4. Good adhesion. The material interacts well with any substances.
  5. Easy processing. Expanded polystyrene can be easily cut using construction power tools. Installation of mounting brackets and communications is also easy.
  6. Variety of products. There are a large number of brands of slabs by density and purpose. Suitable not only for basic construction, but also for thermal insulation and finishing work.
  7. Low price. Compared to the market value of brick and monolithic plates, the costs associated with their use are considered quite affordable and flexible in pricing policy.
  8. Great versatility of use. The slabs can be purchased ready-made, or received by pouring into formwork directly at the construction site.
  9. No sanding required. Initially, the surface of the products is smooth, so special types of plastering are not needed.
  10. Even load distribution. The load-bearing capacity of a wall structure, with a thickness of 30 (cm), can take a load of up to 30 (t) (as experts say).
  11. The low height of standard panels (1.5 m) contributes to ease of use.

Slabs’ drawbacks are taken into consideration:

  1. Construction of buildings no higher than 3 floors. Experts have not yet decided to build multi-storey housing, since the material on the construction market is considered quite new.
  2. Without external finishing, polystyrene concrete granules can fade over time in the hot sun, leaving a concrete frame.
  3. The need for waterproofing and ventilation. This is necessary in order to ensure the uniformity of the receipt of air masses into the room, and serves to prevent the formation of condensate + extends the life of the walls.

Polystyrene concrete panel products are thought to be a viable solution for building reasonably priced, long-lasting housing because their benefits exceed their drawbacks.

Concrete slabs made of polystyrene adhere well to contemporary fiberglass reinforcement.

Average price in Russia

To calculate how much products will cost and how much their installation will cost based on things like:

  • seasonality (in the warm season the price is higher);
  • scope of work (determined after a preliminary examination);
  • urgency of the order;
  • construction site;
  • depreciation and transportation costs for equipment;
  • payment for hours of work of specialists;
  • region of construction (in Moscow Region and St. Petersburg the price for services and materials is always higher).
  • market prices for consumables.

Regardless of their size, type, or purpose, the average cost of polystyrene concrete panels in the Russian Federation is established on an individual basis for each unique instance. When considering construction work, the average cost of a panel in the Russian Federation for the standard size of the plate as defined by GOST 33929-2016 is between 2 and 13 thousand rubles per meter.

Whereas the material’s actual cost per 1 m 3 in rubles is as follows:

  1. Structural – 5,000-8,500.
  2. Structural and thermal insulation – 3,200-4,100.
  3. Thermal insulation – 2,400-3,700.

Construction companies use price lists to tell their clients how much their services—which include product production, delivery, and installation—will cost.

If there is cooperation, a work contract is created with the cost specified. One of the benefits of this kind of interaction is that the terms are prearranged and the client receives a guarantee for the work supplied.

For many construction projects, polystyrene concrete wall panels are a sensible option because they provide a special combination of structural support and insulation. Because these panels are lightweight and manageable, construction can be made easier and labor costs can be decreased. Their ability to insulate helps houses stay warmer in the winter and colder in the summer, which improves energy efficiency.

Polystyrene concrete panels come in a variety of forms to suit different demands and tastes. There is a choice to fit the majority of applications, ranging from generic panels for general construction to specialized options for improved thermal performance. For your project, you can optimize cost-effectiveness and performance by choosing the appropriate type.

To sum up, wall panels made of polystyrene concrete are an effective and adaptable building material. Knowing the various kinds and features of these panels will help you make wise decisions and get better outcomes whether you’re working on residential or commercial projects. They are a useful supplement to contemporary building techniques because of their advantages in insulation and simplicity of use.

Video on the topic

⚡️House made of polystyrene concrete panels⚡️ #polystyrene concrete #barnhouse #shorts

Wall panels made of polysitrene concrete. Advantages and main qualities. Plastblock

POLYSTYRENE CONCRETE PRODUCTS: types, characteristics and features of materials

Construction of a house from polystyrene concrete panels

How to make WALL PANELS from polystyrene concrete?

SUPER-MODERN polystyrene concrete for the construction of a country house! / Main PROS and CONS

What factor is most important for you when choosing materials for building a house??
Share to friends
Fedor Pavlov

Interior designer, author of books on residential design. I will help you make your home not only functional, but also beautiful.

Rate author
StroyArsenal62.com
Add a comment