Heating tariffs are constantly growing, and in this regard, people began to think about the possibilities of energy saving. Many insulate their apartments and houses. They use facade polystyrene, which is considered one of the best for these tasks. This material is also called polystyrene foam. The technology of its production was developed in 1928, but this product went into mass production in 1937. What else is known about this effective insulation material?
Foam invention history
In 1839, a German pharmaceutical specialist randomly received styrene during experiments with styrax. Then, after studying the substance discovered by him, Eduard Simon noticed that after a while the oily substance independently thickened, turning into something like jelly. The pharmacist did not see any practical value in his discovery. The substance was called styrene oxide, and no one else did it.
They returned to this composition in 1845. Chemists Blyth and Hoffmann became interested in styrene.
So, experts from Germany and England conducted several of their own experiments and studies, and during this it was found that styrene turns into jelly without oxygen. Blyth and von Hoffmann called him metastyrene. Then, after 21 years, the compaction process was called "polymerization".
In the 20s of the last century, German specialist chemist German Staudinger made an important discovery. In the process of heating, styrene starts a chain reaction, during which chains of macromolecules are formed. This discovery was then used for the manufacture of various polymers and plastic.
Polyfoam in industrial production
The first styrene synthesis process was carried out by researchers at The Dow Chemical Company. Commercial production of polystyrene began by Basf. In the 30s, engineers developed and adjusted the technology for the production of polymerized styrene. In 1949, a patent was obtained for the manufacture of pentane foam balls. Then, based on this, the industrial production of such a material as facade polystyrene foam began.
How is it produced?
As raw materials, polystyrene in granules is used. To create cells using special reagents that foam the material.
At the first stage of production, the granules are poured into the hopper, where pre-foaming takes place. The granules take the shape of a ball. To obtain an effective thermal insulation material with a low density, this process is repeated several times.
Each time, the balls become more and more. Between stages of foaming, the balls are placed in a special hopper, where within 12-24 hours the pressure inside the granules stabilizes and drying takes place.
Then, the resulting product is placed in a special molding machine, where a block is formed under the influence of high-temperature steam. Granules in a fairly narrow mold are glued together at high temperatures, maintaining their shape after cooling.
Blocks that are serious sizes are cut to standard sizes. However, before this, the material is placed in intermediate storage. In the process of production, the facade foam is gaining moisture, and it just does not work out to cut it evenly. There are two popular technologies for the production of this insulation. This is suspension, as well as polarization in mass. In the CIS countries, in Europe and America, they successfully use both the first and second methods.
Styrofoam classification
Today, this insulation is produced using more advanced technologies, which has significantly improved the properties of the material. So, today they produce foamed polystyrene. The foaming process is started using a hydrocarbon. When heated, it becomes volatile, and polystyrene balls swell and stick together.
Polyfoam facade distinguished by manufacturing technology and divided into groups. This is a heater, which is made by sintering technology, and a plate obtained by foaming their granules.
Also, the material varies in labeling.
- PS - pressed foam.
- PSB - suspension without pressure.
- PSB-S - self-extinguishing suspension without pressure.
- Extruded polystyrene foam - EPS.
The product brand PSB has a uniform dense structure. These characteristics determined the scope of its use. Panels for the facade of this brand can have a density of up to 50 kg / m 3 .
Extruded polystyrene is one of the best materials. Extrusion is used in the manufacturing process. EPS is quite resistant to various kinds of mechanical influences, has a high level of density and has excellent waterproofing characteristics.
The most common, affordable and popular among consumers is PSB foam. It is widely used as a heater. However, if we compare it with the pressed material, then PSB significantly loses in strength.
Differences in Thickness and Density
The energy-saving characteristics that this material possesses are due to the low level of thermal conductivity. If you compare the facade polystyrene with any other insulation available on the construction market, the energy-saving abilities of the foam will be much higher. So, for example, a plate with a thickness of only 12 mm corresponds to a wall of brick 2.1 meters thick (or of wood - 0.45 m).
Characteristics of popular brands of foam
So, PSB-S-15 has a density of 10-11 kg / m 3 , PSB-25 - 15-16 kg / m 3 . Polyfoam PSB-25F facade in density - 16-17 kg / m 3 . The density of PSB C35 is 25-27 kg / m 3 and PSB-S50 is 35-37 kg / m 3 .
Adequate density for facade insulation
A reasonable solution would be to use PSB-35 material with a density of 25 kg / m 3 . You can choose a larger indicator. But in this case, the insulating properties are weaker. If you use PSB-S-25, then this material will not provide rigidity for the facade. In the process of finishing work, there are all risks of damaging the slabs.
Plates of the PSB-15 brand can also serve as a heater and at the same time they will not have significant loads on the walls of the house. However, this foam for the facade is practically not used - everything is to blame for the low strength.
This brand is most often used for warming structures adjacent to the building. It can be the walls of various verandas or balconies. Also, this brand is widely used in finishing work at corners or window openings.
Sufficient foam thickness
Often used slabs, the thickness of which is from 5 to 7 cm. This size is ideal for a huge number of buildings. Plates 150 mm thick are used where it is necessary to intensely insulate the wall. For example, it can be a strongly blown wall.
Do not use slabs that are too thick. This can create certain difficulties, as well as unreasonable costs. In most cases, it is best to use panels with a density of 35 kg / m 3 at a thickness of 15 cm than PSB-S-25 100 cm thick and a density of 25 kg / m 3 .
Facade and foam compatibility
Depending on the building materials of which the building is built, there are suitable or unsuitable insulation for them. So, for houses from timber it is better to use mineral wool.
But for concrete or brick buildings, foam is more effective. Extruded polystyrene foam must be flame retardant before use, as it is very, very combustible in its usual form.
Installation technology
Today, there are many companies that produce insulation itself and all related materials for the installation. Well-established Ceresit products. It is good in that all the work is done with your own hands. The process involves several steps.
Training
The entire surface of the wall must be prepared. So, all garbage, any protruding elements are removed. The surface is cleaned of everything that crumbles. Also, the preparatory phase includes the repair of joints between the bricks.
If there are cracks in the concrete wall, they must be repaired. The base must be impregnated with Aquastop. For maximum effect, the entire working part is treated with deep penetration primers.
Suspension Mounting
The wall should be as flat as possible. In this case, it will be possible to firmly and reliably fix the panels for the facade and at the same time get a surface ready for any further processing. The entire wall is hung with special cords to reveal irregularities and immediately eliminate them.
Sticking panels
For the installation of plates, Ceresit glue is used in this case.
But you can apply other materials. This glue has one important feature. The mass must be applied immediately after preparation. After an hour, the glue will simply dry and will be unusable. The adhesive mixture is applied over the entire area of the sheet or in five places, distributing the adhesive over the maximum area.
Sheets for work are best chosen with a rough surface. In the case of a smooth coating it (roughness) is achieved manually. In the process of gluing, each sheet is aligned in level.
Knitting process
The panels in each row are staggered. For example, even rows begin with a panel cut in half. If the sheets do not coincide with each other and gaps form, then foam is poured between the sheets in liquid form. At the same time, mounting foam is strictly prohibited.
Mechanical installation
Do not leave panels on the glue. Material can blow away with a strong wind. This can be quite expensive if you know how much the facade polystyrene costs. The price, depending on the manufacturer and characteristics, starts from 700 rubles per package and reaches 6,000 rubles. Each sheet is fixed using dowels. Five dowels are used on each panel. After this process is completed, each of the dowels must be treated with glue.
Next, reinforcement is performed, as well as plaster. For the first, fiberglass mesh is used. They will need two types - they use a rigid and soft mesh. Soft will go for corners, and hard is used for walls. Next, you can perform decorative plastering or purchase facade foam coated with various materials.
This technology is used almost everywhere. This method of insulation is very effective and helps to significantly reduce energy costs.