Construction With STYROPOR PDF

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BASF Plastics
key to your success
Technical Information
July 2006
3FHJTUFSFE USBEFNBSL PG
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BASF Plastics
key to your success
July 2006
4UZSPQPS
4IJQQJOH
QPMZTUZSFOF &14
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$MBVTFD
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2
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Construction with Styropor
BASF Plastics
key to your success
July 2006
4 Thermal insulation in the construction industry

Construction with Styropor
5 Roof construction with Styropor
Flat roofs
Pitched roofs
7 Wall constructions with Styropor
10 Insulating plaster
3FHJTUFSFE USBEFNBSL PG 11 Lightweight concrete
13
4UZSPQPS
Prefabricated systems

Floor constructions with Styropor

Footfall sound insulation
4IJQQJOH
Floor heating
14 Styropor : miscellaneous uses in construction
4UZSPQPSJT#"4'TFYQBOEBCMF
Drainage boards 4UZSPQPSJTDPOTJEFSFEUPCF
QPMZTUZSFOF &14
BOEJUDPOUBJOT
Permanent formwork BIB[BSEPVTNBUFSJBMEVSJOH
BWPMBUJMFCMPXJOHBHFOU
Earthwork and foundation engineering USBOTQPSUBUJPO
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Characteristics
16 $MBVTFD of Styropor
t JTUFNQFSBUVSFTFOTJUJWF JF
Thermal properties (FSNBO-BXPOUIF
behavior
Fire FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
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Biological properties )B[BSEPVT.BUFSJBMT
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Fig. 1: USVDLT FYDFQUJPOBMMZ UIFCVZFSNBZBSSBOHF
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striking architectural ele- 5SBOTQPSUBUJPO
ment. Here roof insulating
systems made from /BUJPOBMBOEJOUFSOBUJPOBMUSBOTQPSUB
Styropor offer enduring UJPOSFHVMBUJPOTNVTUCFPCTFSWFE
thermal insulation both
in summer and in winter. = registered trademark of BASF Aktiengesellschaft

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Thermal insulation in the construction industry
BASF Plastics
key to your success
July 2006
By virtue of its properties expanded Construction today and in the future is Construction with Styropor
foam made from Styropor has secu- and will be characterized substantially
By using Styropor rigid foam, archi-
red a firm position for itself as an by requirements for energy saving,
tects and construction engineers
insulating material in the construction noise and environmental protection.
today are also at the same time
sector for more than 50 years.
Virtually all industrialized countries making use of the opportunity
today have statutory minimum presented by system solutions and
Styropor is the expandable poly-
requirements for the constructional incorporate them in their plans appro-
styrene from BASF. It is supplied
3FHJTUFSFE USBEFNBSL PG thermal insulation of heated and air- priately for the functions concerned.
to foamed plastic producers in the
form of bead-like granules. 4UZSPQPS
conditioned buildings.
By now, even in countries with mod-

The trend is clearly toward specific
insulation systems, such as external
wall and roof insulation systems,
BASF has a total of 12 plants
around the world where it produces
4IJQQJOH
erate to tropical climates, a compara-
tively high level of constructional
underfloor heating systems etc.
Styropor , the raw material for a thermal insulation is prescribed, as
4UZSPQPSJT#"4'TFYQBOEBCMF Such systems give the owner of a
4UZSPQPSJTDPOTJEFSFEUPCF
diversity of application areas, insula- is the case in countries with relatively building under construction not only
QPMZTUZSFOF &14
ting and building materials for the low winter temperatures. This is due considerable cost/benefit advantages
construction industry being upper- to BWPMBUJMFCMPXJOHBHFOU
the fact that in these countries USBOTQPSUBUJPO
but also reduce the risk of technical
most. summer thermal insulation namely *O(FSNBOZ
errors in the planning and execution
the5IJTQSPEVDU
energy lost in the air-conditioning ofCZSPBE
work. $MBTT
Foamed plastics from Styropor of buildings is a relatively significant $MBVTFD
t JTUFNQFSBUVSFTFOTJUJWF JF The examples on the following pages
factor in energy calculations, as is (FSNBO-BXPOUIF
The production of Styropor foamed show how Styropor is used as a
winter thermal insulation in other
plastics takes place in three stages: system on a structure. They are
countries. This is so because the
preexpansion, intermediate aging and current practical examples from
energy loss in the air-conditioning
CZ3PBE ((74
moulding. First of all, the granules are internationally known construction

of t
a building on hot summer days is
NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT
preexpanded and thus foamed by applications.
greater than that in the heating of
heating. The blowing agent contained QPSUFEVOEFSXFMMWFOUJMBUFE $MBVTFD
buildings with cold outside tempera- They provide interesting insights
in the raw material inflates the par- in DPOEJUJPOT (FSNBO-BXPOUIF
tures winter. into the unique versatility of foamed
ticles up to about fifty times their ori-
plastics from Styropor as system
5SBOTQPSUBUJPOPG
ginal volume to form closed-cell foam Being forced to use additional insulat-
materials. Of course, this practical
particles. This is followed by an inter- ing layers today means for architects CZ3BJM ((7&

exhibition cannot cover all possible
mediate aging time, during which air and5IFTUBOEBSEQBDLBHJOHGPSBMM
building contractors on the one
diffuses into the material and blowing hand a considerable intervention into
0VUTJEFPG(FSNBOZ
construction applications because
45:30103
/&0103
BOE1&3* there are so many. Even today, 5
agent partially diffuses out of the the103
amount of freedom they have in CZSPBE $MBTT

QSPEVDUTJTDBSECPBSEPDUBCJO decades after its invention, Styropor
material. planning and structural design. On $MBVTFD
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the5IFOFUXFJHIUJTUBOEU
other hand, this intervention has lost nothing of its attractiveness
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and
is more a part of todays con-
Finally, the preexpanded particles are a beneficial effect on the development
GPS/&0103BOE45:30103&' struction industry than ever.
filled into molds and undergo final of new, innovative system solutions. $BSSJBHFPG%BOHFSPVT
foaming, the foam particles expanding SFTQFDUJWFMZ5IFTFQSPEVDUTBSF
Here, Styropor as a material for the (PPETCZ3PBE "%3
once again and fusing together. A EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP

insulation of complete compound CZSBJM $MBTT
rigid foamed plastic with a high air CFMPXBTiPDUBCJOTw

units has for a number of years and $MBVTFD
content is produced, which is trapped in many countries held a significant
in a large number of small cells and %JNFOTJPOTPGUIFPDUBCJOT UIFNFBT
place in practical construction on
brings about excellent long-lasting account of its excellent material prop- (PPET 3*%
thermal insulation! erties. CZTFB $MBTT
UP45:30103&'

The special production process %BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
makes it possible to vary the apparent $PEF 6//P
density of the Styropor foamed BQQSPYN
CZBJS $MBTT
plastics within a wide range. As the t XJEUIBQQSPYN
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properties of the foam depend sub- BQQSPYN
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stantially on the apparent density, t IFJHIUBQQSPYN
foamed plastics can be produced BQQSPYN
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with a variety of qualities suited to
particular applications ranging from 6QPOSFRVFTU TPNFQSPEVDUTDBO 4UZSPQPSJTEFMJWFSFEDBSSJBHFQBJE
insulating boards to lightweight BMTPCFEFMJWFSFEJONFUBMESVNTXJUI UISPVHIUIFBHFODZPGIBVMBHFDPO
structural units. BOFUXFJHIUPGLHPSJOUBOL USBDUPSTDPNNJTTJPOFECZ#"4'
DPMMFDUJPO
5SBOTQPSUBUJPO
4
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BASF Plastics
key to your success
July 2006
Roof constructions with Styropor Flat roofs Unlaminated rigid foam boards are
used on what are known as tarpaulin
From the viewpoint of construction Flat roof insulation is an important
roofs (Fig. 3). In this case, the insulat-
physics, the roof, no matter of what field of application for Styropor
ing boards and the plastic tarpaulin
design, is the most highly stressed foamed plastics. Depending on the
sealing are loosely laid and provided
part of a building. Heat and cold, dry- roof design, the insulating material
with a ballast (eg gravel) or are fixed
ness and wetness, storms and snow is laid loosely, fixed by hot or cold
with special dowels.
act from the outside, internal relative adhesive or mechanically fastened
humidity acts USBEFNBSL
3FHJTUFSFE from inside,
PG either to the underlying surface. Even flat roofs have to be built with
alternately or both at the same time.
Roof designs and materials have to
4UZSPQPS
The insulation of a nonventilated flat
roof is performed simply and econom-
a slope. For flat roofs with a pitch
less than 2%, it is recommended that
of

be adapted to these conditions if the the additional thermal insulation be
roof is to fulfill its protective function. 4IJQQJOH
ically by means of insulating units of
Styropor which have been precoated
configured as a sloped insulating layer
Plastics play a significant part in this made of Styropor slope elements
with roofing felt. The lamination with
connection, as insulating layers, so as to ensure a controlled drainage
roofing felt protects the insulating
waterproofing membranes, vapor bar- QPMZTUZSFOF &14
BOEJUDPOUBJOT ofBIB[BSEPVTNBUFSJBMEVSJOH
the water. Roof elements for slope
layers when the hot bitumen is
riers, underlays, gutters, downpipes BWPMBUJMFCMPXJOHBHFOU insulation are designed and cut in
USBOTQPSUBUJPO
applied to fix the roof seal (Fig. 2).
and many other functional elements. a*O(FSNBOZ
computer-controlled process, so
In the case of rollable insulating
5IJTQSPEVDU that the way
CZSPBE the water is channeled
$MBTT
Whether a flat roof or a pitched roof, sheets, the lamination already counts
as
well as the roof drainage can be
$MBVTFD
whether someones home or an office as the first roof sealing layer.
precisely calculated. Styropor slope
building, on factories, workshops or t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
elements are also very well-suited for
warehouses, whether a roof garden FMFWBUFEUFNQFSBUVSFTTIPVME the renovation5SBOTQPSUBUJPOPG
of flat roofs.
or an underground garage: Styropor CFBWPJEFE )B[BSEPVT.BUFSJBMT
foamed plastics are always involved t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
because they have outstanding insu- t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

lation and offer economical answers
as insulating systems.
5SBOTQPSUBUJPOPG
CZ3BJM ((7&

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45:30103 /&0103BOE1&3*
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$MBVTFD
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Fig. 2: t MFOHUIBQQSPYN
Rollable insulating sheet
$PEF 6//P
BQQSPYN
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t XJEUIBQQSPYN
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Fig. 3:
Tarpaulin roof

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BASF Plastics
key to your success
July 2006
Pitched roofs
In many countries, use of the roof
space for living purposes is already
a consideration during the planning of
a building. Even on existing buildings,
roof space is increasingly being devel-
oped as additional living areas for
guest rooms,
3 FHJTUFSFE play rooms
USBEFNBSL PG or hobby
rooms.#"4' "LUJFOHFTFMMTDIBGU
Adequate thermal insulation of
the roof surface as the area bound-
4UZSPQPS
ing indoors from outdoors must be
provided. Making the insulating layer 4IJQQJOH
adequately thick is also worthwhile
with regard to the effect of sunlight in 4UZSPQPSJT#"4'TFYQBOEBCMF 4UZSPQPSJTDPOTJEFSFEUPCF
the summer. QPMZTUZSFOF &14
Suitable for use as insulation in pitched BWPMBUJMFCMPXJOHBHFOU USBOTQPSUBUJPO
roofs are Styropor rigid foams in *O(FSNBOZ
the form of filler insulating boards 5IJTQSPEVDU CZSPBE $MBTT
between the rafters, laid on the rafters $MBVTFD
(Figs. 4 6) or in the form of thermally t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
insulating structural composite units. FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
Such insulation systems make eco- CFBWPJEFE )B[BSEPVT.BUFSJBMT
nomical construction work possible t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
and offer lasting thermal protection. t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

5SBOTQPSUBUJPOPG
Fig. 5: 1BDLBHJOH )B[BSEPVT.BUFSJBMT
A Laying system: CZ3BJM ((7&

0VUTJEFPG(FSNBOZ
One45:30103
example of /&0103

this offers BOE1&3*

advantages CZSPBE $MBTT Fig. 4:
1 = Tile roofing 103
QSPEVDUTJTDBSECPBSEPDUBCJO
in particular in the case of a subse- Construction and
$MBVTFD insulation with Styropor
2 = Roof battens DPOUBJOFSTXJUITQFDJBMQMBTUJDMJOFST
quently installed roof insulation: foam
3 = Underlying battens (for ventilation) &VSPQFBO"HSFFNFOU
rigid foam
moulded boards with underlying
5IFOFUXFJHIUJTUBOEU
4 = Nailing through the Styropor insulation vapour barrier are laid on the existing DPODFSOJOHUIF*OUFSOBUJPOBM
GPS/&0103
BOE45:30103
&'
5 = Styropor laying system roof battens. The tiles are then re-laid $BSSJBHFPG%BOHFSPVT
6 = Rafters onEFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP
the profiled insulating units (Fig. 7). (PPETCZ3PBE "%3
7 = Formwork CZSBJM $MBTT

8 = External wall with, for example, CFMPXBTiPDUBCJOTw

$MBVTFD
core insulation
(PPET 3*%
CZTFB $MBTT
UP45:30103&'

Fig. 6: Fig. 7:
%BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
Nailing the bearing Foam moulded
$PEF 6//P
BQQSPYN
battens insulating boards
CZBJS $MBTT
t XJEUIBQQSPYN
BQQSPYN
*"5"%BOHFSPVT(PPET
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO
6
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BASF Plastics
key to your success
July 2006
Wall constructions with Styropor

A wall is both a load-bearing and a
protective building unit. It protects the
surrounded space against the effects
of temperature and weather and
against noise. Nowadays, the thermal
insulation function is assumed by
modern insulating
3FHJTUFSFE materials,
USBEFNBSL PG such as
Styropor#"4' "LUJFOHFTFMMTDIBGU
foamed plastics. 4UZSPQPS
In what is the optimum type of exter-
nal insulation from a construction
physics viewpoint, the Styropor insu-
4IJQQJOH
lating layer is applied on the outside 4UZSPQPSJT#"4'TFYQBOEBCMF 4UZSPQPSJTDPOTJEFSFEUPCF
of the load-bearing masonry and QPMZTUZSFOF &14
weather-protected either by a rein-
forced special plaster or by a venti-
lated facing layer. Another effective *O(FSNBOZ
type of external insulation is an insu- 5IJTQSPEVDU CZSPBE $MBTT
lating plaster with foamed Styropor $MBVTFD
particles as lightweight aggregate, t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
applied as a continuous layer. But FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
composite Styropor/plasterboard CFBWPJEFE )B[BSEPVT.BUFSJBMT
units are also used to achieve thermal t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
insulation to todays requirements by t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

insulating external walls from the
inside, for example by subsequent
interior insulation on existing buildings. DPOEJUJPOT (FSNBO-BXPOUIF
5SBOTQPSUBUJPOPG
A method widely used in Europe is 1BDLBHJOH )B[BSEPVT.BUFSJBMT
that of external insulation with CZ3BJM ((7&

Styropor boards and fabric-reinforced 5IFTUBOEBSEQBDLBHJOHGPSBMM
0VUTJEFPG(FSNBOZ
plaster coating. In this method, the 45:30103 /&0103BOE1&3*
insulating boards are fixed to the CZSPBE $MBTT
masonry by bonding mortar and sub- $MBVTFD
sequently covered with a fabric-rein- &VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
forced dispersion plaster (Figs. 8 and DPODFSOJOHUIF*OUFSOBUJPOBM
GPS/&0103BOE45:30103&'
9). The reinforcement of the plaster $BSSJBHFPG%BOHFSPVT
layer with alkaliresistant glass fibre SFTQFDUJWFMZ5IFTFQSPEVDUTBSF
(PPETCZ3PBE "%3
sheets is necessary to absorb the EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP

CZSBJM $MBTT
material and temperature dependent CFMPXBTiPDUBCJOTw

$MBVTFD
stresses in the plaster layer occurring 05*'$BSSJBHFPG%BOHFSPVT
on the insulated facade as the result %JNFOTJPOTPGUIFPDUBCJOT UIFNFBT
(PPET 3*%
of temperature fluctuations. VSFNFOUTCFUXFFOQBSFOUIFTFTBQQMZ

CZTFB $MBTT
Figs. 8 and 9: UP45:30103&'

External wall insulation %BOHFSPVT(PPET *.%(

with the composite ther- t MFOHUIBQQSPYN
mal insuiation system
$PEF 6//P
BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
Mixed
plaster 6QPOSFRVFTU TPNFQSPEVDUTDBO 4UZSPQPSJTEFMJWFSFEDBSSJBHFQBJE
Masonry
Styropor DPMMFDUJPO
insulating
layer 5SBOTQPSUBUJPO
Reinforce- /BUJPOBMBOEJOUFSOBUJPOBMUSBOTQPSUB
ment layer
Plaster

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BASF Plastics
key to your success
July 2006
The production of lightweight large-

panel wall units with a plastercoated
external insulation is widespread. The
supporting board is mounted on a
sectional steel frame and provided
with the insulation and fabric-rein-
forced plaster coating (Fig. 10). The
easy-toassemble compound units
give the
wall.
impression
#"4' of a solid external
"LUJFOHFTFMMTDIBGU
4UZSPQPS
Another system of thermal insulation
which is likewise widespread is the 4IJQQJOH
use of mouldings from Styropor for
the external walls of buildings. The 4UZSPQPSJT#"4'TFYQBOEBCMF 4UZSPQPSJTDPOTJEFSFEUPCF
mouldings are placed dry and then QPMZTUZSFOF &14
filled with concrete. BWPMBUJMFCMPXJOHBHFOU USBOTQPSUBUJPO
Walls and floors are produced in one *O(FSNBOZ
when Styropor formwork elements 5IJTQSPEVDU CZSPBE $MBTT
are used for the production of rein- $MBVTFD
forced concrete ribbed floors. The t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
formwork elements are easy to lay FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
and produce an even, thermally insu- CFBWPJEFE )B[BSEPVT.BUFSJBMT
lated ceiling which can subsequently t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
be plastered or lined (Fig. 11). t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

5SBOTQPSUBUJPOPG
CZ3BJM ((7&

0VUTJEFPG(FSNBOZ
45:30103 /&0103BOE1&3*
CZSPBE $MBTT
$MBVTFD
&VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
GPS/&0103BOE45:30103&'
$BSSJBHFPG%BOHFSPVT
(PPETCZ3PBE "%3
CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

$MBVTFD
(PPET 3*%
CZTFB $MBTT
UP45:30103&'

%BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
$PEF 6//P
BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO
Fig. /BUJPOBMBOEJOUFSOBUJPOBMUSBOTQPSUB
10 (above): Fig. 11 (below):
Installation Floor formwork elements
8
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BASF Plastics
key to your success
July 2006
Fig. 12: There is an extremely wide variety of

Wall construction variations of wall moulding systems:
system large wall units, produced on continu-
ous moulding machines and, for
example, mouldings of Styropor with
stainless steel connecting elements
(Fig. 12) or wall formwork elements
already provided with a pre-coating
4UZSPQPS for plaster bonding.
In the case of a cavity wall, the insu-

lating layer is provided between load-
4IJQQJOH bearing wall and weather-resistant
facing masonry. The closed-cell
boards, rebated all around, make it
QPMZTUZSFOF &14
BOEJUDPOUBJOT possible BIB[BSEPVTNBUFSJBMEVSJOH
to dispense with the other-
BWPMBUJMFCMPXJOHBHFOU wise customary air gap between insu-
USBOTQPSUBUJPO
lation and facing masonry. The cavity
*O(FSNBOZ
5IJTQSPEVDU between
CZSPBEthe two wall skins can be
$MBTT
fully
utilized for insulation (Fig. 13).
$MBVTFD
t JTUFNQFSBUVSFTFOTJUJWF JF For the insulation
(FSNBO-BXPOUIF
of an already exist-
FMFWBUFEUFNQFSBUVSFTTIPVME ing cavity wall, there is likewise an
5SBOTQPSUBUJPOPG
CFBWPJEFE economical
method: foamed particles
)B[BSEPVT.BUFSJBMT
are
blown into the cavity between the
CZ3PBE ((74
t NVTUCFTUPSFEBOEUSBOT two masonry

CZSBJM skins. For this purpose,
$MBTT
holes are drilled into the skin and
closed again after the filling operation.
DPOEJUJPOT
Foamed beads (FSNBO-BXPOUIF
are delivered in special

silo vehicles.5SBOTQPSUBUJPOPG
A method CZ3BJM ((7&

of construction which is as
5IFTUBOEBSEQBDLBHJOHGPSBMM simple as it is economical is the use
0VUTJEFPG(FSNBOZ
of special masonry blocks in which
45:30103 /&0103BOE1&3*
CZSPBE $MBTT

103QSPEVDUTJTDBSECPBSEPDUBCJO the Styropor insulation has already
$MBVTFD
been introduced into the cross-sec-
of the &VSPQFBO"HSFFNFOU
tion block. This may be per-
5IFOFUXFJHIUJTUBOEU

formed by DPODFSOJOHUIF*OUFSOBUJPOBM
the insulating boards being
GPS/&0103 BOE45:30103 &'

pushed
manually into corresponding
$BSSJBHFPG%BOHFSPVT
SFTQFDUJWFMZ5IFTFQSPEVDUTBSF block cavities or already molded-in
(PPETCZ3PBE "%3
EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP during block production.

CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

Another $MBVTFD
method is to fill the block

cavities 05*'$BSSJBHFPG%BOHFSPVT
with preexpanded beads and
then
foam (PPET 3*%
them with steam.

CZTFB $MBTT
This economical production method
UP45:30103&'

makes *OUFSOBUJPOBM.BSJUJNF
possible an integrated insula-
and thus
tion %BOHFSPVT(PPET *.%(

a substantially improved
t MFOHUIBQQSPYN

thermal $PEF 6//P
insulation capacity of the
BQQSPYN
hollow
CZBJSblocks.
$MBTT
t XJEUIBQQSPYN
To reduce *"5"%BOHFSPVT(PPET
heat loss through the mor-
BQQSPYN

tared joints,3FHVMBUJPOT %(3

a light masonry mortar is
t IFJHIUBQQSPYN
generally used.
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO
Fig. 13:
Core insulation

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BASF Plastics
key to your success
July 2006
Insulating plaster
A further possibility of improving the
thermal insulation of external walls is
to coat them with a thermally insulat-
ing lightweight plaster. In this case,
small, foamed Styropor particles are
added to the plastering mortar mix,
3FHJTUFSFE USBEFNBSL PG substantially reducing the apparent
4UZSPQPS density of the plaster and thus
increasing its thermal insulation.
4IJQQJOH The dry mix is delivered to the con-

struction site in sacks or containers
4UZSPQPSJT#"4'TFYQBOEBCMF and is prepared ready-for-use just by
4UZSPQPSJTDPOTJEFSFEUPCF
adding water.
QPMZTUZSFOF &14
BWPMBUJMFCMPXJOHBHFOU Such lightweight Styropor plasters
USBOTQPSUBUJPO
can be mechanically processed and
*O(FSNBOZ
5IJTQSPEVDU sprayed
CZSPBEon$MBTT
up to a thickness of 6 cm
in a single $MBVTFD
operation (Fig. 14).
t JTUFNQFSBUVSFTFOTJUJWF JF 3 to 5 days(FSNBO-BXPOUIF
after applying the layer of
FMFWBUFEUFNQFSBUVSFTTIPVME insulating plaster, a mineral plaster is
5SBOTQPSUBUJPOPG
CFBWPJEFE added
for surface protection.
)B[BSEPVT.BUFSJBMT

Depending CZ3PBE ((74
on the plaster thickness,

t NVTUCFTUPSFEBOEUSBOT CZSBJM and
profiling $MBTT
surface coating, uncon-
QPSUFEVOEFSXFMMWFOUJMBUFE
ventional $MBVTFD
facade designs are also
DPOEJUJPOT possible
(Fig. 15).
(FSNBO-BXPOUIF
5SBOTQPSUBUJPOPG
CZ3BJM ((7&

5IFTUBOEBSEQBDLBHJOHGPSBMM Fig. 15:
0VUTJEFPG(FSNBOZ
Insulating plaster facade
45:30103 /&0103BOE1&3*
CZSPBE
Building: $MBTT Fig. 14:
Les Grottes,

Geneva $MBVTFD Insulating plaster
&VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
GPS/&0103 BOE45:30103 &'

$BSSJBHFPG%BOHFSPVT
(PPETCZ3PBE "%3
CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

$MBVTFD
(PPET 3*%
CZTFB $MBTT
UP45:30103&'

%BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
$PEF 6//P
BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO
10
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BASF Plastics
key to your success
July 2006
Lightweight concrete Prefabricated Systems Such as sheeting with wood or

chipboards as load-bearing wall
Foamed Styropor beads are not only The use of Styropor
foamed plastic
or roof unit in prefabricated home
suitable for lightweight plasters, but boards as thermal insulation in large-
construction: an economical dry
also for the production of lightweight format facade units of normal con-
insulation technique which is used
concrete and porous bricks. The crete (sandwich construction) has
particularly in North America, where
possible applications of Styropor long since proven successful (Fig. 17).
it has been recognized that houses
concrete as a thermally insulating,
The high mechanical load-bearing made from prefabricated Styropor
lightweight construction
3FHJTUFSFE USBEFNBSL PG material have
already #"4'
been"LUJFOHFTFMMTDIBGU
investigated by BASF
years ago and formulations for various
4UZSPQPS
capacity and dimensional stability
of Styropor rigid foam also make
possible a trouble-free production of
units make possible far more cost-

effective construction and energy-
saving living than conventional
apparent density ranges with different
concrete properties developed. 4IJQQJOH
largepanel lightweight units which
can be covered with various materials
building methods.
From the point of view of structural depending on the intended applica-

thermal insulation and economical tion (Fig. 18, see page 12).
QPMZTUZSFOF &14
processing, Styropor concrete is of
particular interest in the low, very light BWPMBUJMFCMPXJOHBHFOU USBOTQPSUBUJPO Fig. 17:
*O(FSNBOZ Prefabricated concrete
apparent density range: for example
as a special prefabricated system in 5IJTQSPEVDU CZSPBE $MBTT unit
which the tubular cavities in the light- $MBVTFD
weight Styropor concrete wall units t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
are later filled with normal concrete, FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
which undertakes loadbearing and CFBWPJEFE )B[BSEPVT.BUFSJBMT
reinforcing functions. Recesses or t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
openings can be cut out simply by t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

using a saw (Fig. 16).
Or for the production of domed DPOEJUJPOT (FSNBO-BXPOUIF
houses, using a blown-up shell on 5SBOTQPSUBUJPOPG
which the Styropor concrete is 1BDLBHJOH )B[BSEPVT.BUFSJBMT
mechanically sprayed. CZ3BJM ((7&

0VUTJEFPG(FSNBOZ
45:30103 /&0103BOE1&3*
CZSPBE $MBTT
$MBVTFD
&VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
GPS/&0103BOE45:30103&'
$BSSJBHFPG%BOHFSPVT
(PPETCZ3PBE "%3
CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

$MBVTFD
(PPET 3*%
CZTFB $MBTT
UP45:30103&'

Fig. 16: %BOHFSPVT(PPET *.%(

Styropor concrete t MFOHUIBQQSPYN
$PEF 6//P
wall units BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO

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BASF Plastics
key to your success
July 2006
Such as sandwich units covered

with fibrated concrete slabs, as infill,
thermal-insulating facade units.
Such as large-format wall and roof
units with metal coating as systems
for industrial constructions and cold
stores. Such structural systems are
preferred inUSBEFNBSL
3FHJTUFSFE particular
PG in countries
where#"4'there
"LUJFOHFTFMMTDIBGU
is a high demand for
cold rooms or cold storage houses,
4UZSPQPS
such as South America and Austra-
lia. In this application, as in the 4IJQQJOH
insulation of refrigerant lines, the
good thermal insulation and dimen- 4UZSPQPSJT#"4'TFYQBOEBCMF 4UZSPQPSJTDPOTJEFSFEUPCF
sional stability of Styropor foamed QPMZTUZSFOF &14
plastics prove effective even at low BWPMBUJMFCMPXJOHBHFOU USBOTQPSUBUJPO
temperatures. *O(FSNBOZ
The lightweight, prefabricated com- 5IJTQSPEVDU CZSPBE $MBTT
posite units can be transported $MBVTFD
costeffectively over large distances. t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
They are therefore also used as a FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
structural system in the construction Fig. 18: CFBWPJEFE Fig. 19: )B[BSEPVT.BUFSJBMT
of houses and housing estates, in Detail of Styropor This region
in West
composite unit

Australia suffers from CZ3PBE ((74
particular in locations where living t NVTUCFTUPSFEBOEUSBOT

quarters have to be created under cyclones and summer CZSBJM $MBTT
QPSUFEVOEFSXFMMWFOUJMBUFE
temperatures of 45C $MBVTFD
difficult climatic and constructional
conditions. Whether in the cold of the DPOEJUJPOT (113F). All the build- (FSNBO-BXPOUIF
ings of this settlement 5SBOTQPSUBUJPOPG
Antarctic or in the heat of dry desert were constructed using
regions: Styropor composite units 1BDLBHJOH )B[BSEPVT.BUFSJBMT
the Styropor sandwich
make economical construction pos- technique. The 50 mm CZ3BJM ((7&

sible and offer pleasant living condi- to 75 mm thick sheet 0VUTJEFPG(FSNBOZ
tions (Figs. 19 and 20). 45:30103 /&0103 BOE1&3*

steelcoated panels were CZSPBE $MBTT
brought 1600 km for $MBVTFD
this project.
&VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
GPS/&0103BOE45:30103&'
$BSSJBHFPG%BOHFSPVT
(PPETCZ3PBE "%3
CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

$MBVTFD
(PPET 3*%
CZTFB $MBTT
UP45:30103&'

%BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
$PEF 6//P
BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
Fig. 20: 6QPOSFRVFTU TPNFQSPEVDUTDBO 4UZSPQPSJTEFMJWFSFEDBSSJBHFQBJE
Australian research BMTPCFEFMJWFSFEJONFUBMESVNTXJUI UISPVHIUIFBHFODZPGIBVMBHFDPO
center in the Antarctic. BOFUXFJHIUPGLHPSJOUBOL USBDUPSTDPNNJTTJPOFECZ#"4'
The building consists
of 100 mm to 150 mm USVDLT FYDFQUJPOBMMZ UIFCVZFSNBZBSSBOHF
thick Styropor sand- DPMMFDUJPO
wich units which have to 5SBOTQPSUBUJPO
withstand temperatures
down to 40C ( 40F) /BUJPOBMBOEJOUFSOBUJPOBMUSBOTQPSUB
and wind speeds UJPOSFHVMBUJPOTNVTUCFPCTFSWFE
of up to 280 km/h
(174 miles/h).
12
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BASF Plastics
key to your success
July 2006
Floor constructions with Styropor Floor heating

Footfall sound insulation Impact sound insulation is often
combined with underfloor heating.
In some countries, structural sound
To avoid downward heat loss, an
insulation is even today only of secon-
insulating layer of Styropor rigid foam
dary importance; nevertheless, in the
is laid between the underfloor heating
meantime noise pollution has become
and the impact sound insulation.
so great everywhere, especially in
3FHJTUFSFE USBEFNBSL PG Boards with moulded-in grooves or
large conurbations, that adequate
sound insulation is becoming ever 4UZSPQPS elevations on the upper side are used
for this to permit easy laying of flexible
more important. As well as limiting
polyethylene hot water pipes (Fig. 22).
sound transmission through external
compound units, impact sound insu-
4IJQQJOH
lation is of great importance. To 4UZSPQPSJT#"4'TFYQBOEBCMF 4UZSPQPSJTDPOTJEFSFEUPCF
achieve effective impact sound insu- QPMZTUZSFOF &14
lation, the sound which is made by
walking on a floor must be prevented
from being transmitted to other com- *O(FSNBOZ
pounds units. For instance, a thick 5IJTQSPEVDU CZSPBE $MBTT
Fig. 21:
carpet may be laid on a concrete
Structure $MBVTFD
of floating
floor. However, this is only a tempo- t JTUFNQFSBUVSFTFOTJUJWF JF floor
(FSNBO-BXPOUIF
rary solution, as the carpet wears FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
out or may be taken up. Another CFBWPJEFE )B[BSEPVT.BUFSJBMT
possibility is to increase the weight of t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
the floor and thus reduce the sound t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT
transmission. However, this is only
possible to a limited extent for finan-
cial and technical reasons. All of DPOEJUJPOT (FSNBO-BXPOUIF
these considerations finally led to the 5SBOTQPSUBUJPOPG
development of what is known as 1BDLBHJOH )B[BSEPVT.BUFSJBMT
the floating floor system, a flooring CZ3BJM ((7&

structure common in particular in 0VUTJEFPG(FSNBOZ
Germany and a number of other 45:30103 /&0103BOE1&3*
CZSPBE $MBTT
European countries (Fig. 21). 103QSPEVDUTJTDBSECPBSEPDUBCJO
$MBVTFD
A floating floor is a flooring (for exam- &VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
ple cement screed) which is laid on a DPODFSOJOHUIF*OUFSOBUJPOBM
GPS/&0103BOE45:30103&'
flexible insulating layer and can freely $BSSJBHFPG%BOHFSPVT
oscillate, thus acting as a spring-mass SFTQFDUJWFMZ5IFTFQSPEVDUTBSF
(PPETCZ3PBE "%3
system. This substantially prevents EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP

CZSBJM $MBTT
the penetration of structure-borne CFMPXBTiPDUBCJOTw

$MBVTFD
sound into the floor structure. 05*'$BSSJBHFPG%BOHFSPVT
Special Styropor foamed plastic (PPET 3*%
boards, which are elasticized by VSFNFOUTCFUXFFOQBSFOUIFTFTBQQMZ

CZTFB $MBTT
special subsequent treatment, have UP45:30103&'
Fig. 22:
Floor heating
proven their value for impact sound %BOHFSPVT(PPET *.%(

insulation. Such boards have a low t MFOHUIBQQSPYN
$PEF 6//P
dynamic rigidity (comparable with BQQSPYN
an air cushion) and are nevertheless CZBJS $MBTT

t XJEUIBQQSPYN
sufficiently compression-resistant to *"5"%BOHFSPVT(PPET
BQQSPYN
bear the load of the floor permanently. 3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO Fig. 23:
Laying moulded
/BUJPOBMBOEJOUFSOBUJPOBMUSBOTQPSUB Styropor elements for
UJPOSFHVMBUJPOTNVTUCFPCTFSWFE the thermal insulation
of the normal floor
construction in Japan

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BASF Plastics
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July 2006
Styropor: miscellaneous uses in

construction
As well as applications in the area of
thermal and impact sound insulation,
Styropor foamed plastics perform
a wide variety of other functions in
construction.
Drainage boards 4UZSPQPS
Drainage boards of Styropor consist
of foamed Styropor beads which are
interconnected in such a way that the
4IJQQJOH
voids produce a large continuous 4UZSPQPSJT#"4'TFYQBOEBCMF 4UZSPQPSJTDPOTJEFSFEUPCF
pore volume. As a vertical filter layer QPMZTUZSFOF &14
in front of cellar walls or retaining
walls, drainage boards prevent seep-
age water accumulating in the ground *O(FSNBOZ
until it exerts hydrostatic pressure. 5IJTQSPEVDU CZSPBE $MBTT
They form a path of seepage from the $MBVTFD
overlying ground to the drain tile at t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
the foundation of the wall (Fig. 24). FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
Drainage boards of Styropor have CFBWPJEFE )B[BSEPVT.BUFSJBMT
also proven particularly suitable for t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
the drainage of roof gardens. The t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

advantages here are the additional QPSUFEVOEFSXFMMWFOUJMBUFE $MBVTFD
thermal insulation and the low weight DPOEJUJPOT (FSNBO-BXPOUIF
in comparison with a drainage layer 5SBOTQPSUBUJPOPG
of gravel. Fig. 24:
1BDLBHJOH
Drainage )B[BSEPVT.BUFSJBMT
CZ3BJM ((7&

Permanent formwork 5IFTUBOEBSEQBDLBHJOHGPSBMM
0VUTJEFPG(FSNBOZ
To reduce the weight per unit area of 45:30103 /&0103BOE1&3*
CZSPBE $MBTT
large-span concrete floors, in particu- 103QSPEVDUTJTDBSECPBSEPDUBCJO
Fig. 26:
$MBVTFD
lar in the case of ribbed floors and DPOUBJOFSTXJUITQFDJBMQMBTUJDMJOFST
Wall formwork system
&VSPQFBO"HSFFNFOU
coffered ceilings, Styropor formwork 5IFOFUXFJHIUJTUBOEU
elements are used. Depending on GPS/&0103BOE45:30103&'
$BSSJBHFPG%BOHFSPVT
requirements, such formwork ele- SFTQFDUJWFMZ5IFTFQSPEVDUTBSF
ments are cut from the block or (PPETCZ3PBE "%3
produced as a foam moulded unit CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

(Fig. 25). $MBVTFD
Fig. 25: 05*'$BSSJBHFPG%BOHFSPVT
Large-format wall and floor formwork %JNFOTJPOTPGUIFPDUBCJOT UIFNFBT
Floor formwork (PPET 3*%
with foamed plastic boards are pro- VSFNFOUTCFUXFFOQBSFOUIFTFTBQQMZ

duced by pushing the board sections CZTFB $MBTT
UP45:30103&'

into a correspondingly designed *OUFSOBUJPOBM.BSJUJNF
structure of galvanized steel wires. %BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
After assembly of the formwork ele- $PEF 6//P
BQQSPYN
ments, concrete is cast in the cavity. CZBJS $MBTT

The thermally insulating Styropor t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
formwork is subsequently plastered BQQSPYN
3FHVMBUJPOT %(3

or lined, the outer steel mats offering t IFJHIUBQQSPYN
a good anchorage (Fig. 26). BQQSPYN
%FMJWFSZ
For making concrete facades,
Styropor textured formwork is used. 6QPOSFRVFTU TPNFQSPEVDUTDBO 4UZSPQPSJTEFMJWFSFEDBSSJBHFQBJE
To create an artistic design on a con- BMTPCFEFMJWFSFEJONFUBMESVNTXJUI UISPVHIUIFBHFODZPGIBVMBHFDPO
crete wall, the image relief may be BOFUXFJHIUPGLHPSJOUBOL USBDUPSTDPNNJTTJPOFECZ#"4'
cut in the foam, for example with a USVDLT FYDFQUJPOBMMZ UIFCVZFSNBZBSSBOHF
hot wire, and the foam then used as DPMMFDUJPO
concrete formwork. 5SBOTQPSUBUJPO
14
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BASF Plastics
key to your success
July 2006
Foundation engineering
Especially in northern countries with
severe winters and deep ground
frosts, Styropor rigid foam has
proven very successful as an insulat-
ing material for protection against
frost damage to foundations and
buried pipelines
3FHJTUFSFE (Fig. 27).
USBEFNBSL PG
The special properties of the closed-
cell foamed plastic, such as stability
4UZSPQPS
and durability, the immunity to mois-
ture and ground bacteria and also the
4IJQQJOH
good thermal insulation have resulted 4UZSPQPSJT#"4'TFYQBOEBCMF 4UZSPQPSJTDPOTJEFSFEUPCF
in rigid foam boards being used as a
QPMZTUZSFOF &14
frost protecting layer in road and
railroad construction. The practical BWPMBUJMFCMPXJOHBHFOU USBOTQPSUBUJPO
experience of this since 1968 in *O(FSNBOZ
particular in Scandinavian countries 5IJTQSPEVDU CZSPBE $MBTT
provided the basis for a new method $MBVTFD
of construction, which has been t JTUFNQFSBUVSFTFOTJUJWF JF (FSNBO-BXPOUIF
developed since 1972 in Norway and FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
in the meantime is also put into use in CFBWPJEFE )B[BSEPVT.BUFSJBMT
other countries: the use of Styropor t IBTBMJNJUFETIFMGMJGF
CZ3PBE ((74
blocks as a loaddistributing substruc- t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

ture for road and bridge approach
ramps in areas with poor loading-
bearing soil conditions. In such DPOEJUJPOT (FSNBO-BXPOUIF
regions, major settlement of the pave- 5SBOTQPSUBUJPOPG
ment structure have occurred over 1BDLBHJOH )B[BSEPVT.BUFSJBMT
the years, necessitating expensive CZ3BJM ((7&

renovation work. Solving the problem 0VUTJEFPG(FSNBOZ
was possible with Styropor rigid 45:30103 /&0103BOE1&3*
CZSPBE $MBTT
foam blocks which, assuming an 103QSPEVDUTJTDBSECPBSEPDUBCJO
$MBVTFD
apparent density of at least 20 kg/m 3 DPOUBJOFSTXJUITQFDJBMQMBTUJDMJOFST
&VSPQFBO"HSFFNFOU
(1.25 pcf), have the strength proper- 5IFOFUXFJHIUJTUBOEU
ties necessary for this application. GPS/&0103BOE45:30103&'
The high bending and shear strength $BSSJBHFPG%BOHFSPVT
of the lightweight block foam made (PPETCZ3PBE "%3
a good pressure distribution possible CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

on the muddy ground. The low weight $MBVTFD
of such a substructure permanently 05*'$BSSJBHFPG%BOHFSPVT
prevents sinking of the road structure. (PPET 3*%
The rigid foam blocks are secured CZTFB $MBTT
UP45:30103&'
Fig. 28:
against slipping by claw plates and *OUFSOBUJPOBM.BSJUJNF
Styropor as a load-
stacked up to a height of 10 m. Then %BOHFSPVT(PPET *.%(

distributing substructure
t MFOHUIBQQSPYN
a 10 cm (3.94 in.) thick layer of con- $PEF 6//P
crete with steel mesh reinforcement is BQQSPYN
CZBJS $MBTT
applied before laying the bituminous t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
pavement (Fig. 28). BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO
Fig. 27:
Foundation formwork

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Characteristics of Styropor foamed plastic
BASF Plastics
key to your success
July 2006
Thermal properties Fire behavior Biological properties

There is virtually no lower temperature Like many other construction materi- Foamed plastics from Styropor have
limit for the application of Styropor als, Styropor foamed plastics are no nourishing value to animals. They
rigid foam in the construction industry. combustible. When assessing their do not rot, are not water soluble and
Wherever a thermally induced volume fire behaviour, it must be taken into do not give off any water-soluble
contraction requires such a limit (for account that this depends to a sub- substances which could contaminate
example in cold store construction), stantial extent not only on material- ground water. If relevant local regu-
this is
3to be taken
FHJTUFSFE intoPG account in
USBEFNBSL related effects but also on application lations are observed, they may be
design. #"4' "LUJFOHFTFMMTDIBGU
If the rigid foam is subjected
to elevated temperatures, the maxi-
4UZSPQPS
conditions. Of considerable impor-
tance in particular is the combination
dumped together with household
refuse.
mum permissible temperature with other construction materials
4IJQQJOH Foamed plastics from Styropor have
depends on the duration of tempera- and the often necessary or desired
been in production and use for several
ture exposure and the mechanical arrangement of protective and cover-
decades. No harmful effects on health
loading of the foam (see table 2 on ing4UZSPQPSJT#"4'TFYQBOEBCMF
layers. 4UZSPQPSJTDPOTJEFSFEUPCF
have been discovered in this time.
page 18). QPMZTUZSFOF &14
With regard to the material-related The health-safety of the application of
In the case of brief exposure (fixing BWPMBUJMFCMPXJOHBHFOU
effects, a distinction has to be made USBOTQPSUBUJPO
rigid foam boards of Styropor is also
with hot bitumen), Styropor rigid between foamed plastics from *O(FSNBOZ
evidenced by the fact that Styropor
foam may also be subjected to higher 5IJTQSPEVDU
Styropor P and -F grades. The latter isCZSPBE
used as$MBTT
food packaging.
temperatures. Under prolonged include a flame-retardant additive $MBVTFD
temperature exposure above 100C t JTUFNQFSBUVSFTFOTJUJWF JF
which distinctly reduces ignitability (FSNBO-BXPOUIF
(212F), the foam structure begins and flame progagation. They achieve
to soften and to sinter. the best possible classification for
combustible construction materials
CZ3PBE ((74
specified by various national regula-

tions.
In Germany,
DPOEJUJPOTthe flammability of con- (FSNBO-BXPOUIF
struction materials had been classified 5SBOTQPSUBUJPOPG
according
1BDLBHJOH to DIN 4102-1 up until now. )B[BSEPVT.BUFSJBMT
According to this standard, Styropor CZ3BJM ((7&

F fulfills the requirements made of
flame-retardant construction materi-
0VUTJEFPG(FSNBOZ
45:30103 /&0103
BOE1&3*
als, Construction Material Class B1, CZSPBE $MBTT
103
QSPEVDUTJTDBSECPBSEPDUBCJO
and it is categorized as non-burning $MBVTFD
dripping. In accordance with Euro- &VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
pean standardization, for now, panels DPODFSOJOHUIF*OUFSOBUJPOBM
GPS/&0103BOE45:30103&'
made of Styropor F have been ran- $BSSJBHFPG%BOHFSPVT
kedSFTQFDUJWFMZ5IFTFQSPEVDUTBSF
in Euroclass E. (PPETCZ3PBE "%3
In CFMPXBTiPDUBCJOTw

the most important fire test invol- CZSBJM $MBTT
ving the entire component to be $MBVTFD
examined, for example, the thermal 05*'$BSSJBHFPG%BOHFSPVT
insulation composite system in the (PPET 3*%
case of plasterboard composite pla- CZTFB $MBTT
UP45:30103
tes, etc., as a rule,

&'

components made *OUFSOBUJPOBM.BSJUJNF
of Styropor F attain a better classi- %BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
fication, sometimes even as high as
$PEF 6//P
Euroclass B.
BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
Therefore, in most cases the use of *"5"%BOHFSPVT(PPET
BQQSPYN
foamed plastics of Styropor F grades 3FHVMBUJPOT %(3

fortconstructional
IFJHIUBQQSPYN
applications may
be permitted,
BQQSPYN
though in each case the

%FMJWFSZ
respective national building regula-
tions are to be observed.
BMTPCFEFMJWFSFEJONFUBMESVNTXJUI
As biological investigations have UISPVHIUIFBHFODZPGIBVMBHFDPO
BOFUXFJHIUPGLHPSJOUBOL
shown, if Styropor rigid foam is USBDUPSTDPNNJTTJPOFECZ#"4'
USVDLT in a fire, the toxicity of the
involved FYDFQUJPOBMMZ UIFCVZFSNBZBSSBOHF
gasses from burning and carboniza- DPMMFDUJPO
tion is lower than that of the same
5SBOTQPSUBUJPO
amounts of wood.
16
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BASF Plastics
key to your success
July 2006
Table 1: Resistance of Styropor rigid foam to chemicals

Active agents Styropor P Styropor F Styropor FH
Salt solutions (seawater) + + +
Soaps and wetting agent solutions + + +
Bleaching lyes, such as hypochlorite, chlorine water,
hydrogen peroxide solutions + + +
Dilute acids
35% hydrochloric acid, up to 50% nitric acid
+
+ 4UZSPQPS +
+
+
+
Anhydrous acids, for example fuming sulfuric acid,
glacial acetic acid, 100% formic acid 4IJQQJOH
Sodium hydroxide, potassium hydroxide,
ammonia solution + 4UZSPQPSJT#"4'TFYQBOEBCMF
+ 4UZSPQPSJTDPOTJEFSFEUPCF
+
Organic solvents, QPMZTUZSFOF &14
such as acetone, ethyl acetate, benzene, BWPMBUJMFCMPXJOHBHFOU USBOTQPSUBUJPO
xylene, paint thinner *O(FSNBOZ
Saturated aliphatic hydrocarbons, 5IJTQSPEVDU CZSPBE $MBTT
surgical spirit, test benzene (+ ) (+ ) $MBVTFD (+ )
Paraffin oil, vaseline + t
(+) JTUFNQFSBUVSFTFOTJUJWF JF + (+) (FSNBO-BXPOUIF
+ (+)
Diesel oil
(+) FMFWBUFEUFNQFSBUVSFTTIPVME (+) 5SBOTQPSUBUJPOPG
(+)
Motor fuel (normal and super gasoline)
CZ3PBE ((74
Alcohols, for example methanol, ethanol + + +

Silicone oil + QPSUFEVOEFSXFMMWFOUJMBUFE + +
$MBVTFD
+ Resistant: + Conditionally resistant: Unresistant:
the foam plastic is not destroyed even after the foamed plastic may shrink or suffer attack to the
5SBOTQPSUBUJPOPG
the foamed plastic shrinks at a greater or lesser rate

prolonged exposure. 1BDLBHJOH
surface after prolonged exposure. or is dissolved.)B[BSEPVT.BUFSJBMT
CZ3BJM ((7&

0VUTJEFPG(FSNBOZ
45:30103 /&0103BOE1&3*
CZSPBE $MBTT
$MBVTFD
&VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
GPS/&0103BOE45:30103&'
$BSSJBHFPG%BOHFSPVT
(PPETCZ3PBE "%3
CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

$MBVTFD
(PPET 3*%
CZTFB $MBTT
UP45:30103&'

%BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
$PEF 6//P
BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO

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BASF Plastics
key to your success
July 2006
Table 2: Physical data for foams made from Styropor for construction
Properties 1) Test standard Unit Test result
Quality assured types GSH quality conditions PS 15 SE PS 20 SE PS 30 SE
Application types DIN 18164, Part 1 W WD WS + WD
Minimum bulk density EN ISO 845 kg/m3 15 20 30
Building material class DIN 4102 B1, Poorly B1, Poorly B1, Poorly
Thermal conductivity
4UZSPQPS flammable flammable flammable

Measured value at +10C DIN 52612 mW/(m K) 36 38 33 35 31 34
Calculated value according to DIN 4108 4IJQQJOH
mW/(m K) 40 40 35
Compressive stress at 10% compressive strain EN 826 kPa 65 100 110 140 200 250
Resistance to sustained compressive QPMZTUZSFOF &14
loads at < 2% strain after 50 years ISO 785 kPa 20 30 35 50 70 90
Flexural strength EN 12089 kPa 150 230 *O(FSNBOZ
250 310 430 490
Shear strength DIN 534275IJTQSPEVDUkPa 80 130 CZSPBE 120 $MBTT
170 210 260
Tensile strength DIN 53430 kPa 160 260 230 $MBVTFD
330 380 480
Modulus of elasticity (compressive test) EN 826 t JTUFNQFSBUVSFTFOTJUJWF JF
MPa 1.0 4.0 3.5 (FSNBO-BXPOUIF
4.5 7.5 11.0
Heat deformation temperature FMFWBUFEUFNQFSBUVSFTTIPVME 5SBOTQPSUBUJPOPG
short-term 53424
based on DIN CFBWPJEFE
C 100 100 )B[BSEPVT.BUFSJBMT
100
long-term at 50 kPa t IBTBMJNJUFETIFMGMJGF
C

75 80 CZ3PBE ((74
80
long-term at 20 kPa t NVTUCFTUPSFEBOEUSBOT
C 75 CZSBJM
80 $MBTT 80
Coefficient of linear expansion 1/K 5 7 10-5 5 7 10-5 5 7 10-5
Specific heat capacity DIN 53765 J/(kg K) 1210 1210 1210
5SBOTQPSUBUJPOPG
Water absorption when submerged (by volume) 1BDLBHJOH )B[BSEPVT.BUFSJBMT
after 7 days EN 12087 Vol. % 0.5 1.5 0.5 CZ3BJM ((7&

1.5 0.5 1.5
after 28 days 5IFTUBOEBSEQBDLBHJOHGPSBMM
Vol. % 1.0 3.0 0VUTJEFPG(FSNBOZ
1.0 3.0 1.0 3.0
45:30103 /&0103BOE1&3*
Water vapor diffusion rate DIN 52 615 CZSPBE $MBTT
Water vapor diffusion resistance factor Calculated DPOUBJOFSTXJUITQFDJBMQMBTUJDMJOFST
according $MBVTFD
to DIN 4108, Part 4 1 20/50 30/70 &VSPQFBO"HSFFNFOU
40/100
5IFOFUXFJHIUJTUBOEU
GPS/&0103 BOE45:30103 &'

$BSSJBHFPG%BOHFSPVT
1) corresponding to Test Norm SFTQFDUJWFMZ5IFTFQSPEVDUTBSF
1 N/mm2 = 1000 KN/m2 =1 MPa =1000 kPa
(PPETCZ3PBE "%3
CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

$MBVTFD
Further information Photo credits

Note
(PPET 3*%
CZTFB $MBTT
This brochure could only give a broad UP45:30103
&'
The
Figure 11: data contained in this publication
outline of the many fields of applica- Rhodius Chemie-Systeme GmbH are based %BOHFSPVT(PPET *.%(

on our current knowledge

tion of Styropor foamed plastics. t MFOHUIBQQSPYN and experience. In view of the many
Figures $PEF 6//P
Details on application techniques, 19 and 20:
BQQSPYN
factors that may affect processing
structural engineering and construc- BONDOR PTY LTD, Australia CZBJS
and application$MBTT
of our product, these
t XJEUIBQQSPYN
tion physics are contained in the *"5"%BOHFSPVT(PPET
data do not relieve processors from

Figure 22: BQQSPYN
Technical Information publications

carrying out3FHVMBUJPOT %(3

their own investiga-
FelixtSchuh
IFJHIUBQQSPYN
& Co. GmbH
by BASF. BQQSPYN
tions and tests; neither do these
Figure 27: %FMJWFSZ
data imply any guarantee of certain
ISORA OY, Finland properties, nor the suitability of the
product for a specific purpose. Any
BMTPCFEFMJWFSFEJONFUBMESVNTXJUI
Figure 28: UISPVHIUIFBHFODZPGIBVMBHFDPO
descriptions, drawings, photographs,
ISOBOFUXFJHIUPGLHPSJOUBOL
Bouw, The Netherlands USBDUPSTDPNNJTTJPOFECZ#"4'
data, proportions, weights etc. given
herein may change without prior
information
DPMMFDUJPO and do not constitute
5SBOTQPSUBUJPO the agreed contractual quality of
the product. It is the responsibility
/BUJPOBMBOEJOUFSOBUJPOBMUSBOTQPSUB of the recipient of our products to
UJPOSFHVMBUJPOTNVTUCFPCTFSWFE ensure that any proprietary rights
and existing laws and legislation are
observed. (May 2006)
18
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KSEN 0606 BE July 2006

BASF Plastics
key to your success
July 2006
4UZSPQPS
4IJQQJOH
QPMZTUZSFOF &14
*O(FSNBOZ
$MBVTFD
CZ3PBE ((74

5SBOTQPSUBUJPOPG
CZ3BJM ((7&

0VUTJEFPG(FSNBOZ
45:30103 /&0103BOE1&3*
CZSPBE $MBTT
$MBVTFD
&VSPQFBO"HSFFNFOU
5IFOFUXFJHIUJTUBOEU
GPS/&0103BOE45:30103&'
$BSSJBHFPG%BOHFSPVT
(PPETCZ3PBE "%3
CZSBJM $MBTT
CFMPXBTiPDUBCJOTw

$MBVTFD
(PPET 3*%
CZTFB $MBTT
UP45:30103&'

%BOHFSPVT(PPET *.%(

t MFOHUIBQQSPYN
$PEF 6//P
BQQSPYN
CZBJS $MBTT
t XJEUIBQQSPYN
*"5"%BOHFSPVT(PPET
BQQSPYN
3FHVMBUJPOT %(3

t IFJHIUBQQSPYN
BQQSPYN
%FMJWFSZ
DPMMFDUJPO
5SBOTQPSUBUJPO
BASF Aktiengesellschaft
/BUJPOBMBOEJOUFSOBUJPOBMUSBOTQPSUB Styrenic Polymers Europe
UJPOSFHVMBUJPOTNVTUCFPCTFSWFE 67056 Ludwigshafen
Germany
www.styropor.com


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t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

t XJEUIBQQSPYN BASF Plastics

with Styropor BMTPCFEFMJWFSFEJONFUBMESVNTXJUI

t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

4 Thermal insulation in the construction industry

t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

moulding. First of all, the granules are internationally known construction

once again and fusing together. A EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP

because they have outstanding insu- t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

and offer lasting thermal protection. t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

7 = Formwork CZSBJM $MBTT

Wall constructions with Styropor

insulation to todays requirements by t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

sheets is necessary to absorb the EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP

of temperature fluctuations. VSFNFOUTCFUXFFOQBSFOUIFTFTBQQMZ

The production of lightweight large-

be plastered or lined (Fig. 11). t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

Fig. 12: There is an extremely wide variety of

t NVTUCFTUPSFEBOEUSBOT two masonry

EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP during block production.

them with steam.

4IJQQJOH The dry mix is delivered to the con-

on the plaster thickness,

Lightweight concrete Prefabricated Systems Such as sheeting with wood or

From the point of view of structural depending on the intended applica-

openings can be cut out simply by t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

Such as sandwich units covered

particular in locations where living t NVTUCFTUPSFEBOEUSBOT

Floor constructions with Styropor Floor heating

system. This substantially prevents EFMJWFSFEJOQBMFUUFEVOJUT SFGFSSFEUP

boards, which are elasticized by VSFNFOUTCFUXFFOQBSFOUIFTFTBQQMZ

an air cushion) and are nevertheless CZBJS $MBTT

bear the load of the floor permanently. 3FHVMBUJPOT %(3

Styropor: miscellaneous uses in

the drainage of roof gardens. The t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

with foamed plastic boards are pro- VSFNFOUTCFUXFFOQBSFOUIFTFTBQQMZ

ments, concrete is cast in the cavity. CZBJS $MBTT

blocks as a loaddistributing substruc- t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

Thermal properties Fire behavior Biological properties

specified by various national regula-

foamed plastics of Styropor F grades 3FHVMBUJPOT %(3

though in each case the

Table 1: Resistance of Styropor rigid foam to chemicals

Alcohols, for example methanol, ethanol + + +

Technical Information publications

KSEN 0606 BE July 2006

t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

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because they have outstanding insu- t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

and offer lasting thermal protection. t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

7 = Formwork CZSBJM $MBTT

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openings can be cut out simply by t NVTUCFTUPSFEBOEUSBOT CZSBJM $MBTT

an air cushion) and are nevertheless CZBJS $MBTT

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