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New, Higher Density/Strength EPS GeoFoam™ (2.5-3 lb/ft³)

Safety Data Sheet

Positive impacts from Kingspan Insulation's March acquisition of Dyplast Products are already advancing, and there will be much more to come. In this Press Release, we announced GeoFoam 2.5 and 3.0 - - higher densities to complement our existing 1, 1.25, 1.5, and 2 lb/ft3 GeoFoam products. The higher densities/strengths of GeoFoam 2.5 & 3.0 may be appropriate for instance when loads and traffic on highways, bridge ramps, or building constructions cannot be affordably achieved with locally available compactible fills.

Herein we will be sharing more on some of the most frequently asked questions about GeoFoam as an introduction to the Datasheet. 

What is GeoFoam (GeoFoam fill)? 

GeoFoam, manufactured as large blocks of Expanded Polystyrene (EPS), is a lightweight replacement for fill dirt, rock fill, or sand fill for applications such as: 

  • Ramps
  • Embankments
  • Landscape Design
  • Pavement/Slab Insulation
  • Utility Protection
  • Golf course slopes
  • Slope Stabilization
  • Retaining Structures
  • Shallow slab foundations
  • Swimming pool foundations (including in high-rises)
  • Airport runways
  • Building foundations

Kingspan | Dyplast GeoFoam is manufactured in a process that expands EPS beads and then molds them (with steam and pressure) into compact, large blocks that are 20 feet by 4 feet by 40 inches. The blocks can be cut into customized/tight dimensions in the factory with specialized hot-wire "saws," or in the field with chain saws. The GeoFoam blocks with the requisite compressive strengths are then positioned and stacked in the field to create the necessary height, width, length, and slope. Typically, the GeoFoam blocks are moved around with a small forklift to save time but can also be positioned by on-sight labor. GeoFoam is sometimes referred to as geotechnical fill, GeoFoam fill, or a replacement for compactible fill. 

How Does GeoFoam Reduce Construction Costs? 

When it comes to ANY construction, a solid foundation is everything. Materials like sand, dirt, and rock that can be used to create these compact foundations are called "compactible fill." Yet in many applications, the available fill is simply not compactible, and trucking in adequate fill and then compacting it is simply too expensive or impossible. Consider, for instance, a swamp in Florida where heavy fill sinks, sand in the Southwest that can't be compacted, bridge ramps in Minnesota where GeoFoam can minimize freeze/thaw damage to roadways, or a high-rise swimming pool where GeoFoam can minimize the structural loads of the alternative - - more concrete. 

How Do Compressive Strengths of GeoFoam Compare with Alternatives? 

It is important to note that: 

1. Kingspan | Dyplast GeoFoam has extensive, demonstrable quality control protocols and meet/exceed ASTM D6817 and D7180 requirements; physical properties are verified by independent third-party labs [buyers are cautioned to insist on third-party testing]; our production and shipping capacities can ensure an on-time delivery for large and small projects - - making Kingspan | Dyplast GeoFoam an optimal choice.

2. Alternative "fills" have wildly varying compressive strengths, other characteristics, and costs that cannot be adequately addressed herein.

Note that the compressive strength of sand could be close to zero, when measured on a "square inch" basis - - similar to average "dirt." To put it in perspective, the compressive strength of sand is so minimal that a shoe heel could penetrate it. The issue is whether the fill will have the adequate strength and other properties to support the average load and traffic for the intended purpose, often involving engineering calculation related to loads spread over many square inches, square feet, or square yards.

And then there is the issue of compactability! What soil/rock/sand? What moisture content? Will moisture content change? How many smooth wheel rollers are necessary to compact? What tonnage compaction?

The final conclusion is that Kingspan | Dyplast GeoFoam is a cost-effective alternative to soil/rock/sand fills! It does not require compaction, and its properties remain consistent over time. 

Don't forget to view the Datasheet for more detail on higher-density GeoFoam and make sure you're subscribed to our newsletters by scrolling to the bottom of this blog and filling out the form . 

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