What is Expanded Polystyrene (EPS) foam?

The word Styrofoam™ is often used to describe expanded polystyrene (EPS) foam; however, ‘Styrofoam’ is actually a trademarked term for closed-cell extruded polystyrene foam made for thermal insulation and craft applications. EPS foam is the correct term for any form of expanded polystyrene.

Expanded Polystyrene insulation is a lightweight, rigid, closed cell insulation. EPS is available in several compressive strengths to withstand load and back-fill forces. This closed-cell structure provides minimal water absorption and low vapor permanence.

Commonly used as insulation for walls, foundations and roofing, there are many benefits to selecting EPS products:

A cost efficient, high performing alternative to extruded (XPS) foam, EPS is the perfect choice for many insulation and construction applications.

The Manufacturing Process

EPS is created in a two-stage process:

Raw beads are expanded using steam, creating pre puff beads, which are then cured in large bags before being conveyed to the mold. Once in the mold, the pre puff beads are again steamed to form a block that is anywhere from 37-1/2″ – 54″ x 49″ x 121-1/2″ – 220″. The blocks are then placed on the storage floor to age for the appropriate length of time before being cut into various shapes and sizes. Blocks are produced in several densities to meet specific project needs. Here at ICA we manufacture Low Density EPS foam blocks all the way up to 2.85 lb density.

EPS Size & Density

ICA’s new state-of-the-art Hirsch mold allows us to manufacture block sizes anywhere from 37-1/2″ – 54″ x 49″ x 121-1/2″ – 220″. Although ICA does not stock any cut foam, regularly cut sizes are: 48 inches by 96 inches and 24 inches by 96 inches. Almost any size is available as a custom order.

Thickness: 1/4″ to 54″
Lengths: Up to 216″ (18′)
Widths: Up to 48″
Densities: .75 lb to 2.85 lbs per cubic foot

Density is a measure of mass per volume. EPS is measured in pounds per cubic foot (lbs/pcf). ICA manufactures expanded polystyrene in the following minimum densities:

0.70 lbs/pcf
0.90 lbs/pcf
1.15 lbs/pcf
1.35 lbs/pcf
1.80 lbs/pcf
2.40 lbs/pcf
2.85 lbs/pcf

Additional densities available by custom order.

Environmental Concerns

EPS is extremely “GREEN“.  NEVER any CFC’s, NEVER any HCFC’s.

Expanded Polystyrene has always been CFC- and HCFC-free. ICA is an environmentally conscientious manufacturing plant. Our in-house EPS trim is recycled and we accept recyclable EPS from our customers and the public, significantly reducing the amount of EPS that would potentially end up in landfills. In 1994 ICA installed a pentane collection system for air quality control. The system captures the pentane that is released during production and reroutes it through our boiler. This reduces the amount of natural gas we use, saving natural resources while being environmentally responsible. We continued our efforts to be mindful of our environment by installing  solar panels and replacing our lighting with energy efficient fixtures. All of these actions help to keep the air of our planet cleaner and lessen the impact of landfills on the population.

EPS Insulation is composed of organic elements – carbon, hydrogen and oxygen – and does not contain chlorofluorocarbons (CFCs) or hydrochlorofluorocarbons (HCFCs). For more information on EPS visit EPS Industry Alliance.

Due to our green efforts, in 2011 we were happy to announce our ICA-LITE® EPS panels and ICA-GEOFOAM were approved to add LEED® points to construction projects.

Code Compliances

ICA-LITE® complies with the following codes and approvals:

• AIA (Section 702.9)
• Underwriters Laboratories
• Factory Mutual (Ceiling Tile)
• LEED®

ICA-LITE® can be manufactured to meet or exceed the following Federal and Military specifications along with others:

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