Polystyrene blocks are lightweight, easily cut, and can be used as concrete forms. They can be shaped for sculptures, insulated concrete walls, and exterior building components. Hot wire and sharp cutting tools are used for carving. Polystyrene blocks are also used for insulation and require proper installation techniques and adhesives.
Polystyrene blocks use expanded foam beads to form a solid material that is lightweight, easily cut, and has sufficient strength to be used as concrete forms. During the forming process, the foam beads are expanded to fill a shape. The shape design determines the finished size and shape of the polystyrene block. A mold can be designed to accommodate a variety of shapes for a variety of uses. Polystyrene shaped blocks are used to carve lightweight sculptures, to form insulated concrete walls, and to insulate exterior building components.
Carving lightweight sculptures from expanded polystyrene blocks for decorative purposes or parade floats requires the correct tools to ensure the blocks retain sufficient strength to hold their shape after installation. Two types of carving tools will carve Styrofoam blocks. Hot wire tools use a superheated wire to rapidly cut through the foam to create intricate details on the surface of the block. Sharp cutting tools also have the ability to create intricate detail, but have a tendency to break the foam if the material thins. Another type of Styrofoam block doesn’t need to be carved and has the strength to be used with concrete.
Polystyrene concrete blocks have a solid outer core with a series of hollow internal cavities that allow concrete to flow through a set of installed blocks. Proper installation techniques and the correct materials are required to ensure that the blocks stay in place as the concrete fills the voids in the blocks. During installation, heavy wire is woven between the block sections to hold them in place. Polystyrene block manufacturers provide cable spacing information to ensure the blocks do not fail as the concrete fills the forms. As the concrete hardens, the blocks are left in place to provide insulation for the finished building.
Tightly compressed polystyrene blocks or sheets are applied to the walls and inside sides of roofs to provide insulation between the inside and outside sides of a building. Special adhesives are used to glue the blocks to metal and wooden wall materials. Adhering to the correct installation methods ensures that the bond between the surface of the polystyrene blocks and the wall material remains strong long after installation. Proper installation includes clearing the wall material of debris, removing loose foam beads from the block, and applying the correct amount of adhesive to the wall material.
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