EPS 15 Geofoam Blocks used in Bridge Construction

Over 600 pre-cut blocks of EPS15 geofoam were used in this bridge project on Interstate 88 over Rt. 23 in De Kalb, IL. The project design required certain areas of the bridge to be filled in with a lightweight material and EPS15 Geofoam was selected by the engineer. EPS15 weighs less than 1 lb per cubic foot and has a compression strength of 520 lbs/sf at 1% deformation. Other uses for EPS15 geofoam include highway construction, tiered seating for theaters, churches and lecture halls, void fill under raised slabs, swimming pool construction, and retaining wall back fill. EPS geofoam densities range from just under a pound per cubic foot to just under 3 lbs per cubic foot with compression strengths up to 2,680 lbs/sf at 1% deformation, making it an ideal fill for many construction projects.

Sales Person

Erich Ferg
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Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.825.8300 ext 237 PHONE | 410.825.5050 FAX

EPS15 Geofoam to fill the area and install an above ground hydrotherapy pool

The original design for this project at the Keenan Football Center, University of North Carolina in Chapel Hills, North Carolina, was to remove an existing in-ground hydrotherapy pool, then pour retaining walls and an elevated 12” slab to build a new pool. Due to a short timeframe and the logistics of getting materials in and through the facility, the plan was revised by the contractor to use EPS15 Geofoam to fill the area and install an above ground hydro pool. The change presented a big savings in time and money which the customer greatly appreciated. When the idea was presented to the structural engineer he did not hesitate to jump on board.

Just under 1,300 cubic feet of EPS15 Geofoam was used to fill the existing void. Weighing just .9 lbs per cubic foot with a compressive strength of 3.6 psi at 1% deformation, the geofoam was the perfect material for the job. The three big advantages of working with EPS Geofoam for in-door projects is that it is lightweight, it is clean, and it does not require any tamping. The blocks can be moved by hand, eliminating the need for heavy equipment. Unlike dirt and stone fill, EPS is shipped in blocks making if fast to install.

Sales Person

Kevin Baker
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Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.498.0000 Ext 228 PHONE | 410.825.5050 FAX

Geofoam is the best material to raise elevation of a concrete slab

EPS geofoam is the most efficient and economical material to raise the elevation of a concrete slab. Geofoam is lightweight and easy to work with. Weighing under 3 pounds per cubic foot, it does not require any compacting, substantially reducing labor costs and shortening the production schedule. It is easier to transport than sand or stone, making it ideal for interior renovations. With compression strengths ranging from 320 psf to 2,680 psf at 1% deformation, it is strong enough for almost any loading requirement. EPS geofoam from Universal Foam Products is manufactured and shipped direct to the job site from locations nationwide.

Sales Person

John Tamburo
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Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.498.0000 Ext 232 PHONE | 410.498.0300 FAX

EPS 12 Geofoam Lightweight Void Fill used in Valley Fair Mall in West Valley City, UT

For this tenant fit out at the Valley Fair Mall in West Valley City, UT the existing floor needed to be raised to different elevations ranging from 19” to 40” above the existing slab. The site also required a variety of handicap accessible ramps making the various levels accessible from the entry level elevation. The void fill needed to be light weight so excessive loading was not placed on the existing floor and structure. EPS12 geofoam, weighing just .75 lbs per cubic foot was chosen by the engineer for the fill. EPS12 has a compression strength of 320 lbs per cubic foot at 1% deformation.

The largest blocks, that were 33-1/2” x 48” x 96”, weighed just 67 pounds, making them easy to handle by one or two people. Installing the foam blocks is a very clean and quiet operation. There is no tamping involved; no loud power tools; just placing the geofoam blocks on the existing slab and sliding them together. Any electrical conduits and plumbing can be installed at the same time as the geofoam. Precut tapered pieces of geofoam were provided for the handicap ramps, reducing installation time.

EPS geofoam is used to raise slabs, fill in sunken lobbies and create the tiered levels in a theater, church and lecture hall settings. It is also used in civil applications such as bridge and highway construction and areas where ther are poor soil conditions.

Sales Person

Scott Hefflon
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Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.498.0000 Ext 246 PHONE | 410.498.0300 FAX

Geofoam ill used to raise the floor elevation

For this renovation project in Northeast Washington, DC, the contractor needed to raise the floor elevation by 16”. The architect specified EPS19 geofoam which was provided by Universal Foam Products. The EPS19 geofoam has a compression strength of 840 pounds per square foot at 1% deformation. The material was delivered in 12” x 48” x 96” panels, each weighing just 37 lbs (1.6 pounds per square foot). The geofoam panels were laid on the existing slab, then woven wire was installed, then the concrete was installed using a pump truck. The 12” geofoam and 4” slab added 51.6 pounds per square foot to the underlying slab. Had sand or gravel fill been used, the additional load would have been 190 pounds to 200 pounds per square foot. For this particular project all 8 of the unique characteristics of EPS geofoam made it the logical decision.

Geofoam vs Organic Fill Material – Comparison

When examining the various fill materials available for a project there are a number of factors to consider. Compression strength is probably the most significant. Material cost is an important factor. Labor to install can be a significant cost. Weight of the material. The most often used fill materials are EPS geofoam, sand, aggregate, gravel and stone. Each material will best fit the requirements of a particular scenario. Often a combination of fill materials required to provide best solution.

One material is unique among all fill materials – EPS geofoam. What makes it unique?

EPS geofoam comes in block and sheet form. It can also be provided in shapes (tapers and curves)
EPS geofoam is extremely lightweight, weighing between .7 lb and 2.8 lbs per cubic foot
EPS geofoam has compression strengths up to 18.6 psi (2,680 psf, 128 kPa) at 1% deformation
EPS geofoam requires no tamping and will not settle over time. It installs fast – reducing both construction time and labor cost
EPS geofoam requires no heavy equipment to install. It can be installed using manual labor.
EPS geofoam is a clean fill material, ideal for interior renovation projects
EPS geofoam ships from locations throughout the United States making it LEED friendly
EPS geofoam is quiet to work with making it ideal for tenant fit-out and remodeling applications.

Sales Person

John Tamburo
E-Mail John Tamburo
Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.498.0000 Ext 232 PHONE | 410.498.0300 FAX

EPS29 Geofoam used in Synagogue Raised Stage Renovation

What is the best way to elevate and level a sloped floor?

To convert the tapered floor to a level floor at this synagogue renovation outside of Charleston, WV, the architect looked at a couple of different options. The existing floor was tapered for about 22-1/2’ and then level for 9-1/2” ending at steps going up to a raised stage. At the lowest point the floor needed to be raised about 18” to make it level. The project would require approximately 925 cubic feet of fill under the new 4” concrete slab. There were a couple of different void fill options that could be considered. Gravel, sand, and EPS geofoam.

Gravel and sand both weigh between 89 and 108 lbs per cubic foot. Either material would need to be brought in by wheel barrow and spread by hand. The total weight of the gravel or sand fill would be between 82,325 lbs and 99,900 lbs creating excessive strain on the existing slab and the underlying support system. Tamping would be require to compact either material before the concrete slab could be installed, adding even more stress to the existing slab below.

EPS29 geofoam, which was chosen by the architect, weighs just 1.8 lbs per cubic foot. The geofoam for the entire project weighed just 1,665 lbs, which is less than 2% of the weight of sand or gravel. The EPS geofoam was delivered pre-tapered as required, and cut mostly into large panels, so installation was very fast. Any cutting could was done with a reciprocating saw and electric hot wire cutting tools. No tamping was required. There was some trimming involved around vents and corners but the majority of the material just had to be set in place.

EPS29 geofoam is both lightweight and incredibly strong. Weighing just 1.8 pounds per cubic foot, a panel 12” x 48” x 96” weighs under 58 lbs. and has a compression strength of 1,570 pounds per cubic foot at 1% deformation. The panels are easily installed by hand with unskilled labor. EPS geofoam is used in both interior and exterior construction. Most new theaters and theater renovations are done with EPS geofoam. Other uses include infilling swimming pools no longer in service, filling roof deck planters and numerous civil construction applications including road and bridgework.

Holly Mildner
E-Mail Holly Mildner
Universal Foam Products, LLC
EPS | STYROFOAM™ | Solutions
410.498.0000 Ext 248 PHONE | 410.498.0300 FAX

EPS15 Geofoam to shape the bottom of the pool

When a swimming pool or spa is to be constructed in a high-rise structure, the architect will design a rectangular recessed area in the floor where the pool or spa will be constructed. After the building is topped off, the pool contractor will then go in and do the final shaping for the finished pool. That was the case for the 229 foot tall apartment building constructed at 123 Linden Boulevard in Flatbush, Brooklyn, NY. The swimming pool and spa are located in an enclosed area on the top floor of the 20 story residential building.

The architect chose EPS15 Geofoam to shape the bottom of the pool. First the Geofoam was installed, then the woven wire was set in place, then the shotcrete was applied. If the taper at the bottom of the pool had been created with concrete, the additional weight would be 229,722 pounds. Crushed stone would have added 153,148 pounds, and sand would have been 148,554 pounds. The EPS15 Geofoam weighed just 1,379 pounds, less than one pound per cubic foot. With a compression strength of 520 pounds per square foot at 1% deformation, EPS15 Geofoam is used as lightweight void fill in dozens of applications from raised concrete floors to handicap ramps to the tiered seating in movie theaters.

Anytime EPS can be used in place of heavier fill materials inside a structure, it is going to have a lower installed price than alternate fills. It does not require tamping. It can be placed with manual labor, not requiring any powered equipment to move it around. It is clean to work with, not creating any dust and it can be take up on a freight elevator as well as a crane. The shop drawing shows the configuration of the EPS geofoam as it was laid out by Universal Foam Products. Very little cutting was required to be done on site because the material was delivered precut, labeled and ready to install.

Sales Person

Kevin Baker
E-Mail Kevin Baker
Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.498.0000 Ext 228 PHONE | 410.825.5050 FAX

DIY Retaining Wall with Geofoam

Our customer in Sammamish, Washington had a bad experience when he built a retaining wall several years ago. The pressure from the back-fill eventually pushed the wall out and collapsed it over time. When he decided to rebuild the wall, he wanted a better option. After some investigation online he determined that EPS geofoam was the correct material to use.

One of the main uses of expanded polystyrene in construction is as lightweight void fill called geofoam. It is used in highway, bridge and retaining wall projects because of its light weight, stability, strength, and ease of installation. When used properly behind a retaining wall, is reduces or completely eliminates lateral pressure on the wall. The EPS15 geofoam was delivered in 10 precut blocks ranging form 8” x 12” x 48” to 8” x 30” x 96” to eliminate the need for any cutting on site. The heaviest block weighed just 12 pounds. The geofoam blocks were stacked behind the wall with some earth placed behind the geofoam blocks. The final step was placing mulch on top of the foam.

From our customer “The wall was intended to protect my shed from erosion and provide access to the back of the shed. I found your product recently and thought it would be an ideal solution for me. The EPS product was easy to install and extremely lightweight. You’ve solved my problem.”

Universal Foam Products ships from locations nationwide making us local to almost everywhere.

Sales Person

John Tamburo
E-Mail John Tamburo
Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.498.0000 Ext 232 PHONE | 410.498.0300 FAX

Geofoam to Fill Part of the Atrium

When space in a hotel, apartment or office complex needs to be repurposed and there is a void to fill, EPS geofoam is the perfect material for the project. It is strong, lightweight, and easy to install.

For this office building at 3310 West End Blvd. in Nashville, Tennessee, the architect specified EPS22 geofoam to fill part of the atrium space previously occupied by sunken planters. Since the exact dimensions were known, the material was provided in precut blocks and sheets 33” thick to fill the space, requiring very little trimming on site. Installation of the geofoam did not require any heavy or noisy equipment. The blocks were brought into the space and installed completely by hand. The EPS22 weighs just 1.35 pounds per cubic foot. The largest blocks were 33” x 48” x 96” weighing 119 pounds. They could be easily set in place by two people. EPS22 geofoam has a compression strength of 1,050 pounds per cubic foot (7.3 psi) at 1% deformation, which exceeds the design requirements for lobby and assembly space.

Other similar applications for geofoam are the conversion of indoor and upper level swimming pools, tenant space modifications, sunken lobby and theater conversions. EPS geofoam is clean and easy to work with and can be installed without the use of heavy equipment. It ships from locations throughout the US

Sales Person

John Tamburo
E-Mail John Tamburo
Universal Foam Products, LLC
EPS | Styrofoam | Solutions
410.498.0000 Ext 232 PHONE | 410.498.0300 FAX

When Ewing Aquatic Pools needed a natural looking privacy wall to separate their sales office from the adjoining property, they contracted with our customer that builds all types of natural looking structures out of EPS, and finishes them with a variety of different coatings.  For this project in Winter Haven, Florida they used 25 blocks of nominal one pound density EPS 12” x 48” x 96” to create the basic structure.  Then, using woven wire and concrete, they crafted the final shape of the wall, applying colored coatings to make what appears to be a natural earth and rock formation.  This same method is used to construct swimming pool grottos for hotels and private residences.  These structures look so natural that it is almost impossible to tell the difference between man-made and what happens in nature.  The walls and grottos are as strong as the real thing and are custom designed around the customer’s requirements.  Waterfalls, water slides and planting areas can all be a part of the project.

EPS is lightweight and easy to work with.  It can be cut with hand tools such as saws and rasps, electric saws, and hot wire tools and hot knives produced specifically for cutting EPS.  Numerous coatings are produced that work well with EPS to create different finishes from rock and slate to stucco and wood.  Water based construction adhesives and foaming adhesives are used to secure blocks together.

EPS is also used by professional and amateur artists to sculpt amazing pieces.  Because EPS is so lightweight large scale projects can be done that would not be practical with other materials.

SALES PERSON
John Tamburo
Email John | 410-498-0000 ext.232