Construction and Building Materials 18 (2004) 235–241

Development and testing of polystyrene mortars using waste EPS

solution-based binders
N.W. Choia,*, Y. Ohamab
a
Research Center of Industrial Technology, Chonbuk National University, 664-14 Deokjin Jeonju, 561-756 South Korea
b
Department of Architecture, College of Engineering, Nihon University, Koriyama, Fukushima-ken, 963-8642 Japan

Received 8 December 2003; received in revised form 9 January 2004; accepted 10 January 2004

Abstract

A styrene solution of waste expanded polystyrene (EPS) is prepared by dissolving EPS in styrene at an EPS concentration of
40%. The polystyrene mortars using waste EPS solution-based binders are prepared with various contents of crosslinking agent,
and tested for working life, setting shrinkage, flexural and compressive strengths, and hot water resistance. As a result, the
working life of the polystyrene mortars is shortened, and their setting shrinkage is increased with increasing content of crosslinking
agent. Their flexural strength decreases while their compressive strength increases with an increase in the content of crosslinking
agent. In addition, the polystyrene mortars have excellent hot water resistance.
䊚 2004 Elsevier Ltd. All rights reserved.

Keywords: Polystyrene mortar; Waste expanded polystyrene; Recycling

1. Introduction thermal insulation materials), was used as a model of

Expanded polystyrene is currently used as a popular
packaging or insulating material in various industrial
fields in the world w1x. A large quantity of expanded
polystyrene is consumed, and is disposed as a waste.
Effective recycling countermeasures against the waste
expanded polystyrene are strongly requested. The pur-
pose of this investigation is to develop the polystyrene
mortars using the styrene solutions of the waste expand-
ed polystyrene as an effective recycling method for the
waste expanded polystyrene. The manufacturing process
and basic properties of the polystyrene mortars using
the waste expanded polystyrene solution-based binders
are demonstrated.
2. Materials
waste EPS. The properties of EPS for binders are given
in Table 1. The styrene for industrial use, specified in
JIS K 6727(Styrene), was employed not only as a
solvent to dissolve EPS but also as a binder for polymer
mortars. Trimethylolpropane trimethacrylate (TMP-
TMA) and g-methacryloxypropyl-trimethoxy silane (sil-
ane) were used as a crosslinking agent and a coupling
agent, respectively. Fifty percentage dicyclohexyl phthal-
ate powder of benzoyl peroxide (BPO) was used as an
initiator, and N,N-dimethyl-p-toluidine (DMT) done as
a promoter. The properties of the monomers for binders
are shown in Table 2.
2.2. Filler and fine aggregates

2.1. Materials for binder systems
The expanded polystyrene (EPS) (density, 17 kgy
m3), specified in JIS A 9511 (Preformed cellular plastics
*Corresponding author. Tel.: q82-63-270-4273; fax: q82-63-270-
2285.
E-mail address: cnw71@mail.chonbuk.ac.kr (N.W. Choi).
Commercially available ground calcium carbonate
was used as a filler, and commercial silica sands No. 26
and No. 100 as prescribed in JIS G 5901 (Molding
silica sand) were done as fine aggregates. The water
contents of the filler and fine aggregates were controlled
to be less than 0.1% by heat drying. The properties of
the filler and fine aggregates are shown in Table 3.

0950-0618/04/$ - see front matter 䊚 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.conbuildmat.2004.01.003
236 N.W. Choi, Y. Ohama / Construction and Building Materials 18 (2004) 235–241

Table 1 Table 2
Physical properties of EPS Properties of monomers for binders

Molecular Density Thermal Compressive Type of monomer Molecular weight Density Purity
weight (kgym3) conductivity wWy(mØK)x strength (Nycm2) (20 8C, gycm3) (%)
ca. 300 000 17 0.040 10 Styrene 104.1 0.91 99.8
TMPTMA 338.4 1.06 97.3

3. Testing procedures
3.1. Preparation of liquid resins and binders
Waste EPS solution with a waste EPS concentration
of 40% was prepared by dissolving EPS in styrene at
approximately 70 8C in a stainless steel vessel. Liquid
resins for polystyrene mortars were prepared by mixing
TMPTMA with waste EPS solution. The binders for
polystyrene mortars were prepared by mixing a coupling
agent, an initiator and a promoter with the liquid resins
according to the binder formulations given in Table 4.
Furthermore, only a binder formulation of Mix No. 2
was applied to the polystyrene mortars for hot water
resistance test.
displacement was measured with the laser beam dis-
placement meter. The length change of the polystyrene
mortars is calculated by dividing the displacement by
the initial length (300 mm) of the polystyrene mortar,
and simultaneously recorded by the personal computer.
Exotherm temperature of the polystyrene mortar is also
measured by means of the thermocouples embedded in
the center of the polystyrene mortar, and recorded at the
same time with the length change. The length change
and exotherm temperature were measured at 5-min
intervals from 10 min (after the addition of an initiator
to a liquid resin) to 600 min.
3.4. Working life test

3.2. Preparation of polystyrene mortars
Polystyrene mortars using the binders with the for-
mulations as shown in Table 4 were mixed with the mix
proportions as given in Table 5 at 20 8C and 50% (RH)
according to JIS A 1181 (Method of making polyester
resin concrete specimens).
3.3. Length change and exotherm temperature tests
A non contact-type automatic measuring system is
shown in Fig. 1, which was used for measuring the
length change of fresh polystyrene mortars. The system
consists of a mold with a bottom plate, side plates and
L-shaped aluminum end plates, a laser beam displace-
ment meter, an AyD transducer, and a personal comput-
er. The bottom plate and side plates are lined with a
Teflon sheet for reducing friction against a fresh polymer
mortar. The L-shaped end plates have a screw bolt to
be embedded in the polystyrene mortar. The L-shaped
end plates are installed at both ends of the polystyrene
mortar to allow the plates to move freely according to
the shrinkage or expansion of the polystyrene mortar.
The polystyrene mortar was placed in the mold, and its
The working life of fresh polystyrene mortars was
determined at 20 8C by the finger-touching method
prescribed in JIS A 1186 (Measuring method for work-
ing life of polyester resin concrete).
3.5. Preparation of specimens
Beam specimens 40=40=160 mm for flexural and
compressive strengths, and cylindrical specimens
50=100 mm for hot water resistance were molded with
fresh polystyrene mortars in accordance with JIS A
1181. After demolding, the beam specimens were sub-
jected to a 7-day-20 8C-60%(RH)-dry cure and a 24-h-
20 8C-60%(RH)-dryq15-h-70 8C-heat cure, and the
cylindrical specimens were subjected to a 24-h-20 8C-
60%(RH)-dryq15-h-70 8C-heat cure. Fig. 2 represents
the process for making specimens from the polystyrene
mortars using waste EPS solution-based binders.
3.6. Strength tests
Tests for the flexural and compressive strengths of
beam specimens were performed according to JIS A
1184 (Method of test for flexural strength of polyester

Table 3
Properties of filler and fine aggregates

Type of filler or fine Size Density Water content Organic

aggregate (mm) (20 8C, gycm3) (%) impurities
Ground calcium carbonate -2.5 2.70 -0.1 Nil
Silica sand No. 26 425–850 2.63 -0.1 Nil
Silica sand No. 100 106–121 2.61 -0.1 Nil
 N.W. Choi, Y. Ohama / Construction and Building Materials 18 (2004) 235–241 237

Table 4 where M0 is the mass (g) of the specimens before hot

Formulations of binders for polystyrene mortars water immersion, and Mn is the mass (g) of the
Mix No. Formulations (%) specimens after hot water immersion.
Liquid resin Silane BPO DMT
(phr*) (phr) (phr)
Relative compressive strength (%)
EPS Styrene TMPTMA
1 36 54 10 0.50 2.00 0.25 s(s28 ys0)=100 (2)
2 32 48 20
3 28 42 30 where s0 is the compressive strength (MPa) before hot
Note: *parts per hundred parts of resin. water immersion, and s28 is the compressive strength
(MPa) after 28-day hot water immersion.
resin concrete) and JIS A 1183 (Method of test for At the same time, the visual inspection of the speci-
compressive strength of polyester resin concrete using mens before and after 28-day hot water immersion was
portions of beams broken in flexure), respectively. carried out.

3.7. Hot water resistance test 4. Test results and discussion

Cylindrical specimens were immersed in water at 60,
80 and 100 8C for 28 days. The mass of the specimens
at water immersion periods of 7, 14, 21 and 28 days
was measured, and the compressive strength test of the
specimens before and after 28-day water immersion was
performed at a test temperature of 20 8C. The mass
change and relative compressive strength were calculat-
ed by the following Eqs. (1) and (2), respectively:
Mass change (%)s{(MnyM0)yM0}=100
Fig. 3 shows the exotherm curves for polystyrene
mortars using waste EPS solution-based binders with
TMPTMA contents of 10, 20 and 30%. Regardless of
the TMPTMA content, the exotherm temperature of the
polystyrene mortars is suddenly increased at approxi-
mately 10 min after placing, and reaches a peak at dry
curing periods of 30–60 min. With increasing TMPTMA
content, the dry curing period to reach the peak exotherm
is shortened, and the gradients of the exotherm curves
(1) become sharp.

Table 5
Mix proportions of polystyrene mortars

Mix proportions (%) Filler: Silica sand No. 26:

Silica sand No. 100
Binder Filler Silica sand
(by mass)
Ground calcium carbonate
No. 26 No. 100
18.0 16.4 49.2 16.4 1:3:1

Fig. 1. Non contact-type automatic measuring system for length change of polystyrene mortars.
238 N.W. Choi, Y. Ohama / Construction and Building Materials 18 (2004) 235–241

Fig. 2. Process for making specimens from polystyrene mortars using waste EPS solution-based binders.

Fig. 4 illustrates the length change of polystyrene
mortars using waste EPS solution-based binders with
TMPTMA contents of 10, 20 and 30%. Irrespective of
the TMPTMA content, a slight expansion of the poly-
styrene mortars is observed at early dry curing periods
of 60 min or less. The conversion from expansion to
shrinkage takes place at 30–60 min before dry curing
periods when the peak exotherm is given. Then, the
shrinkage is increased with additional dry curing period.
The shrinkage continues up to dry curing periods of
300–600 min.

Fig. 3. Exotherm curves for polystyrene mortars using waste EPS

solution-based binders with TMPTMA contents of 10, 20 and 30%.

Fig. 4. Length change of polystyrene mortars using waste EPS solu- Fig. 5. TMPTMA content vs. peak exotherm temperature of polysty-
tion-based binders with TMPTMA contents of 10, 20 and 30%. rene mortars using waste EPS solution-based binders.
 N.W. Choi, Y. Ohama / Construction and Building Materials 18 (2004) 235–241 239

Fig. 6. TMPTMA content vs. 10-h length change of polystyrene mor- Fig. 7. TMPTMA content vs. working life of polystyrene mortars
tars using waste EPS solution-based binders. using waste EPS solution-based binders.

Figs. 5 and 6 exihibit the TMPTMA content vs. peak heat-cured polystyrene mortars are higher than those of
exotherm temperature and 10-h length change of poly- the dry-cured polystyrene mortars.
styrene mortars using waste EPS solution-based binders. Fig. 10 represents the hot water immersion period vs.
Peak exotherm temperature and shrinkage of the poly- mass change of a polystyrene mortar using a waste EPS
styrene mortars increase with an increase in the solution-based binder with a TMPTMA content of 20%.
TMPTMA content. The ambient temperature polymeri- In spite of the hot water temperature, the mass change
zation of the waste EPS solution-based binders is mate- of the polystyrene mortar increases with additional hot
rialized by the existence of TMPTMA with tri-functional water immersion period, and becomes constant at a hot
groups, and the polymerization rate of the waste EPS
solution-based binders is markedly accelerated by raising
the TMPTMA content w2x. However, the TMPTMA
content should be carefully controlled because an exces-
sive TMPTMA content could cause the large free vol-
ume reduction of the binders and the large setting
shrinkage of the polystyrene mortars w3x.
Fig. 7 shows the TMPTMA content vs. working life
of polystyrene mortars using waste EPS solution-based
binders. The working life of the polystyrene mortars is
shortened with an increase in the TMPTMA content,
and their working life keeps from 50 to 90 min at
TMPTMA contents ranging from 10 to 30%. The
working life should also be controlled with a wider
range by adjusting the initiator and promoter contents
of the binders w4x.
Figs. 8 and 9 give the TMPTMA content vs. flexural
and compressive strengths of polystyrene mortars using
waste EPS solution-based binders. In spite of curing
conditions, the flexural strength of the polystyrene mor-
tars is somewhat decreased with increasing TMPTMA
content, while the compressive strength of the polysty-
rene mortars is decreased to some extent with an increase
in the TMPTMA content. Regardless of the TMPTMA Fig. 8. TMPTMA content vs. flexural strength of polystyrene mortars
content, the flexural and compressive strengths of the using waste EPS solution-based binders.
240 N.W. Choi, Y. Ohama / Construction and Building Materials 18 (2004) 235–241

Fig. 10. Water immersion period vs. mass change of polystyrene mor-
tar using a waste EPS solution-based binder with a TMPTMA content
Fig. 9. TMPTMA content vs. compressive strength of polymer mor- of 20%.
tars using waste EPS solution-based binders.
2. The working life of polystyrene mortars using waste
EPS solution-based binders is shortened with increas-
water immersion period of 7 days. The mass change at ing TMPTMA content.
7 days is approximately 0.10%. After this moment, the 3. In spite of curing conditions, the flexural strength of
mass change of the polystyrene mortar becomes nearly polystyrene mortars using waste EPS solution-based
constant. Any changes in their appearance such as binders is decreased with increasing TMPTMA con-
surface cracks, pitting and softening, except little deco- tent, while their compressive strength is increased
loration, were hardly recognized. with an increase in the TMPTMA content.
Fig. 11 exihibits the compressive strength and relative
compressive strength of a polystyrene mortar using a
waste EPS solution-based binder with a TMPTMA
content of 20% before and after 28-day hot water
immersion at hot water temperatures of 60, 80 and 100
8C. The relative compressive strengths of the polystyrene
mortar after 28-day hot water immersion at hot water
temperatures of 60, 80 and 100 8C are 104.5, 98.5 and
97.5%, respectively. The polystyrene mortar has excel-
lent hot water resistance because the polystyrene has
not ester linkage, and also the matrix of the polystyrene
mortar is crosslinked by TMPTMA. The high hot water
resistance of the polystyrene mortar is very advantageous
over conventional polyester mortar and polymethyl
methacrylate mortar w5x.

5. Conclusions

1. The peak exotherm temperature and setting shrinkage

of polystyrene mortars using waste EPS solution-
based binders are increased with an increase in
TMPTMA content. The TMPTMA content of the
polystyrene mortars should be controlled as little as
possible from the view point of low setting shrinkage.
Fig. 11. Compressive strength and relative compressive strengths of
polystyrene mortar using a waste EPS solution-based binder with a
TMPTMA content of 20% before and after 28-day hot water immer-
sion at 60, 80 and 100 8C.
 N.W. Choi, Y. Ohama / Construction and Building Materials 18 (2004) 235–241
4. A polystyrene mortar using a waste EPS solution-
based binder with a TMPTMA content of 20% has
excellent hot water resistance.
Acknowledgments
The authors express their sincere thanks to Prof.
Akihiro Moriyoshi of Hokkaido University for his kind
advice on a non contact-type automatic measuring sys-
tem for length change.
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