The largest sustainability contribution from custom EPS and XPS in Australian construction is operational. High thermal resistance, retained long-term, lowers heating and cooling demand across the life of the building and supports 7-star NatHERS thermal and Whole-of-Home outcomes under NCC 2022 (retained in NCC 2025). On the manufacturing side, Styroboard XPS carries up to 90 per cent recycled content depending on feedstock availability, StyroPod waffle pods carry up to 50 per cent, and clean EPS and XPS offcuts are 100 per cent recyclable through Foamex’s offcut collection and reprocessing system. Specification, R-value and the compliance pathway must be confirmed with the project energy assessor, certifier or fire engineer.
Australia’s construction sector is working through the 7-star NatHERS thermal minimum and the Whole-of-Home score introduced in NCC 2022 and retained in NCC 2025, rising specifier expectations on embodied content, and a steady push toward higher overall energy performance. Builders, architects and developers are looking for materials that hold up on thermal performance, recycled content and end-of-life recovery without trading away structural performance or durability.
EPS and XPS: different materials, different processes, different standards
EPS and XPS are both polystyrene-based insulation materials, but they are made differently and certified to different Australian Standards. The assembly’s structural load, moisture exposure, target R-value and compliance pathway should drive material selection, with the product specified to suit the build-up rather than the build-up adjusted to suit a default material.
Expanded polystyrene (EPS) is produced by pre-expanding small polystyrene beads, then fusing them inside a block mould with steam. The result is a closed-cell block that is then cut to sheets, blocks, panels or custom shapes. EPS is certified under AS 1366.3.
Extruded polystyrene (XPS) is produced by continuously extruding molten polystyrene through a die with a blowing agent, forming a uniform closed-cell board with higher density and lower water absorption. XPS is certified under AS 1366.4. Foamex is the only Australian manufacturer of XPS.
- EPS (AS 1366.3): lower density, cost-efficient, suited to wall, ceiling and roof insulation, waffle pod slabs, void fill and custom-cut panels.
- XPS (AS 1366.4): higher compressive strength, lower water absorption, long-term retained R-values, suited to under-slab, slab edge, perimeter and load-bearing applications.
- Both are produced without CFCs or HCFCs.
Where do Foamex custom foam solutions fit in sustainable construction?
Foamex manufactures EPS and XPS for a range of construction applications. Each product contributes differently inside the building envelope.
- StyroPod EPS waffle pods: up to 50 per cent recycled content. Manufactured to support AS 2870-2011 slab designs when specified by the engineer. Reduces concrete volume per slab compared to a traditional slab.
- Styroboard XPS (StyroTherm, StyroRoof, StyroLink): up to 90 per cent recycled content depending on feedstock availability. R-values retained long-term. StyroTherm for under-slab, slab edge and below-ground. StyroRoof for green and inverted roofs. StyroLink as a roof purlin spacer that preserves the full nominal thickness of thermal blanket insulation.
- Styroboard EPS sheets and blocks (StyroSheet, StyroBloc, GeoFoam, GeoFoamX): can contain recycled content. Suited to wall and ceiling insulation, cut-to-size applications, and lightweight void fill for civil and landscape projects.
Does EPS or XPS insulation help meet 7-star NatHERS and Whole-of-Home targets?
Yes, when correctly specified inside the complete building envelope. NCC 2022 set the residential energy efficiency baseline as a 7-star NatHERS thermal rating plus a Whole-of-Home score of 60 for Class 1 dwellings and 50 for Class 2 apartments. NCC 2025 retains these settings. The provisions apply differently across jurisdictions: NCC 2025 is mandatory in Victoria from 1 May 2026, while New South Wales, Queensland and the ACT continue under NCC 2022 transitional arrangements until 1 May 2027.
In New South Wales, residential thermal performance is captured through BASIX, which now uses the NatHERS engine for a 7-star thermal target and integrates Whole-of-Home assessment. EPS and XPS contribute to these targets through high thermal resistance relative to weight and thickness.
For projects targeting higher NatHERS or Whole-of-Home outcomes, Styroboard XPS offers long-term retained R-values that support whole-of-home energy modelling. Required thickness and total R-value are set by the energy assessor based on climate zone and project-specific NatHERS or BASIX assessment. Confirm specifications with the assessor and certifier before locking in board thickness.
What happens to EPS and XPS offcuts on Foamex construction projects?
Foamex collects and manages all construction site EPS and XPS waste generated from its products. Clean EPS and XPS offcuts are 100 per cent recyclable through the Foamex collection and reprocessing system. Recovered offcuts are returned to manufacturing and used as recycled feedstock for new product.
Custom manufacturing without trading away environmental outcomes
Foamex provides custom CNC and hot-wire cutting, contract manufacturing and specialised architectural services for builders, engineers and architects who need precision-cut EPS and XPS. Custom-cut product reduces on-site cutting waste and improves installation efficiency, which lowers material wastage across the project.
All products are manufactured in Australia. Foamex holds Australian Made certification across its core Styroboard product range and is a member of Expanded Polystyrene Australia (EPSA) and Operation Clean Sweep. EPS production does not use CFCs or HCFCs. XPS production does not use CFCs or HCFCs.
Talk to Foamex about custom EPS and XPS solutions for your next project. Call 1300 AU FOAM (1300 283 626) to discuss product selection, recycled content, custom sizing and the right compliance pathway for your build.
Frequently asked questions
Are Foamex EPS and XPS products manufactured in Australia?
Yes. Foamex has been family-owned and manufacturing in Australia since 1982, with production sites across five Australian states. Foamex is the only Australian manufacturer of extruded polystyrene (XPS) and holds Australian Made certification.
What is the difference between EPS and XPS manufacturing?
EPS is produced by pre-expanding polystyrene beads and fusing them in a block mould with steam, then cutting to shape. XPS is produced by continuously extruding molten polystyrene through a die with a blowing agent, forming a uniform closed-cell board. The two processes produce materials with different densities, compressive strengths, water absorption profiles and applications.
How much recycled content do Foamex EPS and XPS products carry?
Styroboard XPS products (StyroTherm, StyroRoof, StyroLink) carry up to 90 per cent recycled content, depending on feedstock availability. StyroPod waffle pods carry up to 50 per cent recycled content. Styroboard EPS sheets and blocks (StyroSheet, StyroBloc, GeoFoamX) can contain recycled content.
Do Foamex EPS and XPS products support 7-star NatHERS and Whole-of-Home compliance?
Yes, when correctly specified inside the complete building envelope. NCC 2022 (retained in NCC 2025) sets the residential baseline at 7-star NatHERS thermal performance plus a Whole-of-Home score of 60 for Class 1 dwellings and 50 for Class 2 apartments. NSW captures both through BASIX. Confirm required thickness and total R-values with the energy assessor.
Does Foamex manage construction site waste from its products?
Yes. Foamex collects all construction site EPS and XPS waste generated from its products. Clean offcuts are 100% recyclable through the Foamex collection and reprocessing system and are returned to manufacturing as recycled feedstock. Contractors can arrange collection through the Foamex team at the point of order.