Expanded Polystyrene (EPS) Sandwich Panels

Expanded Polystyrene (EPS) Sandwich Panels

EPS sandwich panels consist of two layers of galvanized sheet and an insulating core made of polystyrene foam (Styrofoam). They are produced in two types: regular polystyrene and polystyrene foam. These panels are generally less expensive compared to other types due to their application and quality, and the discontinuous manufacturing process allows for production in various densities.

EPS sandwich panels can be manufactured in different thicknesses and shapes. They are used for both roofing and wall applications. Polystyrene is environmentally friendly and available in three types: regular, resistant, and expanded (Styrofoam). It is the sixth most consumed plastic in the world and has various uses.

These panels provide good sound insulation due to their lower density but are not as effective in thermal insulation compared to polyurethane panels.
 

Methods of Producing Expanded Polystyrene (EPS) Sandwich Panels

Generally, there are two methods for producing EPS sandwich panels:

Continuous Method

In the continuous method, or mechanized process, mechanical devices and robots convert raw materials into the final sandwich panel. In other words, raw materials such as rolls of galvanized sheet, polyurethane foam or polystyrene foam sheets, and adhesives are fed into one side of the machine. On the other side, the completed sandwich panels are cut into desired sizes and prepared for packaging.
 

Continuous EPS (Expanded Polystyrene) Panel Machine

This series of machines emerged after the development of EPS sandwich panels and is relatively new compared to other methods. However, it has become quite popular and widespread. In this method, a continuous machine similar to the polyurethane continuous machine is used. It features two rows of roll holders or roll unwinders—one for the top sheet and one for the bottom sheet. Additionally, it has two rows of rollers and a roll-forming device that shapes the top or bottom sheet. An operator then places 2 or 3-meter EPS foam sheets between the shaped and adhesive-coated sheets. The machine bonds the panel together, presses it, and finally cuts the panel into the ordered sizes.
 

Discontinuous EPS (Expanded Polystyrene) Production Line

In this method, each activity is performed at different stations and then assembled together. The galvanized sheet goes through a roll-forming machine to achieve the desired design and is cut to custom dimensions. EPS foam is cut into various thicknesses and prepared for production. Finally, it is bonded to the panel sheets with special adhesive and pressed until completely dry.

EPS sandwich panels are produced in two types: roofing and wall panels. Roofing panels are made with a width of 107 cm and a useful width of 100 cm, available in thicknesses ranging from 2 to 6 cm with five steps.
 

Wall Sandwich Panels are produced with a width of 102 cm and a useful width of 100 cm, available in thicknesses ranging from 3 to 15 cm in a rail system.



 

Advantages and Disadvantages of Expanded Polystyrene (EPS) Insulation Foam

Advantages:

• Cost-Effective: EPS insulation foam is less expensive compared to other types of insulation due to its quality and application.
• Density Variability: The discontinuous production process allows for varying densities (15 to 25 kg/m³ and up to 30 kg/m³).
• Shape Versatility: EPS foam can be produced in different shapes. After baking, it is pressed in molds or cut into desired shapes using various heating elements.
• Custom Thickness: The thickness of this product can be customized to millimeters according to specifications.
• Lightweight: EPS foam is lighter compared to other insulation materials.

Disadvantages:

• Lower Density: It has lower density or compression, making it less suitable for high-insulation applications such as in greenhouses and cold storage, except in higher thicknesses.
• Weaker Bond: Due to its manufacturing process, EPS particles are compressed into pellets with weaker bonds compared to polyurethane foam.
• Flammability: Earlier EPS foams were highly flammable, but current versions are designed to shrink away from direct flames and are considered flame-resistant, similar to polyurethane.

Applications of EPS Sandwich Panels:

As mentioned earlier, EPS panels are available in wall, roofing, and cold storage varieties, enhancing their versatility across various fields. All EPS wall panels are used for covering industrial building walls, warehouses, and both internal and external walls of different types of buildings.

These sandwich panels can be ordered in both roofing and wall types, with the option to install pipe panels based on customer specifications.