EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

EPS AS A COST-EFFECTIVE, INNOVATIVE BUILDING TECHNOLOGY

The rising cost of construction coupled with expensive cost of finance has made housing unaffordable to

the majority of low and middle-income earners in Kenya. HHL has undertaken research on different low

cost housing alternatives and identified use of EPS 3D panels as one of them. This is a revolutionary

building technology that has already been implemented in other countries such as Italy, Mexico, Britain,

Qatar, Nigeria, Mozambique and USA. It has growing potential in Kenya and its awareness expands to

the masses.

The technology involves using ready-made panels made of EPS form sandwiched between a

galvanized steel wire mesh. EPS 3D wall panels can be used to build both structural and non-structural

walls while EPS 3D floor panels can be used to construct ribbed slabs.

EPS 3D panels are used as a substitute to traditional materials used in erecting walls, stairwells, floors

and roofs.

On average, EPS 3D panels can reduce construction costs and construction periods by up to 30% and

50% respectively. A standard three-bedroom house built using this technology will take up to three

weeks to complete, exclusive of finishing.

Cost savings are largely achieved through reduced labour costs as construction time is reduced by up to

50%, less costs associated with price fluctuations of construction materials due to shorter construction

time, less transport costs as one entire house can be delivered in a single lorry load and lower costs in

wastage of construction materials because leftover EPS panels are recyclable.

EPS USE IN KENYA

The use of EPS technology is a recent phenomena which the construction industry is adopting in a bid

to satisfy the rising demand for affordable houses in Kenya. According to Kenya Bureau of Standards

(KEBS), the annual demand for new houses is in excess of 150,000. Whereas the annual national

output of new homes is about 60,000 houses. EPS use in construction is significantly helping to

alleviate this deficit.

EPS’s greatest advantage is it’s light-weight nature which translates to lesser structural dead weights,

thereby resulting in reduced steel reinforcement and concrete requirements for structures.

Consequently, the overall construction costs are significantly lowered.

Moreover, the low weight also speeds up the construction process and reduces the labour cost,

ultimately making housing more affordable.

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

CATEGORIES OF EPS PANELS

EPS 3D panels are manufactured to specifically suit design specifications

or needs. However these panels can broadly be classified into three

categories indicated below:-

i) Single panel

This panel consists of a sheet of of polysyrene sandwiched between two

mats of welded wire mesh which can be shaped as required and thickness

can vary according to needs. This panel can be used for the construction of

single and multistory buildings according to local bulding requlations.

ii) Double panel

This consists of two single panels joined together with an intermediate cavity

(empty space within a solid object). The empty space is to be filled with

concrete having suitable characteristics and strength. The thickness of the

concrete casting inside the double panel as well as the characteristics of the

concrete itself will be defined according to structural needs. The external

faces of the panel are usually finished in plaster.

Insulating double panels are excellent for reinforced concrete walls such as

load bearing walls and retention walls.

iii) Floor/Roof panel

This panel is used for construction of floors and roofs.

Other types of panels include stairs panel and landing panels that are shaped according to design

requirements.

EPS panels are adaptable to all types of structures and are widely used in:

i. Construction of structures/buildings of up to 6 stories high.

ii. Repair and construction of roads and streets, runways, industrial areas as an insulating

material. It effectively protects the base of roads from freezing and can withstand the load of

heavy vehicles.

iii. Repair and construction of railways

iv. Embankment slopes and extreme foundations of bridges in order to achieve efficiency in

design.

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

EPS AND ENVIRONMENTAL SUSTAINABILITY

EPS has significant positive environmental impact because its use reduces CO

emissions by up to 40%

during the construction process and up to 65% during the use of the building. This is derived from

reduced consumption of energy in heating costs due to EPS low heat conductivity.

The EPS used in construction is more-or-less the same material used in packaging around the world. It

is 100% recyclable and does not produce any green house or ozone depleting gases

Haven Heights Ltd’s production line incorporates a recycling system that helps the factory achieve up to

90% recycling of EPS scrap from the CNC shape cutting machine, making the entire EPS production

process very energy efficient and environmentally safe and friendly.

The whole production process carried out in a factory does not emit harmful substances into the

environment, the only effluent being spent steam.

Since the wall panels are cut to suit the site requirements, there is minimal waste. In addition, wastage

reduced as left over material can be recycled.

EPS 3D PRODUCTS

Haven Heights Ltd largely manufactures the following types of panels of standard plan dimensions of

3000mm length by 1200mm widths. These are, namely;

Wall Panels

 60mm thick EPS 3D Wall Panel

 80mm thick EPS 3D Wall Panel

Floor Panels

 150mm thick EPS 3D Floor Panel

 190mm thick EPS 3D Floor Panel

 230mm thick EPS 3D Floor Panel

 290mm thick EPS 3D Floor Panel

Although the above sizes are the company’s base products, others of different dimensions can be

produced depending on client specifications.

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

EPS 3D PANELS CONSTRUCTION TECHNOLOGY

INTRODUCTION

EPS stands for expanded polystyrene, which is an industrial product made from expandable

polystyrene, which is a rigid cellular plastic containing an expansion agent, usually pentane. An EPS

panel is made up of the foam that is sandwiched between two high-tensile steel meshes.

EPS blocks produced from the manufacturing process are cut into panels of sizes, shapes and designs

as required. Discussed below are EPS panels used for:

 Walls

 Floor slabs

 Earth fill material

A. EPS WALL PANEL

EPS wall panels are manufactured in common sizes of 60mm and 80mm thickness and are used for

internal and external walls respectively. However, the client is not limited to these sizes as the

technology allows for the manufacture of other thicknesses according to the client’s specifications.

The panels are manufactured by having EPS foam sandwiched between two high tensile steel meshes

electro-statically welded together using double steel wire connectors (ties).

i) Specifications (KS 2620:2015)

 Density of 15kg/m

 Standard panel sizes

(1200mmx3000mmx60/80mm)

 100mm

/m of steel mesh

reinforcement with f

>=600N/mm

ii) Site Installation

Installation of EPS wall panels requires

basic understanding of building technology

and training. A thin layer of shotcrete (20-35mm) is applied on both sides of the wall to give it strength

and make it behave as a stress-skin panel when loaded axially. EPS wall panels when shotcreted with

proper grade of concrete (class 25 or higher) perform as a composite column in bearing axial wall loads.

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

The end user can put a finish that is in

accordance to his/her taste.

iii) Benefits

Low weight-to-strength Ratio - The wall

panel’s core is EPS with a density of approx.

15 kg/m

against a density of 1800-2200kg/m

for block/stone walling but with the same load resistance as block/stone walling. Therefore, EPS has

lower weight-to-strength ratio compared to masonry block/stone walling.

EPS wall panels can be used to build structures up to 6 storeys.

Rapid Installation - The low weight of EPS makes it easy to handle on site and to transport to site. EPS

ease of handling and installation therefore results in substantive labour savings of up to 30%.

The duration of construction is also greatly reduced because the panels are transported to site as

already assembled products from the factory.

Convenience & Versatility - EPS wall panels can be manufactured into exact sizes as required by the

engineer to specifically suit different project’s requirements.

Environmentally-friendly - The whole production process carried out in a factory does not emit harmful

substances into the environment. Since the wall panels are cut to suit the site requirements, there is

minimal waste. In addition, wastage reduced as left over material can be recycled.

Thermal Insulation & Sound proofing - Due to its closed air-filled cell structure that inhibits the

passage of heat or cold, a high capacity for thermal insulation is achieved.

Waterproof - The EPS wall panel does not absorb moisture and its thermal and mechanical properties

are unaffected by dampness, humidity or moisture.

B. EPS FLOOR PANEL

EPS can be used in construction of reinforced concrete

floors using EPS floor panels. Floor panels are

manufactured in sizes of 150mm, 190mm, 260mm and

290mm thick panels; or depending on the Engineer’s

specifications.

i) Specifications (KS 2620:2015)

 Density of 15kg/m

 100mm

/m of steel mesh reinforcement with fy>=

Figure 2: Shotcrete Application

Figure 1: EPS Wall Panel

Figure 3: EPS Floor Panels

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

600N/mm

 Standard panel sizes

(1200mm x 3000mm x 150/190/260mm)

ii) Benefits

Lesser concrete and steel reinforcement –

The reduced dead weight resulting from the use

of EPS floor panels result in lower stresses

especially in the slabs (ribbed) and beams,

conversely reducing the steel reinforcement required. This derives savings in the overall costs of floor

slab construction vis-a-vis other forms of slab construction.

Low weight void former – EPS density of 15kg/m

allow for light and safe construction works. In the

design of ribbed slabs, especially for slabs with big spans, EPS floor panels are ideal for use as a

lightweight fill material (void former) as opposed to alternatives such as hollow blocks/hollow pots. The

bulk density ratio of EPS to hollow block is 1:30

Thermal Insulation - Due to its closed air-filled cell structure that inhibits the passage of heat or cold, a

high capacity for thermal insulation is achieved.

Waterproof - The EPS wall panel does not absorb moisture and its thermal and mechanical properties

are unaffected by dampness, humidity or moisture.

Fire Resistance – EPS 3D panels are manufactured using self-extinguishing polystyrene and with the

addition of the concrete layers, combustion is further prevented.

Rapid Installation - The low weight of EPS makes it easy to handle on site and to transport to site.

Compatibility - EPS is completely compatible with other materials used in construction including

cements, plasters, salt, fresh water and so on.

Versatility and flexibility - EPS floor panels can be cut into exact depths as required by the structural

engineer to specifically suit different project’s requirements. In particular, EPS is ideal for large span

slabs, giving the Architect more flexibility in design of bigger functional spaces.

Figure 4: EPS Floor Panel Soffit before finish

Figure 5: EPS Floor Panels installed on site

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

iii) Structural cross-sections of EPS ribbed floor slabs

Short/Normal Spans (2.0m-5.0m)

Schematic (I): Solid Slab at Mid-span

Schematic (II): EPS 3D Ribbed Slab at Mid-span

Long Spans (5.0m-10.0m)

Schematic (III): Hollow block Ribbed Slab at Mid-Span

Schematic (IV): EPS 3D Ribbed Slab at Mid-span

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

C. EPS AS EARTHFILL MATERIAL

The need for construction of new roads sometimes requires construction over soft or loose soils that are

incapable of bearing additional loads. Engineers must identify innovative materials and construction

techniques to address the problem of building on soft soils or where sensitive existing utilities or

wetlands are present while, at the same time, accelerating construction project schedules. EPS

‘geofoam’ can be used to replace compressible soils or in place of heavy fill materials be used to

prevent unacceptable loading on underlying soils and adjacent structures.

i) Benefits

High compressive resistance - The high compressive resistance of EPS geofoam makes it capable of

bearing traffic loads associated with secondary roads such as feeder roads connecting rural areas to

urban centres within counties and those interconnecting the counties at large.

Reduced time spent on road tests on site - Being an engineered product that has undergone rigorous

tests prior to arrival on site, EPS geofoam also saves time during road construction. Moreover, it is easy

to handle with no need to use special equipment on site.

Reduced volume of natural fill material requirement - In the use of EPS geofoam as a fill in road

embankments and sub-grades, the volume of natural fill materials required in the filling of cuts and

embankments is greatly reduced. This leads to lesser amounts of earthworks done and less machinery

Figure 6: EPS use for earthfill

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

being mobilized which ultimately reduces the costs of road-construction in terms of labour and capital.

The negative impacts of road construction on the environment are also reduced due to need for less

natural fill material.

Protection against spills - In some cases, protection against fuel spills on pavements maybe required.

In this case, a hydrocarbon resistant geo-membrane can be placed over the uppermost EPS block

course to protect the pavement from possible hydrocarbon attack.

These technologies are more advanced and specific in other localities globally. Further guidance is

available from EPS construction manuals as well as international and local design and specifications

guidelines such as EN13163, ASTM D6817 and KS2620: 2015.

EPS 3D PANEL PRODUCTION PROCESS

History of EPS

The EPS used in construction is more-or-less the same material used in packaging around the world. It

is 100% recyclable and does not produce any green house or ozone depleting gases. EPS 3D Panels

are manufactured using raw material with a flame retardant additive.

EPS was discovered in Germany over 50 years ago and today is used extensively in construction

around the world. In 1839, a German apothecary Eduard Simon discovered styrene. Although Simon

was able to isolate the substance from its natural resin, he did not know what he had discovered. It

wasn’t until 80 years later that organic chemist Herman Staudinger created a plastic polymer comprised

of long chains of styrene molecules.

In 1930, scientists at BASF developed a way

to commercially manufacture polystyrene in

pellet form.

Today, EPS is one of the most versatile and

cost effective materials for both packaging

abd building/construction applications,

because of it’s benefits in product,

performance and recycling.

EPS PRODUCTION PROCESS

Our EPS production line incorporates the use of high tech, fully automated PLC controlled machines for

efficient production. All our machines have CE certification.

Figure 7: Polystrene beads

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

EPS 3D Panels are produced from two main raw materials;

 Expandable polystyrene beads

 Low carbon, zinc coated galvanised steel wire

It is, therefore, a two-line production process.

A. EPS Production Line

In commercial manufacturing, EPS is a derivative of ethylene and benzene, and is made using

polymerization process which produces translucent spherical beads of polystyrene, about the size of

sugar granules. During this process, a low boiling point hydrocarbon, usually pentane gas, is added to

the material to assist expansion during subsequent processing.

EPS Production Cycle

EPS goes through a three stage production process.

Pre-expansion – upon contact with steam, the pentane gas or other pre-foaming agent within the

polystyrene beads starts to boil and the beads are expanded up to 40 to 50 times their original

volume.

Conditioning/Maturation – after expansion, the beads undergo a maturing period prior to molding.

Moulding – the beads are then transferred to a mould and again reheated with steam. The pre-

foamed beads expand further, fusing together under pressure.

The beads are moulded to form large blocks for cutting and shaping or customised products such as

produce boxes or pods. The finished product is approximately 98 per cent air.

The diagram below shows the production cycle of EPS products.

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

EPS Production Machines

i) Batch pre-expander Machine

The batch pre-expander is a PLC controlled automatic machine that uses steam and compressed air to

pre-expand the polymeric beads from their original size of 0.7-0.9mm to about 2.5-5.0mm – a 40-50

times expansion. It features an automatic batching and weighing system, automatic feeding, drying

system through a fluidized drying bed and conveyance system to maturation silos.

ii) Vacuum block moulding Machine

The vacuum block moulding machine is a PLC controlled auto-pneumatic machine that uses steam and

compressed air to achieve fusion of expanded polystyrene beads into a homogenous compressed block

of EPS.

It features a vacuum support system with EPS beads feeding system from silo storage, hopper for

mould, weighing and printing system.

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

iii) 2D CNC Shape Cutting Machine

The CNC shape cutting machine is a software-controlled hot wire shape cutting machine that is used to

cut all kinds of EPS shape products as input by the operator. It is user-friendly and utilises AutoCAD

software for profile design.

iv) EPS Recycling System

It is a system that comprises of a crusher, de-duster, a mixer, conveyance fans, canvas silos and

connecting pipes. It helps the factory achieve up to 90% recycling of EPS scrap from the CNC shape

cutting machine, making the entire EPS production process very energy efficient and environmentally

safe and friendly.

v) Auxiliaries Equipment for EPS Plant

The entire factory operations rely on compressed air and EPS production requires steam. For this

support, the plant has a fully operational steam boiler with a capacity of 2 tonnes of steam per hour with

output pressures of up to 10 bars. It is coupled to a 15m

steam storage tank.

A twin screw 2.0m

/min air compressor system is also part of the ancillaries support together with a

10m

compressed air tank.

The plant also has a beads storage system in the form of nylon net silos, 2 for holding recycled EPS

beads and 6 for virgin beads.

Finally, a cooling water system is also provided for condensing effluent steam during production for

water recycling.

B. EPS 3D Panels Production Line

i) Steel wire mesh Machine

It welds the structural mesh from high strength

galvanised steel wires of either 2.5mm or

3.0mm. The spacing of wires for the steel wire

mesh can be set at 50 mm, 75mm or 100mm

depending on the anticipated use of the

welded mesh.

Haven Heights Ltd uses structural steel mesh

with 3.10mm steel wires at 70mm spacing,

providing an area of mesh reinforcement

equivalent to approx. 100mm

/m. This mesh is

EPS 3D PANELS

Haven Heights Ltd | P.O. Box 1192-00232, Ruiru – KENYA | Email: sales@eps3d.co.ke | Sales: +254796212600

equivalent in structural strength to a BRC A98 mesh.

ii) 3D Panel Assembling Machine

The final process of producing the EPS 3D panel involves assembly of the EPS panel and the steel wire

mesh using an EPS 3D Panel Assembly machine.

Haven Heights Ltd’s EPS panels are made by connecting top and bottom mesh with double connectors

to achieve a very rigid 3D panel with superior weld that can withstand immense weld pull-off force

(>=680N per weld spot); ensuring that the panel’s mesh do not detach during use.