Affordable, safe housing based on expanded polystyrene (EPS) foam and a cementitious coating

Abstract

This paper describes an ongoing project to demonstrate an affordable, safe, and energy-efficient housing technology based on expanded polystyrene (EPS) panels with a cementitious coating. The concepts being described are (1) EPS panels embedded with galvanized steel trusses, steel mesh welded or clipped to the protruding points of the trusses and finished with a coating of cement plaster; (2) fiber-reinforced cement board panels and a core of EPS, glued together with high-strength adhesive, dried under high pressure, and connected with cellulose fiber cement board splines; and (3) EPS panels coated with a fiber-reinforced composite. The scope of this project is to model energy flows, analyze costs, simulate seismic forces, test against environmental conditions, and build pilot houses initially in California, Texas and Afghanistan. Results from air quality and energy flow analyses, preliminary cost modeling, structural calculations, and fire testing are reported. The performance goals address seismic safety; energy efficiency in extreme temperatures to reduce fuel use and indoor air quality hazards; affordability and simplicity of construction, as well as ease of expansion for future development; local employment opportunities and small-scale capital investments; and finally, cultural acceptance through education and adaptation to traditional architecture.

Use of Expanded Polystyrene Technology and Materials Recycling for Building Construction in Kenya

“…A building material that meets the safety standards (including seismic resistance) and the dwellers 'comfort requirements must also be thermally insulating, light weight and inexpensive [11]. All these requirements are made possible using the Expanded Polystyrene (EPS) initiative which represents one of such new materials that have found their way into the previously conservative construction industry [12].…”

An Alternative Holistic Approach to Affordable Housing: Homes of Foam

“…Expanded polystyrene (EPS) is an innovative nonconventional building material that is revolutionizing home construction (Lee et al 2005). EPS foam is being used as the core of structural insulated panels (SIPs) for wall, roof, and floor construction.…”

“…When used to build homes and other structures, expanded polystyrene beads are inflated using a pentane blowing agent and a flow of steam (Lee et al 2005). Expanded polystyrene then forms the sandwiched core of panels that will eventually become the walls, roof and, if so desired, the floor of the structure.…”

“…Based on preliminary cost estimates by the Federation of American Scientists (FAS), the One World Living Systems (OWLS) ($26.70/m 2 ) approach to SIP technology is most cost effective when compared to the MonoTech ($82.10/m 2 ) and ThermaPanel ($40.40/m 2 ) technologies on a starter home of 72 square meters. 2 a) wire mesh panels b) cellulose cement panels c) fiber-reinforced cement panels Source: Lee et al (2005) These sandwiched panels, collectively referred to as structural insulated panels (SIPs), have undergone numerous tests to prove their strength and safety as a viable building material (Sherwood and Spelter 1994). Able to withstand compression, axial, transverse and shear loads (OWLS 2004), expanded polystyrene's physical and mechanical properties ensure its structural integrity in building construction (EPS Molders Association 2005).…”

“…Nontoxic and completely inert, EPS does not contribute pollution to the environment. Using pentane as a blowing agent, no chlorofluorocarbons (CFCs), formaldehyde or other harmful gases are emitted in the production of EPS (Lee et al 2005). The gases and vapors that emanate from expanded polystyrene once subject to fire are harmless; in fact, they are less dangerous than those emitted from many natural materials such as timber and cork (Lee et al 2005).…”