5 Must-Have Features in a XPS foam insulation production

Extruded polystyrene (XPS) closed-cell, rigid XPS insulation significantly improves the energy efficiency of unfinished exterior and interior walls for remodeling and new construction. In addition, the XPS boards provide thermal resistance with an R-value of 4.6 to 5.0, depending on their density, to create a comfortable indoor temperature and reduce utility bills. Moisture-resistant XPS panel insulation, with an absorption rate of 0.3 percent, resists moisture intrusion during and after application to help protect against damaging and unhealthy mold and rot.

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Lightweight, versatile, and simple to install, extruded polystyrene sheets typically come in 8-foot and 5-foot lengths, ranging from 16 inches to 4 feet wide and ¾-inch to 4-inches wide. The sheets come unfaced, and are covered with a foil facing, or laminated with plastic. The facing adds water resistance, and the lamination offers strength, but neither affects the sheets’ R-value. XPS sheets come in an array of colors (typically blue, green, and pink), based on the manufacturer, not insulating quality.

What is an XPS Insulation Board Used For?

Flexible XPS boards come in various compressive strengths, making them ideal for numerous applications in all areas of the building envelope:

• Above-grade insulation applications (walls, attics, ceilings, floors, and roofs)
• Below-grade walls (basements and foundation)
• Cool/refrigerated rooms
• In addition, you can use high compressive strength XPS panels to insulate rooftop parking garages and decks.

How is XPS Insulation Made?

Manufacturing XPS insulation involves combining polystyrene crystals with special additives and a gas blowing agent. Manufacturers feed the mixture into an extruding machine that blends and melts it into a thick liquid. The liquid then gets processed through a die, which expands it into foam, shapes, cools, and trims it into standard-sized rectangular or square boards, with surfaces according to the intended use.

XPS Surfaces

Specially designed machines produce XPS boards in smooth, rough, and grooved surfaces.

XPS Smooth Edge Panels

Demanding applications, like below-grade installation, utilize smooth XPS panels. Smooth, closed-cell XPS panels protect against absorption and diffusion due to long-term water exposure.

XPS Rough Surface Panels

Rough surfaces increase the adhesion of the facade plaster.

XPS Panels with Grooves

Grooves in the XPS panel enhance wall drainage and thermal insulation for foundations.

The Benefits of XPS Insulation

XPS insulation offers many benefits contributing to an eco-friendly, healthy, durable, and safe building envelope.

Energy-Efficient

XPS closed cell insulation, with an R-value of 4.6 and 5.0, gives it a high thermal resistance value, making it extremely energy efficient, by saving energy in buildings and reducing CO2 emissions.

Recyclable

100-percent recyclable XPS allows manufacturers to melt and reform the thermoplastic polystyrene resin into new XPS foam insulation.

XPS High Compressive Resistance

XPS insulation’s high compressive strength allows it to withstand a high pressure of >300 kPa, so it can withstand more than lbs ft2 (30,000 kilos m2) with a maximum deformation of 10 percent, making it ideal for challenging applications:

• Below-grade walls – foundations, basements, crawl spaces
• Perimeter insulation – protecting foundation walls from the side of the ground
• Inverted roofs – applying the waterproofing layer beneath instead of above the insulation
• Cavity walls – a wall with a hollow center
• Pitched roofs – roofs that slope downwards, often in two parts at an angle from a central ridge
• Walkable plates – the strength of XPS insulation makes it ideal for horizontal applications like floors, flat roofs, and heavily trafficked areas

Moisture-Resistant XPS Insulation

XPS insulation provides water and freeze-thaw resistance, to protect the insulation’s thermal performance from damaging rot and unhealthy mold. In addition, the high permeability of XPS insulation makes it ideal for bathrooms and other high-moisture rooms.

Simple to Install XPS Insulation

Lightweight XPS insulation allows for easy application without irritating the worker’s skin.

Problems with XPS Insulation

• The combustibility of polystyrene foam makes XPS’s proper installation vital to avoiding a fire hazard and the emission of toxic fumes.
• The blowing agents in the manufacturing process may deplete over time, lessening the insulation value.
• XPS’s low-permeability can lead to condensation and mold problems.
• Over time, the gas bubbles within the XPS leak out, leaving air that lessens the panels’ insulation value.
• Most building professionals do not recommend XPS insulation on flat roofs because it will deform above 80 degrees.

How to Install XPS Boards

Applying XPS insulation boards involves gluing the lightweight sheets to the substrate, which is much simpler than batts, blown-in fibers, or spray foam insulation. It is important to only use the manufacturer’s recommended foam-safe adhesive. The wrong glue can melt the foam. In addition, butt the sheets snugly together and seal joints with a manufacturer-recommended adhesive seam tape.

Tips for Filling Wall and Ceiling Cavities

To insulate the stud, joist, and rafter cavities, cut the sheets to fit snug in the cavities, inserting them flush with the framing. To prevent airflow that can diminish the R-value, fill gaps along the edges with expandable insulation foam, safe for use with XPS. You can increase the R-value in two-by-six and larger dimension framing by inserting an additional layer of rigid foam insulation.

Tips for Cutting the XPS Boards

You can simply cut thin XPS sheets (less than 2-inches) by holding the straight edge of a utility knife along the cut line, scoring it about 3/4-inch deep. After scoring, lay the sheet on a table scored side up with the cut about 1-inch off the table. Firmly hold the sheet down and snap along the line. Trim the rough edges with the utility knife

For thicker sheets (greater than 2-inch), you will need a handheld drywall saw, or a table saw.

Tips for Installing XPS on Exterior Sheathing

Installing 2-inch EPS boards on exterior sheathing requires additional furring strips or other structural supports. In addition, 2-inch XPS does not supply the strength needed to support the weight of the siding. Therefore, Sto strongly recommends that you check with your local building authority to determine the required type of additional support before installing 2-inch XPS as exterior sheathing.

Sto XPS Continuous Insulation Wall Systems

Sto offers superior, simple-to-apply cladding solutions for applying XPS to an exterior wall system compared to XPS insulation boards: StoTherm ci XPS and StoPanel XPS ci. In addition, Sto XPS CI wall systems meet the requirements of fire, energy, and green building codes.

Sto XPS Wall Systems meets the requirements of NFPA 285 and NFPA 268 for use on non-combustible construction (Types I-IV).

Sto XPS Wall Systems International Building Codes (IBC)

• Ch. 26: Types I-IV (non-combustible) Construction, Ignition Resistance, Surface Burning Characteristics
• Ch. 17: Special Inspections, Types I-IV (non-combustible) Construction
• Ch. 16: Structural – Transverse Wind Load Resistance
• Ch. 14: Exterior Insulation and Finish Systems, Weather Resistance
• Ch. 7: Fire Resistance Rated Construction

Sto XPS Wall Systems International Energy Conservation Code (IECC)

• Ch. 4: Continuous Insulation (ci) over Metal Frame Walls – All Climate Zones (with sufficient ci thickness)
• Ch. 4: Continuous Air Barrier

Sto XPS Wall Systems International Green Construction Code (IGCC)

Ch. 6: Energy Conservation, Efficiency and Atmospheric Quality (Section 606: Building Thermal Envelope insulation and Air Sealing) Alternative Compliance Path: ASHRAE 189.1-

Sto XPS Wall Systems ASHRAE 90.1

• Section 5: Building Envelope Continuous Insulation (ci) over Metal Frame Walls – All Climate Zones (with sufficient ci thickness)
• Section 5: Continuous Air Barrier

Sto XPS Wall Systems ASHRAE 189.1 Green Building Standards Compliance

• Normative Appendix A: Building Envelope
• Continuous Insulation (ci) over Metal Frame Walls – All Climate Zones (with sufficient ci thickness) Normative Appendix B: Continuous Air Barrier

StoTherm® ci XPS 

Durable StoTherm® ci XPS, one of StoTherm® ci wall systems, is a drainable exterior insulation finishing system that incorporates high R-value XPS insulation into the wall system, and StoGuard® fluid-applied air and moisture barrier, with Owens Corning Foamular CI-C or Dow STYROFOAM™ Panel Core 20 insulation. StoTherm® ci XPS produces water and airtight air walls to ensure superior durability and thermal efficiency.

The unique, durable system sustains maximum curb appeal and lowers energy bills to save money. In addition, StoTherm® ci XPS can be finished with a variety of Sto textured finishes or specialty aesthetic finishes to accommodate your building’s design needs.

StoPanel XPS ci Wall System

Lightweight StoPanel XPS ci prefabricated panels incorporate extruded insulation within the panel assembly, and create exterior wall cladding with excellent air and weather tightness, superior thermal performance, and long-lasting durability. In addition, architects and designers can choose from Sto’s numerous decorative and protective color and finish options.

StoPowerwall® ci with Crack Defense option

StoPowerwall® ci energy-efficient stucco wall systems include StoGuard® air and water-resistive barrier, Owens Corning or Dow Type IV XPS insulation board, Sto DrainScreen, and Sto textured finishes.
StoPowerwall ci integrates continuous XPS insulation, air/moisture barrier, drainage, and Sto’s extensive collection of aesthetic surfaces in a hard coat stucco system.

Sto Colors

Designers can use Sto’s unique Color System as a planning tool for choosing the colors for their architectural designs. The Sto Color System provides several benefits:

• Clear, logical system makes it quick and easy to understand
• Ensures reliable application of Sto’s endless and harmonic colors for use on exterior and interior
• Efficient, perception-oriented presentation media for all phases of color design

The Sto Color Collections include:

• Sto Color 800 Collection
• Sto Color Architectural Collection
• Sto Color Classic Collection
• Sto Color Southwest Collection

Sto Traditional Finishes

Sto’s extensive selection of finishes features pure white marble aggregate, acrylic polymers in various textures, and a wide range of color options to boost your design and harmonize with the surrounding environment. In addition, durable, high-performing Sto finishes resist dirt and water, protect the building’s facade, and enhance its curb appeal. Sto high-quality finishes include:

StoCast Finishes

Specialty Aesthetic Finishes

StoSignature

Sto Traditional Finishes

iQ Technology

Sto Has the Best XPS Wall Insulation Solutions

Sto offers superior, sustainable, simple-to-apply, multiple code-compliant cladding solutions for applying XPS to an exterior wall system compared to XPS insulation boards. Drainable StoTherm® ci XPS and StoPanel XPS ci create high-performing, sustainable, and attractive cladding systems, improve indoor comfort and air quality, save both money and energy, and ensure long-term durability:

• StoTherm® ci XPS integrates continuous XPS insulation, air/moisture barrier, drainage, and Sto’s extensive collection of aesthetic surfaces.
• StoPanel XPS ci incorporates XPS insulation within the panel assembly, to create a prefabricated finished exterior wall solution with a wide range of high-end aesthetic options.
• StoPowerwall ci integrates continuous XPS insulation, air/moisture barrier, drainage, and Sto’s extensive collection of aesthetic surfaces in a hardcoat stucco system.

XPS foam, or Extruded Polystyrene foam, is a versatile building component used globally due to its many advantageous features. It is a popular go-to choice for architects, builders, and homeowners. But have you ever wondered what XPS foam is, how it's made, or its numerous applications? We’ll delve right into all aspects servicing your curiosity about XPS foam in this extensive guide.

Understanding XPS Foam

Extruded Polystyrene (XPS) foam is a rigid thermal insulation material manufactured from polystyrene. Invented in the labs of Dow Chemical Company, it started to attune with the construction sector since the mid-40s, evolving with different variants over the years.

How Is XPS Foam Produced?

The production of XPS foam might seem complex but can be simplified into four primary stages:

1. **Pre-treatment:**This stage involves feeding polystyrene resin pellets into an extruder, combining them with critical elements essential for the foaming process such as blowing agents, fire retardants, and additives.

2. Extrusion: In the second stage, a combination of heat and pressure melt the material, allowing the blowing agents to develop a foam structure.

   The company is the world’s best XPS foam insulation production supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

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   Shaping: The next phase shapes the foam by running it through a die immediately after the extrusion stage.

4. Cooling and Cutting: Lastly, the foam cools down and is cut into different sizes based on its intended usage.

Applications of XPS Foam

Its innate properties such as thermal insulation, moisture resistance, compressive strength and lightweight stature have made XPS foam desirable for a wide range of applications.

Construction

The most prevalent use of XPS foam is in the construction industry. Here’s why:

• Insulation: XPS foam is a high-performance material that helps to significantly reduce heat loss from buildings. It's commonly used in roofs, walls, floors, and building façades.
• Below grade application: XPS foam is also used for the insulation of basements and underground structures due to its high resistance to water and moisture.
• Green roofing systems: Being durable and providing good insulation, it is ideal for use in modern green roofing systems.

Packaging

XPS foam is preferentially used in packaging delicate goods owing to its exceptional shock absorption properties.

Arts and Crafts

With a smooth, flat surface, XPS foam is perfect for designing arts and crafts, such as carving, painting, and modeling.

Environmental Impact of XPS Foam

While Extruded Polystyrene provides numerous benefits, it's essential to address its environmental impact. XPS foam is up to 100% recyclable. Many manufacturers and recycling centers globally accept XPS foam for recycling, contributing towards a circular economy.

Frequently Asked Questions about Xps Foam

Q: Is XPS Foam Board toxic?

XPS foam, in its solid form, is not considered toxic. However, if burned, it can release toxic gases. That's why it's important to dispose of XPS foam correctly and not burn it in open fires.

Q: Can XPS Foam be recycled?

Yes, XPS foam can be recycled. However, the recycling process is not very common due to its cost-effectiveness. Therefore, it is always better to try to repurpose the foam or dispose of it responsibly through waste management services instead.

Q: How long does XPS Foam last?

XPS Foam has an impressive lifespan. Its physical and thermal properties are maintained over the long term. So, essentially, your XPS Foam Insulation would last as long as the lifespan of the building itself.

Q: How to cut XPS Foam for use?

While XPS foam can be cut with a simple utility knife, the use of a foam cutter will achieve a smoother and more precise cut. Always remember to take necessary precautions since foam cutters typically operate at high temperatures.

Q: Is XPS Foam water-resistant?

Yes. One of the key characteristics of XPS foam is its excellent moisture resistance, which makes it a good choice for damp areas and insulating purposes in areas where water may be a problem.

Q: What is the R-value of XPS Foam?

XPS foam has a relatively high R-value, usually averaging around R-5 per inch of thickness. The R-value is a measure of how well a barrier, such as a layer of insulation, resists the conductive flow of heat.

Q: Is XPS foam safe for the environment?

While XPS foam is not toxic, it does have a considerable environmental impact. The manufacture and disposal of XPS foam create greenhouse gases. So despite its benefits, XPS foam usage should be carried out with an environmental consciousness.

Q: Can XPS Foam be painted?

Yes, XPS Foam can be painted. This high-density foam accepts paint well, and it is often used in stage design, craft projects, and other creative uses where it may need to be painted.

Q: Does XPS Foam absorb sound?

While XPS foam has excellent thermal insulation properties, it is not particularly known for its soundproofing abilities. However, it does provide some measure of sound reduction.

Pros of XPS Foam

Excellent Insulation Properties

One of the primary advantages of XPS foam is its high insulating capacity. XPS foam, also known as Extruded Polystyrene foam, provides one of the highest R-values (measure of thermal resistance) per inch of thickness among insulation materials. This makes it an excellent choice for insulating walls, roofs, and floors.

Water and Moisture Resistance

XPS foam is highly resistant to water and moisture, which makes it an ideal material for use in areas exposed to water, such as basements or bathrooms. In fact, its closed-cell structure does not permit water infiltration, adding to the longevity of structures built using it.

High Compressive Strength

With a high load-bearing capacity, XPS foam can withstand substantial weight, thanks to its dense structure. This feature means it's suitable for use in flooring underlays or as a foundation for heavy machinery in industrial settings. So whether it's used in a domestic or commercial capacity, structures made from XPS foam will continue to maintain their integrity over time.

Resistance to Mold and Mildew

XPS foam is naturally resistant to mold and mildew growth. Given that moisture can't permeate its surface, this reduces the chances of fungus growth, providing a healthier environment for occupants. This is great for builders or homeowners looking to reduce upkeep costs and effort.

Easy to Work With

In terms of installation, XPS foam is widely recognized as being an easy-to-handle material. Its lightweight nature makes it easy to transport and maneuver. Additionally, it can be easily cut to suit an array of specifications or installation requirements.

Cons of XPS Foam

Environmental Impact

While XPS foam’s prevalent use is due to its excellent insulating properties, it does not bode well for the environment. The production process of XPS foam releases harmful greenhouse gases, such as hydrofluorocarbons (HFCs), which contribute to global warming. Furthermore, XPS foam is non-biodegradable and can take hundreds, if not thousands, of years to decompose in landfills.

High Cost

Compared to other insulation materials such as EPS or fiberglass, XPS foam is relatively expensive. While its benefits are substantial, the initial outlay required to purchase XPS foam may be a deterrent to some, particularly in larger scale projects.

Flammability

While XPS foam is usually treated with a fire retardant, it is inherently a flammable material. This can pose safety concerns and require that additional safety measures be implemented. This not only requires added effort, but could increase the overall cost of the project.

Limited Flexibility

XPS foam is very rigid, which has a lot to do with its high load-bearing capacity. However, this stiffness can limit its usefulness in applications that require a degree of flexibility. As such, for projects that demand a malleable or conformable material, XPS foam might not be the best choice.

Potential for Shrinkage

Over time, exposure to varying temperatures and UV light could cause XPS panels to shrink or warp. Although the shrinkage is minimal, it could lead to a reduction in the material’s insulating capabilities. Proper installation and care can mitigate this to a certain extent, but it’s a factor to consider during material selection.

Myth 1: XPS Foam is Non-Recyclable

One of the most common misconceptions about XPS foam is that it isn't recyclable. This is not entirely accurate. While XPS foam is not as broadly recyclable as materials like aluminum or cardboard, it can be recycled under specific conditions. Not all recycling facilities have the capability to process XPS foam due to the complexity involved, but the facilities that do are capable of repurposing this material into new products.

Fact 1: Challenges in Recycling XPS Foam

The difficulty in recycling XPS foam stems from its physical properties, as its light weight and buoyant nature can cause it to become airborne and litter the surroundings during the recycling process. Nonetheless, some recycling facilities have developed specialized equipment and procedures that can handle this material effectively.

Fact 1.1: Specialty Recycling Programs

In recent years, more and more recycling programs for XPS foam have started to appear. These specialty programs are designed to accept used XPS foam and process it in a way that allows the foam to be repurposed. While these programs might not be as widespread as those for other materials, they are steadily growing in number.

Myth 2: XPS Foam is Bio-Degradable

Another common misconception about XPS foam is that it is bio-degradable. In reality, XPS foam is made from a type of plastic called polystyrene, which is not readily broken down by biological organisms like bacteria or fungi. Thus, XPS foam is not considered to be bio-degradable.

Fact 2: XPS Foam and the Environment

Unfortunately, because XPS foam cannot be degraded biologically, it can contribute to litter and waste problems if not properly managed. Its lightness can lead it to be carried away by the wind, flowing streams, or ocean currents, reaching remote areas and potentially harming wildlife. Therefore, there's a significant importance for correctly disposing or recycling XPS foam products.

Myth 3: XPS Foam is a Poor Insulator

Another myth surrounding XPS foam is that it provides poor insulation. This simply isn't true. XPS foam, or extruded polystyrene foam, is actually known for its excellent insulation properties.

Fact 3: The Insulating Properties of XPS Foam

XPS foam is widely used as a thermal insulator in construction, particularly in roofing, wall insulation, and under-slab applications. Far from providing poor insulation, it is one of the most efficient materials available for preventing heat loss or gain. Its tightly packed cellular structure provides it with a high resistance to both heat flow and water absorption, making it an ideal choice for insulation purposes.

Myth 4: XPS Foam is Flammable

Some believe that XPS foam is highly flammable and presents a fire risk when used in construction. Again, this is a misunderstanding. While XPS foam will catch fire if directly exposed to an open flame or extremely high temperatures, it is not significantly more flammable than many other construction materials.

Fact 4: Fire Safety Measures in XPS Foam Manufacturing

Most XPS foam is manufactured with a fire retardant to minimize the material's inherent flammability. While it's true that XPS foam, like many materials, will burn under certain conditions, it's important to remember that these conditions typically involve failures in fire safety measures or extreme situations. Under normal circumstances, XPS foam used in construction does not pose a significant fire risk.

Fact 4.1: Building Code Compliance

Moreover, XPS foam products that are used in building construction are typically manufactured and tested according to rigorous building codes and safety standards, which include fire safety considerations. This ensures that when used properly, XPS foam can be safely utilized as a construction material.

As with any material, knowledge and appropriate safety measures are key to minimizing potential risks. With proper handling and installation, XPS foam can be a highly effective and safe material for a variety of applications.

Summary

So, there you have it, a quick rundown on XPS foam. This material is super versatile, showing up in all sorts of places like building insulation and craft projects due to its lightweight but durable nature. If you're looking for a product that offers high performance, long-lasting service life and is environment-friendly, you can't go wrong with it.

We've seen that this product is so much more than just your ordinary foam. XPS foam offers advanced thermal performance and moisture resistivity that other foams can't compete with. So, it's not just about the material, it's about its exceptional functionality, making it the go-to choice for both professionals and DIY enthusiasts.

All in all, it's clear how much value XPS foam brings to the table. Whether you're looking to insulate your house, creating modelling projects or even crafting your beloved cosplay costumes, this material can handle it all. It's safe to say, XPS foam is truly a game-changer in the foam industry.

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