# Foamex

> High Performance Building Insulation

> Contact: foamexmarketing@gmail.com

### Posts

#### Achieving maximum star rating for your construction with Foamex Expanded & Extruded Polystyrene
A six-star rating in construction indicates that a building achieves a high level of thermal energy performance.
Choosing construction materials to ensure the building will meet the crucial six-star rating is of the utmost importance for architects, builders, and specifiers. Foamex expanded polystyrene is a high performance construction material that can play a major role in a six-star energy rating for your building project.
 

#### Add insulation from the ground up when building your home
Foamex StyroPod is a faster and more efficient way of building concrete slabs for new homes, extensions or commercial buildings.The diamond patterned waffled pod lies above the surface, as opposed to traditional foundations, which are dug into the earth. The on ground slab creates air pockets which form an extra insulating layer between the build structure and the ground.

#### Adelaide Zoo Light Creatures made possible with versatile EPE sheets
During last year’s COVID lockdown, A Blanck Canvas, founded in 2013 by Melbourne-based artist Joe Blanck, decided to create something big and beautiful that could be showcased outdoors when it was safe for people to go out and congregate together again.
The A Blanck Canvas team had previously worked with several zoos, which are great outdoor locations to experience art. With the support of Adelaide Zoo, the idea flourished, and the interactive installations developed into Light Creatures at Adelaide Zoo as part of the Illuminate Adelaide festival.
“We have worked with zoos many times before,” says A Blanck Canvas founder, Joe Blanck. “The best jobs we have done have always been about creating awareness for endangered animals and doing something that has more of a positive outcome, rather than just something pretty to look at.”
The Light Creatures at Adelaide Zoo artworks included two towering giraffes, Adelaide Zoo’s own pandas eating bamboo, a huge colourful skink, and Underwater World. The larger animals are inflatable with backlighting, whereas the smaller and more intricate elements are made from EPE foam.

#### An inside look at Foamex Geofoam
Foamex Geofoam expanded polystyrene blocks are a cost-effective void filler utilised by civil engineers, construction companies and landscapers across a variety of geotechnical applications.
Offering both strength and flexibility, Foamex Geofoam can provide protection from noise, vibration dampening, and even earthquake shocks. One of the many benefits of Foamex Geofoam is its lightweight nature and highly controllable qualities. Geofoam’s lighter load can reduce settlements while improving stability against bearing and slope failures. With a comparable service life to other construction materials, Foamex Geofoam retains its physical properties under engineered conditions of use and can help solve the challenges of working with soft ground, as well as slope stabilisation and retaining walls.

#### Are you correctly disposing your EPS waste?
There’s a right and a wrong way to dispose of expanded polystyrene. Which are you using?
Expanded polystyrene (EPS) sits in that undefined gray area when it comes to disposal. Does it go in the recycling bin? Does it go in the general waste bin? Are we required to use a more specific method for getting rid of our unwanted EPS? Is it best to hoard it until we’ve stockpiled enough of it for a bulk pick up?
Correctly disposing of EPS is important due its ubiquity. It’s easy to accumulate a whole lot of EPS, and we generally don’t repurpose or reuse it ourselves. In fact, it is all but impossible to re-use EPS as it is purpose-moulded for specific use.
The bulky nature of EPS means that it occupies a lot of space in landfill. According to the NSW Environment Protection Authority, the true cost of landfilling EPS is a whopping $2,500/tonne.
Expanded Polystyrene Australia (EPSA), the national industry body for all EPS manufacturers and distributors in Australia, advises that EPS is recyclable at many stages of its life cycle.
Despite being a highly visible waste product, there is typically low community recognition that EPS is indeed a recyclable product.
The truth is that yes, EPS is recyclable. And if a product is able to be recycled, then we should certainly recycle it and not simply throw it in the general waste bin.
So, how do we responsibly dispose of EPS? Recycling EPS requires a specific process.

#### Artist Fleur Harris Brings The Magic Faraway Tree’ To Life With Recycled EPS
When Melbourne artist Fleur Harris reached out to Foamex about our recycled foam earlier this year, the conversation wasn’t focused on products or specifications. It was about magical storytelling.Fleur was in the early stages of reimagining Enid Blyton’s ‘The Magic Faraway Tree’ as a large-scale sculptural installation for a special Christmas window at the iconic David Jones Bourke Street store – a project that would be seen by over a million people throughout the festive season. Her vision: a giant storybook with wild toadstools growing from its cover,  decorated with a whimsical forest scene inspired by Blyton’s iconic tales.What followed was a creative collaboration that blended art, material science, sustainability, and a fun amount of experimentation and problem-solving.								
				
					
				
		
					
				
				
												
																					
										
									
				
					
				
		
					
				
				
									 Starting with curiosity (and lots of testing!)Like many sculptors and set designers, Fleur initially gravitated toward XPS foam board as a base material. Extruded polystyrene (XPS) is commonly used in creative builds due to its strength and stability – and Foamex’s StyroTherm XPS sheets offered something rare in the global market: it is the only XPS manufactured in Australia and it can contain up to 90% recycled EPS packaging collected from local communities via StyroCycle and commercial recycling streams.For Fleur, making sustainable material choices is a critical aspect of her creative practice..Fleur shared much of her process behind the build with her instagram community online, valuing transparency around why specific materials were selected and how they were used throughout the build.As with any ambitious creative project, testing quickly revealed realities. StyroTherm XPS is designed as a high-performance construction insulation material, built to withstand compressive loads and deliver long-term durability. That density, while ideal for building applications, made intricate hand-sculpting slow and with a deadline of only two months, it was impractical at the scale required for the installation.Fleur and our Foamex team put their thinking caps on to workshop a new material choice and sculpting method that would allow her to deliver an exceptional sculpture in a short amount of time, and the pivot delivered incredible results!								
				
				
				
																														
				
					
				
		
					
				
				
									 Finding a Practical Way ForwardRather than pushing forward with a material that wasn’t behaving as needed, the focus shifted to problem-solving: understanding why it wasn’t working, what alternatives were available, and how to keep the project on track without compromising the creative outcome or the installation timeline.Foamex worked closely with Fleur to explore an alternative: recycled EPS blocks – expanded polystyrene blocks manufactured specifically for profiling and shaping. These blocks are made from recycled EPS packaging and are commonly used for geotechnical void fill (EPS void fill), signage, and custom formsUsing detailed CAD drawings supplied by Fleur, Foamex’s team produced profiled EPS foam blocks that formed the base shapes of the giant book, the toadstools and additional structural elements. These custom EPS blocks provided a practical base for Fleur to refine and finish by hand in her studio – where the real magic happened!Back at the studio, she assembled, carved, painted, and textured the pieces by hand – transforming raw foam into organic, whimsical forms that were alive with craftsmanship and storytime nostalgia.  The final result bore no resemblance to its technical origins – and Fleur’s fans on instagram were wowed by the transformation. 								
				
				
				
																														
				
					
				
		
					
				
				
									 Creativity, Collaboration, and Circular ThinkingBehind the scenes, sustainability wasn’t treated as an add-on or a talking point – it was an important part of how the project was managed.Materials were handled thoughtfully, with excess product and clean offcuts bagged and separated so they could be recycled where possible. Just as importantly, Fleur chose to share the process openly with her highly engaged audience, including the challenges, the testing, and the realities of being a solo artist building something at this scale.That openness mattered. It showed that more responsible outcomes don’t come from perfect materials or ideal conditions, but from informed decisions, flexibility when things don’t go to plan, and a genuine effort to keep resources in use rather than discarded.								
				
					
				
		
					
				
				
									 From Workshop to WindowAs installation day approached, dozens of individual elements were transported and assembled inside the David Jones Bourke Street window – each piece designed to fit through doors, be assembled on site, and sit safely within a public display to be viewed by millions over the season.The finished installation captured exactly what Fleur had envisioned: wonder, nostalgia, and imagination at scale.For Foamex, it was a reminder that materials engineered for construction, insulation, and infrastructure can also play a role in cultural and creative spaces – and that is is particularly special when they are locally manufactured, responsibly sourced, and part of a broader circular economy.								
				
					
				
		
					
				
				
																														
				
					
				
		
					
				
				
									 Why This Collaboration MattersProjects like this sit at the intersection of art, industry, and sustainability.They challenge assumptions about materials like EPS and XPS, showing that when managed responsibly, recycled foam can be a resource, not a liability. They also highlight the high value of collaboration – between artists, manufacturers, and recyclers – in finding solutions that respect both creative ambition and environmental responsibility.Most importantly, they allow us to explore the great things that  happen when people come together from different sectors and think outside the box to bring a special kind of magic to the world.‘The knowledge, encouragement and practical support that the Foamex team provided me with from the beginning of this project through to the end made this artwork installation an absolute joy to create. Their solution focused, outcome oriented approach was something that I truly appreciated – and they’re really lovely people!’ – Fleur Harris _____________________Foamex is proud to support Australian artists, designers, and builders by supplying locally manufactured EPS and XPS materials – and by working collaboratively to find the right material for the job.								
				
					
				
		
					
				
				
									 
 
Learn More

 	Foamex StyroBloc® 
 	Fleur Harris
 	StyroCycle – Recycle Polystyrene Packaging

Frequently Asked Questions

  What is the difference between XPS foam and EPS foam?
  XPS (extruded polystyrene) is manufactured differently and is typically denser and more rigid, often used in construction insulation applications where compressive strength matters. EPS (expanded polystyrene) can be supplied in blocks that are commonly profiled into shapes and forms for a wide range of applications, including creative and signage work.
 

  Is recycled foam suitable for creative builds?
  Yes – recycled EPS blocks can be a practical option for creative builds, particularly when large base shapes are required. The key is selecting the right foam type for the method being used (profiling, carving, finishing) and planning for clean separation of offcuts where possible.
 

  Can foam offcuts be recycled after a sculpting project?
  Clean offcuts (free of paint, heavy glue, or contaminants) can often be collected and returned for recycling through the appropriate recycling stream or program. For best results, keep offcuts clean, bag them, and separate them from general waste during the build.
 

  How can creators reduce environmental impact when working with EPS or XPS foam?
  A few practical steps help: choose recycled-content materials where feasible, plan cuts to minimise waste, keep offcuts clean and bagged for recycling, and use methods that reduce unnecessary dust and small particles. The best outcome comes from aligning the material choice to the creative technique from the start.
 

#### At the heart of the ocean
Generally, we discuss the merit behind the application of foam within the construction industry, however in this blog we will take a detour down a coastal highway. Foam’s versatility has helped evolve a pastime that has been part of the Australian culture since 1915. Surfing.
First introduced to Australia in 1915 by Hawaiian legend Duke Kahanamoku, it wasn’t until the 1950’s that surfing’s popularity really started to take off in Australia thanks to a visit by Hawaiian and mainland American lifeguards. During their display, the crowds were treated to the sight of the increased performance capabilities that fiberglass/balsawood boards possessed. These shorter and lighter designs, now equipped with fins and rocker, were already popular in California and able to manoeuvre and accelerate across the face of a wave.

#### Australian green building market set to flourish
Australia currently has one of the most active green building markets in the world, and the level of activity is expected to grow over the next three years to 2021.
That’s the key takeaway from the recently released World Green Building Trends 2018 SmartMarket Report [1], produced by US-based Dodge Data & Analytics and released in late 2018.

#### Australian made Foamex Styroboard XPS – Tough and durable
Styroboard XPS is an Australian made and owned product; produced on extruding machines in Foamex’s state of the art facility in Victoria.
Due to its high compressive strength and superior thermal performance, Styroboard XPS extruded polystyrene has long been the material of choice across residential, commercial and industrial sectors.

#### Australian made XPS for guaranteed strength and durability
Foamex Polystyrene is continually leading the way in developing innovative, green building products that deliver superior performance and strength, and Styroboard XPS is a testament to this innovation.

#### Australian-made XPS versus imported XPS
Despite the doom and gloom stories about Australian manufacturing, there is still plenty of local manufacturing taking place in many sectors. While it is true that the manufacturing sector in Australia has been gradually shrinking (the number of manufacturers in Australia has fallen from 96,000 10 years ago to just under 84,000 last year), Professor Peter Gahan from the University of Melbourne says that manufacturing remains an important contributor to Australia’s GDP.
“All in all, the evidence overwhelmingly suggests the Australian manufacturing sector has, even in a period of decline, continued to represent a core source of economic prosperity for Australia – and should continue to do so. In short, it has outperformed many other sectors in terms of its contribution to Australia’s sustained economic performance and its capacity to generate quality jobs. It still produces around 6.5 per cent of Australia’s GDP.”
A 2016 CSIRO report into Advanced Manufacturing in Australia stated that “Australian manufacturing can and must be a thriving component of Australia’s economy through the application of advanced manufacturing technologies, systems, and processes. The sector will focus on pre-production (design, R&D) and post-production (after-sales services) value-adding, sustainable manufacturing, and low volume, high margin customised manufacturing”.
The CSIRO also concluded that opportunities will also emerge for businesses that embrace the circular economy concept, taking responsibility for whole-of-life impacts. Businesses can achieve step-change improvements to resource efficiency through waste reduction, recycling, remanufacturing and reuse. From energy-efficient products to products designed with recycling, recovery and collaborative consumption in mind.

#### Benefits of foam insulation panels for building and renovating
Foam insulation panels for building and renovating are a well-tested and proven modern building technology that offers builders and home owners a wide range of benefits.
Expanded polystyrene building sheets are a highly versatile material ideal for the building and construction industries.

#### Benefits of Polystyrene Diamond Pod system vs Concrete Slab system
Foamex Diamond Pods, a polystyrene waffle pod slab system, is leading the way in alternative concrete slab filling solutions, providing concrete slab support and increased thermal insulation. Using Foamex Diamond Pods, construction is quicker and more cost effective than traditional concrete slabs. Reasons for choosing the Foamex Diamond Pod polystyrene system over a traditional concrete slab include:

A traditional concrete slab can crack and move within the soil as a result of heat, humidity and wet weather. The Foamex Diamond Pod system will move with the building and absorb the pressure of the heave, leaving your slab in structurally intact.
Excellent insulation from the natural air pockets in the expanded polystyrene (EPS) and the specially designed moulded cells within the Foamex Diamond Pod.
Minimal earthworks are required as there are no internal trenches to dig.
Diamond Pods bring the house further out of ground – beneficial in areas that are more prone to wet weather – the higher the better.
Increased thermal “R” values from the house foundation being made up of insulating EPS with a layer of concrete over the top. This thermal mass then acts as an insulated bank.
Construction is quicker
More cost effective than traditional pours as less concrete is required
Work can continue in adverse weather
Less environmental disturbance as the slab sits on the site as opposed to in the ground

#### Benefits of Polystyrene Wall Cladding for Residential and Commercial Buildings
Wall systems in Australia carry more pressure than most people realise: heat load, moisture shifts, energy targets and compliance demands. Foamex delivers polystyrene wall cladding solutions that respond to real site conditions while answering the question, what are the benefits of polystyrene wall cladding?

Improves thermal performance across wall assemblies.
Reduces structural load through lightweight construction.
Supports compliance with current building standards.
Contributes to long-term energy cost control.

A wall is never only a surface. It absorbs heat, blocks wind, manages moisture and supports structural loads. When cladding underperforms, the consequences appear gradually: uneven temperatures, higher cooling demand, surface cracking and rising maintenance costs. That pressure has pushed builders to reconsider traditional systems and look closely at insulated alternatives.
Why Polystyrene Wall Cladding Performs in Australian Conditions
Australian climates shift from coastal humidity to inland heat. An insulated external wall layer stabilises these fluctuations. Expanded Polystyrene (EPS) used within insulated wall cladding systems creates a consistent thermal barrier that reduces heat transfer through the wall structure.
The Australian Building Codes Board requires insulation products to comply with AS/NZS 4859.1 for material properties and performance under the National Construction Code. Correctly specified EPS wall panels can contribute meaningfully to meeting these insulation requirements when integrated into a compliant wall system.
Thermal stability improves comfort. Reduced heat transfer supports lower HVAC cycling. Over time, that translates into operational savings across residential and commercial buildings.
Lightweight Construction Without Structural Compromise
Traditional brick veneer adds significant mass to framing and foundations. Lightweight building cladding systems reduce this load, which can simplify installation and reduce structural demand. EPS wall panels are engineered to deliver insulation and substrate support without unnecessary weight.
In renovation projects, weight matters. In multi-storey construction, it matters even more. A lighter façade can ease logistics and improve installation efficiency without compromising performance when installed correctly.
Energy-Efficient Wall Systems That Work as Assemblies
Energy performance does not rely on a single product. It depends on how components connect. Exterior wall insulation integrated with framing, membranes and finishes forms part of a larger envelope strategy.
The Insulclad Rendered Wall System combines fire-retardant EPS with a rendered finish to create insulated wall cladding that improves thermal continuity across the facade. When continuity improves, temperature fluctuations reduce. When temperature fluctuations reduce, mechanical systems work less aggressively.
That relationship between envelope performance and energy demand is well established in building science research. The Australian Government’s Your Home guide outlines how continuous insulation improves overall building energy efficiency.
Installation Practicalities and Cost Considerations
Is polystyrene wall cladding easy to install and cost-effective? The answer depends on system design and installer discipline. Compared to brick veneer or timber, insulated cladding systems often reduce construction time because they combine insulation and external finish in a coordinated sequence.
Material handling is simpler due to reduced weight. Cutting and shaping EPS components requires standard site tools. Labour efficiency can improve when sequencing is planned correctly.
Cost evaluation should consider more than upfront supply, as lower structural load, faster installation and long-term energy savings all contribute to whole-of-life value.
Material Composition and Performance
What materials are polystyrene wall cladding panels made from? Panels typically use Expanded Polystyrene (EPS) as the insulating core. EPS consists of expanded polystyrene beads formed into rigid boards with controlled density and compressive strength.
Fire-retardant additives, compliant render systems and reinforcement mesh complete the assembly in rendered wall applications. When installed according to system specifications, insulated wall cladding can meet structural, thermal and durability requirements within Australian building codes.
Comparison With Traditional Systems
How does polystyrene wall cladding compare to brick veneer or timber? Brick veneer provides durability and thermal mass, yet it does not deliver inherent insulation without additional layers. Timber cladding offers aesthetic flexibility but requires separate insulation strategies.
Polystyrene wall cladding integrates insulation within the external layer. That integration reduces reliance on cavity-only insulation and can improve thermal continuity when detailed carefully. Performance depends on correct specification, fire compliance and moisture management.
FAQs on Polystyrene Wall Cladding
What are the benefits of polystyrene wall cladding?
The benefits of polystyrene wall cladding include improved thermal performance, reduced structural load due to lightweight construction, and support for meeting insulation standards within compliant wall systems.
How does polystyrene wall cladding improve energy efficiency in homes?
Polystyrene wall cladding improves energy efficiency in homes by reducing heat transfer through walls, which helps stabilise indoor temperatures and reduce heating and cooling demand.
Is polystyrene wall cladding easy to install and cost-effective?
Polystyrene wall cladding can be cost-effective when installation is well planned, as lightweight panels simplify handling and can reduce construction time compared to heavier systems.
Can polystyrene wall cladding help meet building code insulation standards?
Polystyrene wall cladding can help meet building code insulation standards when specified and installed in accordance with NCC and AS/NZS 4859.1 requirements.
Connect with the Foamex team today to discuss polystyrene wall cladding built for the Australian performance required for your projects.

#### Bring your Christmas Party theme to life with oversized polystyrene prop
70’s Disco Theme, A Winter Wonderland, Life at the Beach or a Venetian Masquerade. These are some of the top Christmas party themes.

#### Bring your party to life with oversized polystyrene party props
Bring your theatre production, event or party to life with oversized theatre props and sets built with Styroboard EPS expanded polystyrene. Expanded polystyrene props and sets are lightweight, reusable, and highly portable. Foamex can hot wire cut a range of shapes, signs and sculptures to fit your exact specifications – virtually any size and shape is possible.

#### Build Better with Foamex StyroPod
The building industry has seen many changes, and evolved many times, in order to find safer and more efficient methods and materials to use. From single to double storey dwellings, wood and stone to concrete, built-onsite to pre-fabricated. Although we are only scraping the tip of the iceberg, all these innovations and changes have enabled homes and buildings to be built faster and safer than ever before.

#### Buy polystyrene sheets: how to specify the right grade, thickness and format
Polystyrene sheet specification across Australian construction begins with the position. The density grade, thickness and format selected against AS/NZS 1366.3 determine whether the installed board performs to its rated thermal, compressive and dimensional values once it is in service. The following article sets out the variables that typically resolve an EPS specification in Australia, with reference to the relevant Australian Standards and the National Construction Code (NCC) pathway.Foamex manufactures StyroSheet expanded polystyrene (EPS) sheets in Australia under AS/NZS 1366.3 (Rigid cellular plastics sheets for thermal insulation – rigid cellular polystyrene, moulded EPS). The product is available in eight density grades, in thicknesses from 10 mm to 600 mm, and in standard and custom-cut formats, including foil-faced configurations where reflective performance is required.What polystyrene sheets arePolystyrene insulation sheets are rigid cellular plastic boards produced through one of two manufacturing routes. Expanded polystyrene (EPS) is produced by expanding and fusing polystyrene beads under steam, resulting in a closed-cell board with bead boundaries visible at the surface. Extruded polystyrene (XPS) is produced by extruding polystyrene polymer with a blowing agent through a die, producing a continuous, dense closed-cell foam without bead boundaries. The two routes deliver measurable differences in water absorption (classified under AS/NZS 4859.1 Appendix), compressive stress at 10% deformation and long-term R-value retention.EPS sheets are specified across wall, floor and ceiling insulation, garage door panels, Exterior Insulation and Finish Systems (EIFS), packaging assemblies, and architectural fabrication and signage. Foamex manufactures StyroSheet EPS without chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs) or other ozone-depleting substances, in accordance with the Foamex Styroboard ozone-depletion potential report.Specification variablesEPS specification typically resolves on five variables. Confirming each against the project documentation before order placement reduces the risk of installed performance falling short of rated performance.Position and exposureThe building element being insulated determines the rest of the specification. A timber-framed wall cavity, a suspended floor, a garage door panel, a cool room build-up and a packaging application each create distinct compressive, thermal and moisture conditions on the board. The position should be classified first, with the relevant compliance pathway, exposure category and adjacent material assemblies identified before density grade or thickness is considered.Compressive load and AS/NZS 1366.3 density gradeAS/NZS 1366.3 classifies EPS by compressive stress at 10% deformation, with the density grades expressed as SL, S, M, H, VH, VVH 32, VVH 36 and VVH 38. StyroSheet EPS is manufactured across the full range, from SL at 70 kPa through to VVH 38 at 350 kPa. Decorative work, signage, architectural fabrication and packaging assemblies are typically specified at SL or S grade. Wall, ceiling and light load-bearing floor positions typically specify M, H or VH grade. Civil and structural fill applications, including void fill and lightweight structural backfill, typically specify the VVH range. Density grade selection should account for sustained load over the design life of the assembly, not peak load alone.Moisture exposureEPS performs predictably in dry, lined and protected cavities. Where the insulation will be exposed to persistent ground moisture, hydrostatic pressure or external weather, extruded polystyrene (XPS) is typically the more appropriate specification. Foamex manufactures StyroTherm XPS for slab-edge, under-slab, perimeter and below-ground positions. Where the brief calls for EPS in damp positions, the assembly should be reviewed for vapour control, drainage and condensation risk against the project’s hygrothermal documentation.Thermal performance and NCC pathwayR-value targets for the building element are typically set by the project designer, accredited NatHERS assessor or building certifier against NCC 2022 Section J for Class 2 to 9 buildings, or against the NCC 2022 Volume Two / NatHERS pathway for Class 1 and 10a buildings. State-based requirements such as BASIX in New South Wales may also apply. The installed R-value depends on thickness, density grade and the as-installed condition of the board (including gap and compression behaviour). Thermal performance for StyroSheet EPS is tested in accordance with AS/NZS 4859.1 and ASTM C518 for thermal resistance and thermal conductivity. Final R-value selection should be confirmed with the project designer or energy assessor against the project-specific NCC pathway.Sheet dimensions and custom-cut formatsStandard sheet dimensions influence transport, install time and offcut volumes. StyroSheet is manufactured in widths up to 1.2 m, lengths of 2.5 m, 3 m and 5 m, and thicknesses from 10 mm to 600 mm. Custom-cut sheets are available where the cavity, panel or fabricated detail does not suit a standard format, and foil-faced or otherwise finished sheets are available where the build-up requires a reflective or laminated surface. Specifying a closer-to-final dimension at order stage typically reduces on-site cutting and offcut generation.StyroSheet EPS density gradesCompressive stress is reported at 10% deformation in accordance with AS/NZS 1366.3:Density gradeCompressive stress at 10% deformationTypical applicationSL70 kPaLight insulation, packaging, signage, displaysS85 kPaWall and ceiling insulationM105 kPaFloor and wall insulationH135 kPaLoad-bearing wall, light slab applicationsVH165 kPaHeavier wall and floor loadsVVH 32250 kPaCivil and structural fillVVH 36300 kPaHeavy structural applicationsVVH 38350 kPaHigh-load civil applicationsCurrent grade availability and full technical data should be confirmed against the current StyroSheet technical data sheet or by direct consultation with the Foamex specification team before final design.Specifying EPS or XPSEPS (StyroSheet) is typically the appropriate specification for internal, dry and protected positions where the project benefits from the AS/NZS 1366.3 density-grade range and from custom-cut sheet formats. XPS (StyroTherm) is typically the appropriate specification where the board will be exposed to persistent moisture, ground contact or external weather; at slab-edge, under-slab, perimeter or green roof positions; or where retained long-term R-value under damp conditions is required for the design pathway. Foamex StyroTherm thermal performance is published with R-values, K-values and compressive stress data tested to AS/NZS 4859.1, ASTM C518, AS 2498.3 and ASTM D1621.Common applications for StyroSheet EPSStyroSheet EPS is specified across:External wall insulation, including Exterior Insulation and Finish Systems (EIFS)Internal wall, floor and ceiling insulationGarage door insulation panelsCool room, chiller and refrigerated assembly constructionPackaging, in sheet, block and custom-moulded formatsArchitectural profiling, signage and display fabricationPrototyping and theatrical propsWhere the project crosses multiple applications, density-grade and dimension selection can typically be consolidated through specification consultation with the Foamex team.Australian manufacturing, recycled content and the StyroCycle recycling pathwayStyroSheet is manufactured in Australia and is manufactured containing recycled material recovered through Foamex’s closed-loop recycling system, StyroCycle. Recovered streams include clean construction offcuts and post-consumer EPS packaging, which are reprocessed back into new product. Clean construction offcuts can be returned through the StyroCycle take-back network rather than being directed to landfill, and StyroCycle drop-off points are operated in conjunction with participating council programs.Where a project is targeting waste-diversion or circular-economy outcomes, the take-back recycling pathway can be referenced in the specification alongside the product itself.Contact the Foamex specification team to confirm StyroSheet EPS density grade, thickness and format selection, or to request custom-cut or foil-faced sheets for a specific application.Frequently asked questionsWhere can polystyrene sheets be sourced in Australia?Foamex manufactures StyroSheet EPS in Australia under AS/NZS 1366.3 and supplies builders, fabricators, packaging customers and wholesalers nationally. Density grade, thickness, format and delivery should be confirmed with the Foamex specification team.What thickness is required for a given application?Thickness depends on the target R-value, the available cavity depth and the compressive load the board will carry. StyroSheet is available from 10 mm to 600 mm. The required R-value should be confirmed with the project designer or accredited NatHERS assessor against the applicable NCC 2022 pathway and any state-based requirement such as BASIX.Which AS/NZS 1366.3 density grade should be specified?Density grade is selected against the sustained compressive load on the board. Light-duty applications (packaging, signage, architectural fabrication) typically specify SL or S grade. Load-bearing wall, floor and slab applications typically specify H, VH or one of the VVH grades. Civil and structural fill typically requires the VVH range.Are custom-cut polystyrene sheets available?Yes. Foamex supplies custom-cut StyroSheet for fabrication, packaging, architectural profiling and any application where the standard sheet format would create unnecessary trimming on site. Foil-faced and laminated configurations are available where the build-up requires them.Are Foamex polystyrene sheets recyclable?Yes. StyroSheet is recyclable through the StyroCycle take-back network, which accepts clean construction offcuts and post-consumer EPS packaging for reprocessing into new product. StyroSheet is also manufactured containing recycled material drawn from the same closed-loop process.Should the project specify EPS or XPS?EPS is typically the more appropriate specification for internal, dry and protected positions across the AS/NZS 1366.3 density-grade range. XPS (StyroTherm) is typically the more appropriate specification for slab-edge, under-slab, perimeter, green roof and below-ground positions, or any position with sustained moisture exposure. The selection should be confirmed against the project documentation with the designer or specifier.

#### Changing the Built Environment with Foamex Lightweight Polystyrene Waffle Pods
As a committed member of Expanded Polystyrene Australia (EPSA), Foamex developed the Diamond Pods® lightweight polystyrene waffle pods as an alternative solution to the traditional void former system for under concrete slab insulation and construction. In comparison with traditional pours, the lightweight polystyrene waffle pods produce superior insulation suitable for residential, commercial, and industrial applications.
The expanded polystyrene used in the production of Diamond Pods® contains natural air pockets which effectively inhibits heat transfer to and from the system. Foamex takes the insulation power up a notch by integrating moulded cells within the unique design of the lightweight polystyrene waffle pods. With a long-term R-value of R1.0 (W/mK thermal resistance), the under concrete slab insulation material is able to maintain a year-round comfortable indoor temperature.

#### Choosing EPS and XPS insulation for your application
Expanded polystyrene (EPS) and extruded polystyrene (XPS) are rigid, closed-cell insulation materials made by Foamex in Australia. EPS is moulded from expanded beads; XPS is extruded as a continuous foam board. Both require a product specification that accounts for thermal resistance, loading and the conditions where the insulation will be installed.This comparison uses Foamex’s published StyroTherm XPS and conventional Styroboard EPS data. It does not cover graphite-enhanced EPS or establish a universal ranking for every EPS and XPS product.The short answerConsider XPS insulation for moisture-exposed or below-ground positions, and where the required R-value must fit within a limited depth. It is also used in protected-membrane roof systems, with the product and roof build-up specified for that application.Consider EPS where a choice of grades, custom-cut dimensions or large blocks suits the project. It is used for insulation, void forming and lightweight fill, with compression performance selected for the intended loading.Where either material is suitable, compare the actual grade, thickness, installation requirements and quoted cost. Neither material should be selected on its name alone.StyroTherm XPS, published performanceThickness (mm)R-value (m²K/W)K-value λ (W/mK)Compressive stress at 2% (kPa)Compressive stress at 10% (kPa)300.940.031>90>250401.290.031>150>350501.550.033>230>350601.820.033>240>350752.150.034>280>350Styroboard EPS, published performanceGradeNominal density (kg/m³)Compressive stress at 10% deformation, min. (kPa)Thermal resistance at 50 mm, min. (m²K/W)L1150R1.0SL13.570R1.20S1685R1.22M19105R1.25The EPS figures are from Foamex’s Styroboard EPS technical data sheet. Thermal resistance is reported for a 50 mm sample at a mean temperature of 23°C; compression values are minimum stresses at 10% deformation. The six standard classes run from L to VH. VVH 32, VVH 36 and VVH 38 are additional Foamex grades outside those classes.Comparing the published figures at 50 mmA shared thickness makes the thermal comparison easier to read. Compression results must also be compared at the same percentage deformation.StyroTherm XPS has a published R-value of R1.55 at 50 mm. The EPS grades shown range from R1.0 to R1.50 at 50 mm. XPS therefore has the higher published R-value within this comparison, although the difference is small against the highest EPS grade. Check the exact product where installation depth is limited.These figures measure the pressure needed to squeeze the insulation by 10% of its original thickness. For 50 mm StyroTherm XPS, the published rating is above 350 kPa. Styroboard EPS has minimum ratings from 50 kPa for L grade to 350 kPa for VVH 38. Because XPS is rated above 350 kPa, the figures do not confirm that the highest EPS grade and XPS are equally strong.The figures help compare products, but they do not tell you what load the insulation can safely carry in a building. An engineer must check the expected loads and how much the insulation may compress over time before specifying the product.Choosing by applicationWhere it goesWhat the position demandsUsual choiceUnder slabThermal resistance, design loading and moisture exposureEitherwith the product and thickness checked against the slab designSlab edgeInsulation continuity, moisture exposure and protectionEPS or XPSwhere supported by the specified slab-edge detailCavity and external wallsThermal performance, fixing, moisture control and fire requirementsEitherwithin a suitable wall system; do not select on cavity depth aloneRoof insulation above the membraneExposure to water and the roof’s loading requirementsXPSspecified for the roof system, including drainage and waterproofing detailsBelow ground levelResistance to moisture uptake and any imposed loadXPSwith appropriate drainage and waterproofingCold rooms and refrigerationThermal continuity, moisture control and any floor loadingEitherwhere the complete enclosure specification supports itCivil fill and void formingLow weight, required compression performance and geometryEPSblocks in an engineered fill or void-forming designMoistureFoamex’s XPS technical data sheet lists maximum water absorption below 0.5% by volume under AS 2498.8. The EPS sheet lists maximum total-immersion absorption from 4% to 1% by volume, depending on grade, under ASTM C272. Because the methods differ, these values should not be presented as a direct numerical comparison.XPS is used in moisture-exposed positions, but it is not a waterproofing layer. For either material, resolve drainage, waterproofing and vapour control as part of the complete design. An added vapour barrier is not a universal solution for every wall, roof or below-ground installation.Frequently asked questionsIs XPS insulation better than EPS?It depends on the application and the products being compared. In the published Foamex range shown here, XPS has a higher R-value at 50 mm and is used in moisture-exposed positions. EPS offers a range of grades and custom-cut formats. Check the thermal, load and moisture requirements together.What R-value does XPS insulation give?The StyroTherm product range shown here runs from R0.94 at 30 mm to R2.15 at 75 mm, including R1.55 at 50 mm. These are product R-values, not ratings for a complete wall, roof or floor.Is XPS stronger than EPS?Compare the specific grade and test result. At 50 mm, StyroTherm XPS is listed at greater than 350 kPa at 10% deformation. Styroboard EPS grades range from 50 kPa to 350 kPa minimum at the same deformation. These values cannot be treated as identical design capacities.Which one goes under a concrete slab?Both EPS and XPS are used for under-slab insulation. The product must meet the slab’s thermal, loading and moisture requirements. Refer to our under slab insulation guide and confirm the specification with the structural engineer.Can polystyrene insulation be used below ground?XPS is used in below-ground applications because of its resistance to water absorption. Specify it with the necessary drainage and waterproofing details; it does not replace those layers.Are EPS and XPS made in Australia?Yes. Foamex manufactures both EPS and XPS products in Australia. For the ranges compared here, see our XPS insulation sheets and polystyrene sheets. For the EPS production process, read how expanded polystyrene is made.SourcesFoamex StyroTherm XPS product dataFoamex Styroboard XPS Technical Data Sheet 2025Foamex Styroboard EPS Technical Data Sheet 2025Foamex Styroboard EPS brochureFoamex materials and application guidanceFoamex XPS specification considerations

#### Choosing the Right EPS Waffle Pod Size for Strong, Efficient Australian Slabs
Quick answer: Pod height for an Australian residential slab is selected to match the AS 2870-2011 site classification, the slab loadings and the engineered design. Foamex StyroPod EPS waffle pods are manufactured in 1090 mm by 1090 mm format with standard heights of 150 mm, 225 mm, 300 mm and 375 mm. As a starting point, 150 mm pods suit set-downs and step-down panels, 225 mm pods suit M-class sites, 300 mm pods suit H-class sites and 375 mm pods suit E-class sites. Final pod height must be confirmed by your structural engineer.Slab performance starts below the finished floor. Soil reactivity, rib depth and reinforcement layout decide how the foundation responds once the building is loaded. Selecting the right waffle pod size aligns lightweight concrete slab systems with the actual site classification, rather than forcing one default height across every job.In this guide, we explain how Foamex StyroPod EPS waffle pods are sized, how soil classification under AS 2870-2011 maps to pod height, how EPS contributes to under-slab thermal performance, and how Foamex manages offcut recycling. The aim is to give specifiers, builders and homeowners a practical reference, not a substitute for engineered design.Foamex StyroPod EPS Waffle Pods at a GlanceFoamex manufactures StyroPod EPS waffle pods in Australia. Pods sit on a level, compacted base in a regular grid. Reinforcement runs between the pods, forming the trench reinforcement for the concrete ribs, and a top mesh layer reinforces the slab above the pods. The whole layout is poured in a single concrete operation.SpecificationFoamex StyroPod EPSNotesFormat1090 mm x 1090 mmDesigned to align with standard residential slab gridsStandard heights150, 225, 300, 375 mmFinal height confirmed by structural engineer under AS 2870-2011MaterialExpanded polystyrene with diamond mould profileComposed of approximately 98 per cent air for low weightUnder-slab thermal contributionApproximately R0.5 to R1.0Depends on pod height, configuration and rib coverageRecyclableYes, clean offcuts collected and reprocessedEstimated 85 to 90 per cent recovery from clean site offcuts via the Foamex collection serviceManufacturingAustralian-manufactured EPSSteam expansion process, no ozone-depleting blowing agentsHow Soil Classification Drives Pod Height SelectionAustralian residential slabs are designed under AS 2870-2011 Residential Slabs and Footings. The standard sets out site classes based on how reactive the soil is to moisture changes. Reactive clays expand when wet and shrink when dry. The bigger that movement, the more the slab has to be designed to absorb it without distress in the structure above.Pod height selection starts with the AS 2870 site class, but it is not the only input. Slab loadings, configuration, design and the geotechnical report all feed into the final design. The structural engineer makes the call.Pod heightAS 2870 site classTypical site reactivityCommon application150 mmSet-down panels and step-downsLocal depth variationShowers, garages, internal step-downs and slab transitions225 mmMModerately reactiveMost M-class residential slabs on moderately reactive soils300 mmH1 / H2Highly reactiveReactive clay sites needing greater rib depth375 mmEExtremely reactiveHighly reactive sites where engineered design calls for deeper ribsA note for builders and homeowners: Pod height is not a procurement decision. It is an engineered output of the slab design. Order pods to the height nominated on the engineer drawings, not the height that happens to be on the truck.Why 1090 mm by 1090 mm Pods Make Sense on SiteFoamex StyroPod EPS waffle pods are manufactured in a 1090 mm by 1090 mm format. The format is designed to align with common residential slab grids, which keeps rib spacing consistent and reduces cutting on-site. EPS is light to handle and weather-resistant, so set-out moves quickly and the slab base stays clean during preparation.The diamond mould profile is engineered to support the load of the wet pour. Pods sit firmly on a prepared base, hold position during reinforcement placement and resist deflection during concrete placement. Crews working with the format consistently can set out a typical residential slab efficiently.Thermal Performance Under the SlabA concrete slab is a useful thermal mass, but it is also a heat loss path if it sits directly on cold ground. EPS waffle pods break that path by introducing a low-conductivity layer beneath part of the slab area.EPS waffle pods provide an under-slab insulation contribution up to R1.0. The exact value depends on pod height, configuration and the share of slab area covered by ribs versus pods. A 300 mm pod in standard EPS, for example, can provide approximately R0.75 to R1.0 of thermal resistance over the pod footprint, contributing to slab edge and sub-slab insulation when designed as part of the foundation.That contribution is one part of a building envelope strategy. NatHERS and BASIX assessments evaluate the whole envelope, including walls, roof, glazing and floors. Under the National Construction Code 2022, the minimum NatHERS performance for new homes increased from 6 stars to 7 stars in most jurisdictions. EPS pods can support that pathway when the assessment captures the under-slab contribution and the design integrates the rest of the envelope correctly.Speak with your NatHERS or BASIX assessor about how the slab system fits the energy target for your project. Avoid claims that a single product alone delivers compliance.Material Efficiency and Site HandlingConcrete volume drives a big share of slab cost, transport and pour time. EPS pods reduce the amount of concrete needed by displacing non-structural volume. The reduction flows through to fewer concrete trucks, fewer pump movements and a faster pour for the same footprint.Concrete volume on a typical waffle pod slab is roughly 25 – 40% lower than the equivalent traditional slab.Pump and truck movements scale down with the pour volume.Pod placement adds a defined preparation stage that can be planned ahead of the pour day.Reinforcement layout follows a regular grid, which can speed set-out compared with variable beam profiles.EPS is light to handle, with no specialised equipment required for cutting on site.On most projects above 100 m² of slab area, the concrete saving offsets pod and labour cost. On smaller jobs, the crossover depends on pod cost, concrete pricing and access conditions. Get quotes for both options once you have the engineer drawings and site classification.Sustainability and the EPS Recycling PathwayLoose offcuts on a slab job can become avoidable waste if they are not managed. Foamex operates an offcut collection service for clean EPS site waste, returning material to manufacturing for reprocessing into new EPS and XPS products. Estimated recovery is roughly 85 – 90% of clean site offcuts when collected through the service.The recycling pathway is straightforward. Builders bag clean EPS offcuts on site. Foamex coordinates collection or depot drop-off. The material is transported back to a manufacturing facility, where it is compacted, pelletised and reintroduced into new product.EPS itself is roughly 98 per cent air, which means a small volume of raw material produces a relatively large volume of finished pod. EPS manufacturing uses steam expansion, which means the process does not rely on ozone-depleting blowing agents. Steam recovery systems reduce energy demand during production.Sustainability outcomes depend on more than the recycling label. Specify the right pod height, cut efficiently, bag offcuts cleanly and book the collection service. That is what supports circular-economy outcomes in practice.5 Common Mistakes When Specifying Waffle Pod SizesDefaulting to one pod height across every project, regardless of site classification.Selecting pod height before the geotechnical report and slab design are issued.Treating the under-slab R-value contribution as the only insulation pathway in the building envelope.Ignoring set-down requirements for showers, garages and step-downs (where 150 mm pods are useful).Disposing of clean offcuts in general waste rather than booking the offcut collection service.How to Order the Right Foamex Waffle Pod SizeConfirm AS 2870-2011 site classification from the geotechnical report.Receive engineered slab drawings nominating pod height and rib spacing.Match pod height (150, 225, 300 or 375 mm) to the design.Plan delivery and pod placement around the pour programme.Book Foamex offcut collection ahead of the slab pour to keep clean waste in the recycling stream.Discuss your waffle pod size with the Foamex team. Contact us for product specifications, pod height options and offcut collection support on your next residential slab.Frequently asked questionsWhat is a waffle pod slab system?A waffle pod slab system is a stiffened raft slab that uses expanded polystyrene (EPS) pods as void formers in a regular grid, with a network of reinforced concrete ribs running between the pods and a thin top slab over the layout. It is designed under AS 2870-2011 and is widely used on reactive Australian residential sites.Is a waffle pod slab cheaper than a traditional concrete slab?A waffle pod slab typically reduces concrete volume by 25 to 40 per cent for the equivalent slab area, which lowers concrete supply, transport and pour cost. Pod supply and placement add a preparation stage. On most projects over 100 m² of slab area, the concrete saving offsets pod and labour cost, but exact pricing depends on local concrete rates and your site classification.What thermal performance does a waffle pod slab provide?EPS waffle pods contribute approximately R0.5 to R1.0 of under-slab thermal resistance, depending on pod height and configuration. This contribution sits inside a complete building envelope strategy. NatHERS or BASIX outcomes depend on the whole envelope, including wall, roof, glazing and floor systems.How do I know what waffle pod height I need?Pod height is selected by the structural engineer based on the AS 2870-2011 site classification, the slab loadings and the engineered design. Common heights are 150 mm, 225 mm, 300 mm and 375 mm. Discuss your geotechnical report and slab design with your engineer before procurement.Can a waffle pod slab be used on any soil class?Waffle pod slabs are designed for a wide range of site classes from S through to E when the slab design suits the soil reactivity. Problem (P) sites generally require additional geotechnical and structural engineering. The engineer assesses suitability for each project.How long does it take to install a waffle pod slab?Installation time is project specific. On equivalent floor area, the pour itself is typically 20 to 40 per cent shorter because of the lower concrete volume, while pod placement and reinforcement add roughly one to two days of preparation on smaller projects. Crew size, slab complexity and access also affect the result.

#### Construction industry favours Australian made EPS solutions
Foamex recently won a $1.4 million contract to supply expanded polystyrene (EPS) blocks for the massive West Gate Tunnel Project, which is delivering Melbourne residents with a vital alternative to the West Gate Bridge.
Foamex is supplying the major infrastructure project with S Grade Polystyrene manufactured at its Bayswater North facility on the east side of Melbourne, where it is cut into various dimensions. Using state-of-the-art equipment to hot wire profile the individual blocks, Foamex technicians precisely cut the EPS blocks to the profile according to the specifications set out by the engineers on the project.
“EPS has great tensile strength which gives it the ability to resist loads without failure because of excessive stress or deformation,” explains Foamex General Manager Justin Kelsey. “And this is why it is very commonly used within large construction projects.”
As Australia’s leading and longest serving polystyrene manufacturer, involvement in the West Gate Tunnel Project continues our long-running support of large critical infrastructure projects. And the same EPS products being used in the West Gate Tunnel are also being used in residential and commercial construction projects by Foamex customers throughout Australia.

#### Diamond Pods by Foamex save time, money and the environment
Did you know that concrete is one of the world’s most widely used building materials, and has literally been used for thousands of years? During the 700 years of The Roman Empire, concrete was used extensively, with many structures still surviving today.
But it wasn’t until the 1850s that reinforced concrete was developed in both Europe and the US, and more recently the concrete slab became a staple building technique in the post World War II building boom.
In more recent years, reinforced concrete slabs have benefited from the use of polystyrene, which has led to innovations like Foamex’s Diamond Pod product. According to Expanded Polystyrene Australia (EPSA), expanded polystyrene waffle pods have contributed to a revolution in slab construction methods, enabling stronger, better-engineered slabs to be constructed faster and cost-effectively over traditional methods.

#### Does underfloor insulation increase likelihood of termite attack?
It is estimated that Australian homes attacked each year by termites cause up to one and a half billion dollars in damage, with the average cost of repairs per home being $7,000 after a termite attack.
Termite colonies work 24 hours a day, and signs of termite infestations can go undiscovered until serious damage is done.

#### EPS Geofoam Blocks for Road Embankments and Civil Fill in Australia
Lightweight EPS blocks replace heavier conventional fill (sand, soil, aggregate) where dead load on the underlying ground needs to come down. Foamex StyroBloc and GeoFoamX EPS blocks weigh roughly one per cent of compacted soil fill and one to two per cent of compacted rock fill, which makes them a working solution for road embankments on soft soils, void fill behind retaining structures, bridge approach fill and landscape construction over weak subgrade. EPS is certified under AS 1366.3 and specified by the project geotechnical and civil engineer for compressive grade, density and embedment detail.
Civil and infrastructure specifiers reach for lightweight fill when conventional materials would over-stress the subgrade, cause unacceptable settlement, or require extensive ground improvement before construction can proceed. EPS blocks are one of a small set of lightweight fills used in Australian civil works, alongside expanded clay and lightweight concrete. EPS blocks are commonly grouped under the term “geofoam” in engineering documentation, and Foamex supplies both StyroBloc and GeoFoamX product variants for these applications.
Why EPS geofoam blocks suit road embankments and bridge approach fill
Soft soils respond poorly to additional dead load. Conventional soil or rock fill on a soft clay or peat subgrade can trigger consolidation settlement that continues for years, push out adjoining structures, or require lengthy preload programmes before final construction. EPS blocks weigh a small fraction of conventional fill at the same volume, which keeps the design load on the subgrade close to the pre-construction baseline.
Practical advantages on site include faster placement (blocks are stacked without compaction equipment), reduced earthmoving and haulage requirements, and a narrower construction footprint for the same finished embankment volume. Each of these affects programme and cost, not just engineering performance.

Density: typical engineering-grade EPS for civil fill ranges roughly between 15 and 30 kg/m3, depending on the grade specified. Conventional compacted soil fill is in the order of 1,800 to 2,000 kg/m3.
Compressive performance: civil-grade EPS blocks are specified by compressive resistance at 1 per cent strain (or similar engineering check). The grade is selected by the project engineer against the live and dead loads above the fill.
Water absorption: closed-cell structure limits long-term water uptake. Designs typically still allow for site water and drainage detailing around the EPS layer.

Where StyroBloc and GeoFoamX get specified
Foamex EPS blocks are used across a range of civil and infrastructure applications. The product variant and grade are selected to match the load and detail, not selected first.

Road and rail embankments over soft subgrade. Lightweight fill keeps the embankment dead load within the subgrade’s allowable bearing capacity, reducing the need for preload, vertical drains or ground improvement.
Bridge approach fill. The transition zone between a bridge structure and the adjoining embankment frequently sees differential settlement when conventional fill is used over soft ground. EPS blocks reduce settlement risk at the transition.
Void fill behind retaining walls. EPS reduces lateral earth pressure on the retaining structure, which can reduce structural demand on the wall or allow a lighter wall section.
Slope stabilisation and landslide repair. Replacing slip-prone soil with lightweight fill reduces the driving load on the slope.
Civil and landscape construction over services or weak subgrade. EPS blocks distribute load over service zones, basement decks or weak ground where point loads from conventional fill would be unacceptable.
Stadium, podium and rooftop landscape projects. Lightweight fill is used to build planters, planting beds and topographic landscape elements above structural decks without overloading the structure below.

For some lightweight fill or landscape applications, GeoFoamX is the appropriate Foamex specification, particularly where higher compressive performance or specific block geometry is required. Confirm product and grade with the Foamex team and the project engineer.
Engineering specification considerations
Civil fill is not a default-grade selection. The block density and grade are determined by the project loading, fill geometry, finished surface treatment and any vehicle or foot traffic above the fill. Specifying engineers typically work through the following decision points.

Loading. Permanent and live loads above the EPS layer determine the compressive grade. Roads, plant access, building deck loads and landscape loads have different requirements.
Settlement tolerance. Long-term creep behaviour of EPS is allowed for in the design through grade selection and overload factors.
Buoyancy and uplift. EPS blocks below the design flood level need uplift restraint. The design typically uses ballast layers or restraint detailing to manage this.
Fire performance. Where the EPS fill is exposed (uncovered) or close to flammable materials, project-specific fire engineering may apply. EPS blocks are commonly buried under cover material that removes the fire path.
Chemical exposure. EPS is not compatible with petroleum solvents. Designs near fuel handling, fuel storage or contaminated soil should detail a barrier layer to protect the fill.
Edge protection and surface preparation. Above-ground edges of an EPS fill need a protective surface (concrete cap, paving, soil cover) to manage UV exposure, mechanical damage and trafficked loads.

Sustainability profile of EPS civil fill
Styroboard EPS sheets and blocks (including StyroBloc, GeoFoam and GeoFoamX) can contain recycled content. Clean EPS and XPS offcuts generated during cutting and on site are 100 per cent recyclable through the Foamex collection and reprocessing system, and Foamex collects all construction site EPS waste from its products.
Foamex is a member of Expanded Polystyrene Australia (EPSA) and Operation Clean Sweep, and manufactures EPS in Australia without CFCs or HCFCs.
Talk to Foamex about EPS blocks for your next civil or infrastructure project. Call 1300 AU FOAM (1300 283 626) to discuss StyroBloc, GeoFoamX, grade selection, block geometry and delivery scheduling.

Frequently asked questions
What are EPS foam blocks used for in civil engineering?
Lightweight fill in applications where conventional soil or rock fill would over-stress the subgrade or surrounding structures. Common uses include road and rail embankments over soft soils, bridge approach fill, void fill behind retaining walls, slope stabilisation, and structural landscape construction above decks or services.
Are EPS blocks strong enough to support roads?
Yes, when specified to the correct grade. Civil-grade EPS blocks are manufactured to defined compressive performance values. The project geotechnical and civil engineer selects the grade against the design loads. EPS blocks are typically covered with a load-distribution layer (concrete or aggregate base) before pavement construction.
How does EPS civil fill compare with conventional fill?
EPS weighs roughly one per cent of compacted soil fill at the same volume. That dramatically reduces the dead load on underlying ground, eliminating or shortening preload requirements on soft subgrade, and reducing earthmoving, haulage and compaction work compared with bulk soil or rock placement.
Does EPS fill absorb water?
EPS is a closed-cell foam with low long-term water absorption. Designs typically still allow for site water and surface drainage around the fill, and address buoyancy where the fill sits below the design flood level.
Is Foamex StyroBloc Australian-made?
Yes. Foamex has been family-owned and manufacturing in Australia since 1982, with production sites across five Australian states. Styroboard EPS products including StyroBloc are manufactured locally and certified to AS 1366.3.

#### EPS has much better thermal properties than traditional brick veneer
When it comes to choosing between expanded polystyrene and traditional brick veneer, it’s clear-cut that expanded polystyrene has the superior thermal properties to keep your house cool in summer and warm in winter.
Insulation is an important feature of your house. A well-insulated home will keep your house cooler in the summer and warmer in the winter, reducing your heating and cooling bills and contributing to a more comfortable home for you and your family.

#### EPS Insulation in Coastal Homes: Fighting Salt, Wind and Extreme Glare
Salt haze, wind-driven rain and hard summer glare turn a coastal build into a daily stress test. Foamex supplies EPS Insulation panels that perfectly suit Australian projects for which the homeowner is asking ‘How does EPS Insulation improve home comfort and save energy?’

Reduces heat transfer through exposed walls, roofs and floors.
Supports tighter, more consistent energy-efficient building envelopes.
Brings lightweight handling advantages to busy coastal sites.
Helps manage moisture risk when specified and installed correctly.

Your coastal home will not groan and fail in a single Hollywood-style moment. It wears down in small ways: salty air that accelerates corrosion, gusts that drive fine spray deep into gaps and bright, reflected light that pushes indoor temperatures up fast.
When the building envelope cannot buffer those loads, you feel it as uneven temperatures between rooms, noisy nights, gritty surfaces and air-conditioning that runs longer than it should.
The Punishment of Coastal Conditions
Wind exposure and salt do not only affect cladding and fixings. They amplify pressure changes, which can pull humid air through wall and roof assemblies. Glare adds another layer by increasing radiant heat and temperature swings, especially in north- and west-facing rooms.
Insulation has to work alongside shading, air sealing and sensible ventilation.
Where EPS Fits and Why It Helps
Expanded polystyrene insulation boards suit coastal work because they are light to handle, stable and practical to cut and fit around framing. StyroSheet EPS sheets are described as lightweight, moisture resistant and supportive of acoustic comfort, which aligns with the coastal pain points people mention most: heat, damp and noise.
The performance benefit comes from continuity when boards fit tightly and junctions are well detailed.
R-Values and REAL Comfort
R-value only helps when it reflects the whole assembly, not a single layer. The Australian Government’s Your Home guidance explains that total R-value comes from adding the resistance of components in the roof, wall or floor system, including insulation.
Aim for continuity around slab edges and roof-to-wall transitions, where coastal wind pressure tends to expose weak points.
Installation Details for Windy Sites
EPS boards install cleanly, yet coastal sites demand discipline. The National Construction Code requires insulation, where required, to comply with AS/NZS 4859.1 and be installed so it forms a continuous barrier with adjoining elements and abuts or overlaps adjoining insulation.
These on-site habits keep the system working:

Plan continuity at corners, ceiling-to-wall lines and floor junctions.
Keep boards protected and flat so edges stay square for tight joins.
Seal obvious air paths first, then insulate; insulation does not stop draughts by itself.
Coordinate penetrations so services do not leave permanent leaks.

Moisture Management & No Musty Surprises
Coastal humidity can create a false diagnosis: people blame insulation for a heavy indoor feel, when the real issue is unmanaged moisture and uncontrolled air movement.
Moisture-resistant insulation panels help, yet they still need compatible wraps, flashing and ventilation paths so assemblies can manage vapour safely. In coastal zones, treat vapour control and drainage as part of insulation performance, not a separate trade issue.
Sustainability and Long-Term Cost Savings
Australian coastal homes demand materials that perform for decades, not just at handover:

If insulation steadies indoor temperatures, it reduces HVAC cycling and supports lower energy use across decades.
Lower mechanical strain often means fewer maintenance pressures over time.
Product recyclability also matters, especially when site offcuts stay clean and recoverable.

In coastal regions where replacement cycles can shorten due to environmental stress, durability and recoverability carry real financial and compliance weight.
FAQs on EPS Insulation
How does EPS Insulation improve home comfort and save energy?
EPS Insulation improves home comfort by reducing heat transfer through the building envelope, which can help save energy.
Is EPS Insulation suitable for Australian climates and building codes?
EPS Insulation is suitable for Australian climates and building codes when the design meets NCC requirements and installation follows relevant standards and continuity rules.
How easy is EPS Insulation to install in walls, roofs and slabs?
EPS Insulation is usually easy to install because boards are lightweight, yet accurate cutting, tight joints and protected storage drive the final result.
Does EPS Insulation help with sustainability and long-term cost savings?
EPS Insulation supports sustainability and long-term cost savings by reducing energy demand over the life of the home. Plus clean offcuts are recycled where feasible.
What are the real-world benefits of EPS Insulation over other materials?
Real-world benefits of EPS Insulation over other materials include lightweight handling, stable thermal performance, and moisture resistance when properly detailed.
Can EPS Insulation reduce my heating, cooling and noise issues?
EPS Insulation can reduce heating and cooling demand by limiting heat transfer and can also help reduce external noise when installed continuously.
Choose Foamex for EPS Insulation that holds coastal comfort. Contact us today.

#### EPS panels in Australia: the types, and the EPS core behind them
“EPS panels” is not one product. The term covers rendered facade and EIFS panels, structural insulated panels, sandwich panels and cool room panels. What they share is an expanded polystyrene core. Foamex does not make the finished panels. Foamex manufactures the EPS core inside them, and supplies panel and EIFS manufacturers across Australia with certified, cut-to-profile expanded polystyrene made to AS 1366.3. If you build panels, this is about where the core comes from and why it matters.
Specifiers and builders use “EPS panels” loosely, so the first job is to separate the products it refers to. The second is the part that decides how the finished panel performs: the EPS core itself.
What “EPS panels” actually means
EPS panels are building products that use a rigid expanded polystyrene board as the insulating core. The core is the constant. The facing, the finish and the structural role change from product to product, and so does the manufacturer who makes them. The EPS is graded to AS 1366.3, and its grade, density and thickness set the thermal and mechanical performance the finished panel can claim.
The main types of EPS panel

Rendered facade and EIFS panels. An EPS board fixed to the wall, reinforced with a base coat and mesh, and finished with a render. Used for lightweight, insulated facades.
Structural insulated panels (SIPs). An EPS core bonded between two structural facings such as OSB, plywood or magnesium board, used as load-bearing wall and roof elements.
Sandwich and composite panels. An EPS core between steel or aluminium skins, used for walls, roofing and cold storage.
Cool room and cold storage panels. EPS-cored panels for temperature-controlled rooms, where continuous insulation and consistent core density matter to the thermal result.

Each is a different finished product from a different manufacturer. The one thing they have in common is the board in the middle.

What every EPS panel depends on: the core
The finished panel is only as good as the EPS it was built and tested with. Grade (SL, S, M or H per AS 1366.3) sets the mechanical and impact performance. Density and thickness set the insulation value, specified to AS/NZS 4859.1. When a manufacturer certifies or tests a panel, that evidence assumes a specific core. A variable or wrongly graded board puts both the thermal claim and the compliance evidence at risk, which is why manufacturers care as much about core consistency as about price.
Fire and compliance in short
EPS is combustible. A compliant panel carries its fire performance as a complete, tested assembly, not from the core alone. For external walls, full-scale testing to AS 5113 is the common evidence pathway, and the wall must meet the NCC provisions for the building’s class, height and construction type. Cold storage and structural panels have their own applicable requirements. The core is supplied to grade; the finished, fire-tested panel is the panel manufacturer’s.
Where the EPS core comes from: Foamex
Most panel and EIFS brands do not mould their own polystyrene. They build a tested product around an EPS core bought from a manufacturer, so the core has to be consistent, correctly graded and dimensionally accurate. Foamex makes that core. For panel and EIFS manufacturers, Foamex supplies:

EPS to grade, certified to AS 1366.3, with batch-to-batch consistency a panel’s test evidence can rely on.
Cut-to-profile and custom shapes through hot-wire cutting: to the sizes, profiles and tolerances a panel design needs.
Consistent density and dimensional accuracy, so the board delivered matches the board that was tested.
Australian manufacture since 1982 across five states, which means supply reliability, lead time and the volume to support production runs.
Recycled content where feedstock allows, plus clean-offcut recovery through the Foamex collection system.
Product documentation and technical support for the manufacturer’s own compliance file.

For panel and EIFS manufacturers
If you manufacture insulated, structural, sandwich, cool room or render panels and want a local EPS core partner, Foamex supplies expanded polystyrene to your grade, size and profile, made in Australia and certified to AS 1366.3, with the batch consistency your product’s test evidence depends on. Talk to Foamex about core supply, custom profiles and production volumes. Call 1300 AU FOAM (1300 283 626).
Sustainability
Styroboard EPS sheets and blocks can contain recycled content. Clean EPS offcuts from cutting and manufacture are 100 per cent recyclable through the Foamex collection and reprocessing system, and Foamex collects EPS production waste from its products. Foamex is a member of Expanded Polystyrene Australia (EPSA) and manufactures EPS in Australia without CFCs or HCFCs.

Frequently asked questions
What are EPS panels?
Building panels that use a rigid expanded polystyrene board as the insulating core. The term covers rendered facade and EIFS panels, structural insulated panels (SIPs), sandwich or composite panels, and cool room panels.
Does Foamex make EPS panels?
No. Foamex manufactures the EPS core that panel and EIFS makers build their products around. Foamex supplies the expanded polystyrene to grade, size and profile, certified to AS 1366.3; the finished panel is the panel manufacturer’s.
What grade of EPS is used in panels?
It depends on the panel. Grade (SL, S, M or H per AS 1366.3) is chosen for the panel’s mechanical, impact and thermal requirements, and is set by the panel manufacturer’s specification.
Can Foamex supply custom EPS core sizes and profiles?
Yes. Foamex hot-wire cuts EPS to custom sizes, profiles and tolerances, to the grade a panel requires, manufactured in Australia.
Are EPS panels fire-compliant?
A compliant panel earns its fire performance as a complete tested assembly, commonly through AS 5113 testing for external walls, and must meet the NCC provisions for the building. EPS is combustible and is not fire-rated in isolation.

#### EPS Signage and 3D lettering gets you noticed
3D signage is sure to get your brand or product noticed – its the first thing everyone sees and from quite a distance. 3D signage and EPS lettering has a unique look that simply can’t be matched by other signs.
3D signs grabs people’s attention in a way that traditional or digital signs simply cant – making an immediate impact for your business.
An ideal material for 3D low cost signage, Expanded Polystyrene (EPS) is also highly durable, lightweight, cost effective, versatile and overall easy to use.

#### EPS vs XPS for Slabs: Choosing the Right Polystyrene Sheets
For slab-on-ground construction, selecting the correct rigid insulation board is critical. The choice between Expanded Polystyrene (EPS) and Extruded Polystyrene (XPS) affects structural performance, thermal efficiency and long-term durability.
Builders, architects and engineers designing concrete slabs — particularly in projects targeting energy compliance — must consider compressive strength, moisture exposure and perimeter detailing before specifying polystyrene sheets.
In Australian construction, the two primary rigid polystyrene sheet types used around and beneath slabs are:

Expanded Polystyrene (EPS) sheets

Extruded Polystyrene (XPS) sheets

Both materials are widely used in slab systems. The key is understanding where each performs best.
When choosing polystyrene sheets for slab construction, the key decision is typically between EPS and XPS. EPS offers cost-effective thermal performance in multiple density grades, while XPS provides higher compressive strength and lower water absorption, making it suitable for slab edges and higher-load conditions.
What Are Polystyrene Sheets in Slab Construction?
Polystyrene sheets are rigid foam boards installed:

Beneath concrete slabs
Around slab edges/perimeters
Within suspended slab systems
In specialised lightweight fill applications

They improve thermal performance, reduce heat transfer to ground and contribute to energy efficiency outcomes under NCC performance pathways.
EPS vs XPS: What’s the Practical Difference?

Performance Factor
EPS Sheets
XPS Sheets

Manufacturing process
Expanded bead structure
Continuous extrusion

Compressive strength
Available in multiple grades
Typically, higher compressive grades are available.

Water absorption
Low when properly detailed
Generally lower absorption rate

Cost
More economical
Premium performance

Typical slab applications
Under-slab insulation, engineered void fill
Slab edge insulation, under-slab in higher load or moisture areas

 
The decision is not about which material is “better.” It is about selecting the appropriate performance level for the slab design.
Choosing Polystyrene Sheets for Slab Applications
#1 Under-Slab Insulation
When installed beneath concrete slabs, insulation boards must withstand:

Concrete dead load
Live loads
Construction traffic during pour
Long-term compressive stress

Higher-density EPS sheets are commonly specified for under-slab insulation where engineering design permits (for example, Foamex StyroSheet® EPS sheets). XPS sheets may be selected where higher compressive resistance or reduced moisture absorption is required (for example, Foamex StyroTherm® XPS sheets).
Selection should always be aligned with structural documentation rather than defaulting to a material type.
#2 Slab Edge / Perimeter Insulation
Slab edges are a critical thermal junction. Heat loss often occurs at the perimeter rather than the centre of the slab.
Rigid XPS boards are frequently used vertically around slab perimeters due to:

Compressive strength at ground interface
Lower water absorption
Durability in exposed edge conditions

Properly detailed slab edge insulation contributes significantly to meeting energy modelling outcomes under NCC energy provisions. Where projects include roof insulation systems or specialised roof assemblies, XPS materials may also be used in roof spacer applications such as StyroLink® XPS roof spacers.
#3 Moisture & Ground Conditions
Below-ground applications require consideration of:

Soil moisture
Drainage
Hydrostatic pressure
UV exposure during construction

XPS is often selected where boards are in contact with ground moisture for extended periods. EPS performs effectively when detailed within a compliant building system and protected from prolonged exposure.
Neither product replaces waterproofing membranes.
Performance Metrics Engineers Should Review
When specifying EPS or XPS sheets for slab systems, design professionals should confirm:

Compressive strength (kPa rating)
Thermal conductivity (λ-value)
Long-term creep performance
Water absorption characteristics
Compliance with AS/NZS 4859.1 (where applicable)

Thickness alone does not determine performance. The board must meet structural and thermal requirements simultaneously.
Common Specification & Installation Mistakes
Even correctly specified boards can underperform if poorly detailed. Common issues include:

Selecting thickness without confirming compressive strength
Ignoring long-term load and creep behaviour
Leaving boards exposed to prolonged UV before pour
Failing to protect slab edge insulation during backfill
Assuming rigid insulation replaces damp-proofing systems

Correct installation and protection are essential to maintaining performance over the life of the slab.
How Insulation Choice Impacts NCC Energy Compliance?
In slab-on-ground construction, perimeter insulation can have a disproportionate impact on overall thermal performance.
Energy modelling pathways (such as NatHERS or JV3 assessments) often highlight slab edge heat loss as a key performance factor. Specifying appropriate rigid insulation at slab edges can assist in achieving required energy efficiency outcomes under the NCC.
Insulation continuity across junctions, penetrations and slab transitions is equally important as nominal R-value.
Slab Insulation in Climate Zones 6 & 7
In heating-dominant regions such as NCC Climate Zones 6 and 7 — which cover much of Victoria and parts of southern NSW and Tasmania — slab heat loss can significantly influence overall building energy performance.
In these zones:

Ground temperatures can contribute to winter heat loss.
Slab perimeter insulation often has a greater impact than mid-slab insulation.
Energy modelling frequently highlights slab edges as a key thermal junction.

Specifying appropriate rigid insulation at the slab perimeter, and ensuring continuity between vertical and horizontal insulation layers, can assist in meeting energy performance requirements under NCC pathways such as NatHERS or JV3 assessments.
Material selection should align with both structural requirements and project-specific energy modelling outcomes.
Sustainability Considerations in Slab Systems
Rigid polystyrene sheets contribute to operational energy reduction over the building’s lifespan.
Additionally:

EPS is recyclable at end of life. XPS is also recyclable when offcuts sold by Foamex are returned to Foamex
Both EPS & XPS sheets can contain recycled content.
Foamex XPS is the only extruded polystyrene Made in Australia with renewable energy sources and containing recycled EPS packaging.
Durable insulation reduces lifecycle energy demand.

Material selection should consider both performance and long-term environmental impact.
Making the Right Choice for Your Slab
When specifying polystyrene sheets for slab construction, assess:

Structural load requirements
Ground moisture exposure
Slab edge detailing
Thermal performance targets
Energy modelling requirements

Both EPS sheets (such as StyroSheet®) and XPS sheets (such as StyroTherm®) are established materials in Australian slab construction. The correct choice depends on the performance requirements of the specific project.
Consult manufacturer technical data before final specification — including EPS technical specifications and XPS technical specifications — and confirm alignment with engineering documentation for slab design.
FAQ 
What is the difference between EPS and XPS for concrete slabs?
EPS sheets are manufactured from expanded beads and are available in multiple density grades for under-slab insulation. XPS sheets are extruded, providing a more uniform structure, typically higher compressive strength and lower water absorption. The correct choice depends on structural load and moisture exposure conditions.
Is slab edge insulation required in Australia?
Slab edge insulation is commonly specified in heating-dominant climate zones to reduce perimeter heat loss and support NCC energy compliance. While requirements depend on the project’s compliance pathway, properly detailed slab edge insulation can significantly improve overall thermal performance.
Can EPS insulation be used under a concrete slab?
Yes. Higher-density EPS sheets can be used beneath concrete slabs when specified to meet engineering load requirements. Selection should be based on compressive strength and design documentation rather than thickness alone.
For slab-on-ground construction in Australia, both EPS and XPS sheets remain widely specified materials when matched correctly to structural, moisture and energy performance requirements.
Contact Us for a specilaised quote.

#### Expanded polystyrene recovery, recycling and reuse
In Australia, approximately 45,0001 tonnes of expanded polystyrene (EPS) is produced and used each year.
Much of this EPS is embedded in long-term use, such as waffle pods used in housing construction, EPS blocks for road embankments, and in engineering/manufacturing components.

#### Expol for Existing Homes
If you have purchased an existing home, there is a good chance you’ve had some changes in mind since you first fell in love with your place. Maybe a lick of paint to brighten up some rooms and the outside? Rip up some carpet and let the floorboards shine through?
And when you ripped up the carpet the summer sun was warming the home, and your newly exposed floorboards made the home cooler. But now, as winter is creeping in, the first tendrils of cold air are slipping through the cracks, turning your toes to icicles. Sure, you can get a rug to cover up most of the floor, but it won’t cover all of it.
Maybe you just need to turn up your heating and have it run longer throughout the day? Of course, this will result in your electricity bill soaring through the roof. On the positive side, you’ll have a new spot for a skylight.
Yet there is a solution to stopping the cool air creeping into your home in winter and your electricity bill rising; insulation. Depending on the age of your home, there is a good chance you may already have insulation in your walls and ceiling in some form or another, but we are not talking about them.
What many owners are not aware of is there is a solution for stopping the cool air creeping through the floorboards, and it’s not re-laying the carpet or using oversized rugs.  It’s underfloor insulation.

#### Expol Rigid Underfloor Insulation Panels for Timber Floors
Rigid underfloor insulation panels are seeing a rise in demand in the Australian building and construction industry. As one of the industry leaders specializing in the development of polystyrene products, Foamex designed Expol™ rigid underfloor insulation panels to provide continuous protection for homeowners against extreme outdoor temperatures.
For 36 years, Foamex has provided a multifaceted range of polystyrene products across the Australian market, allowing them to build a formidable working relationship with major industry specifiers. The team positions Expol™ as the material of choice for residential and commercial applications, as it inhibits heat to enter from outside during summer while maintaining convective heat in winter. By using polystyrene underfloor insulation, homeowners can cut an estimated 12% on energy costs, while still enjoying a warm and comfortable indoor climate.

#### Extruded polystyrene foam sheets: performance, specification and application
Extruded polystyrene foam sheets, commonly abbreviated to XPS, are specified across Australian construction at positions where the insulation board must resist moisture, carry sustained compressive load and retain its rated thermal performance across the design life of the assembly. The closed-cell extruded foam structure is what allows the same material to do all three. The following article covers what XPS sheets are, how they perform in Australian conditions, the test data that supports specification, and the positions where they are typically used.
Foamex manufactures extruded polystyrene foam sheets in Australia under the StyroTherm brand, made from Foamex Styroboard XPS. Thermal performance is reported in accordance with AS/NZS 4859.1 and ASTM C518, and compressive stress is reported in accordance with AS 2498.3 and ASTM D1621.
What extruded polystyrene foam sheets are
XPS sheets are rigid cellular plastic insulation boards produced by extruding polystyrene polymer with a blowing agent through a die. The process produces a continuous closed-cell foam with a dense, uniform structure throughout the thickness of the board.
Expanded polystyrene (EPS), by contrast, is produced by expanding polystyrene beads under steam and fusing them in a mould, producing a closed-cell board with visible bead boundaries at the surface. The two materials are visually similar but behave measurably differently under moisture exposure, sustained compressive load and long-term thermal cycling. Fibrous insulation products, such as glasswool and rockwool, rely on air trapped between fibres for thermal performance and respond differently again to moisture and load.
Foamex manufactures three XPS products that map to different specification positions: StyroTherm for foundation, slab-edge and perimeter work; StyroRoof for green roof installations; and StyroLink as an XPS purlin spacer for metal roofing assemblies.
Closed-cell structure and Australian operating conditions
Australian building elements operate in a range of conditions that affect insulation performance over time. Insulation under slabs, around slab perimeters and within roof assemblies is in regular or continuous contact with moisture. Seasonal humidity cycles, heavy rainfall events and ground moisture each act on the board through the life of the assembly.
Water conducts heat more readily than the trapped air responsible for the insulating effect of the foam. If an insulation product absorbs water, its installed R-value will fall below the rated value. The continuous closed-cell foam structure of XPS restricts water movement through the board, which supports retained thermal performance in damp and ground-contact positions where open-cell or beadboard insulation is more likely to lose performance.
The same dense closed-cell structure delivers compressive stress at 10% deformation high enough to support engineered loading. This is what allows XPS to be specified beneath loaded slabs, beneath rooftop landscaping and within engineered floor build-ups.
XPS, EPS and fibrous insulation compared
The differences between the three product families show up in service across four practical measures:

Water penetration through closed-cell XPS is lower than through EPS or fibrous insulation, particularly under sustained or repeated exposure
Compressive stress at sustained load is higher in XPS than in most EPS density grades and substantially higher than in fibrous insulation
Retained R-value through service is more stable in XPS at positions with moisture exposure
Boards can be cut, shaped and installed without specialised equipment

For internal, dry, lined and protected cavities, EPS is often the more cost-effective specification across the AS/NZS 1366.3 density-grade range. For positions with moisture exposure, ground contact or external weather, XPS is generally the more appropriate specification.
Thermal performance and the NCC pathway
Heating and cooling represent a substantial share of building energy use in Australia. The Australian Government’s Your Home guide notes that improving the thermal performance of the building envelope reduces reliance on mechanical heating and cooling, with downstream effect on building energy consumption.
XPS contributes to building envelope performance in two ways. The continuous closed-cell foam structure resists water absorption that would otherwise raise the in-service thermal conductivity of the board. The K-value (lambda) of XPS is low and stable across normal service temperatures, supporting retained R-value performance over time.
Where XPS is installed beneath a slab, around a slab edge, within a roof build-up or as part of a green roof assembly, the board contributes to the building envelope calculation used for compliance against NCC 2022 Section J for Class 2 to 9 buildings, against NCC 2022 Volume Two and the NatHERS pathway for Class 1 and 10a buildings, and against state-based requirements such as BASIX where applicable. The actual contribution to a specific compliance outcome should be confirmed by the project designer, accredited NatHERS assessor or building certifier against the project documentation.
StyroTherm XPS published performance data
Foamex publishes the following thermal and compressive performance data for StyroTherm XPS at a sheet size of 2400 mm x 600 mm:

Thickness
R-value (m2.K/W)
K-value (lambda, W/m.K)
Compressive stress at 2% deformation
Compressive stress at 10% deformation

30 mm
0.94
0.031
>90 kPa
>250 kPa

40 mm
1.29
0.031
>150 kPa
>350 kPa

50 mm
1.55
0.033
>230 kPa
>350 kPa

60 mm
1.82
0.033
>240 kPa
>350 kPa

75 mm
2.15
0.034
>280 kPa
>350 kPa

 
Test methods: thermal performance is reported in accordance with AS/NZS 4859.1 and ASTM C518; compressive stress is reported in accordance with AS 2498.3 and ASTM D1621. Current values should be confirmed against the latest StyroTherm technical specification sheet before final design.
Positions where XPS is typically specified
Under-slab insulation
XPS installed beneath a ground slab is in continuous contact with the ground and the underside of the concrete. The closed-cell foam structure supports retained R-value in moist conditions, and the published compressive stress at 2% and 10% deformation supports the sustained load of the slab and the building above.

Slab-edge and perimeter insulation
Slab edges are a recognised thermal bridge in Australian residential construction and a known weakness in unconditioned envelope performance. XPS detailed at the slab perimeter reduces conductive heat loss at the slab edge and operates predictably under the exposure conditions seen at that position.
Below-ground and retaining wall applications
Below-ground installations are exposed to hydrostatic pressure and persistent moisture. XPS is the typical specification at these positions because of its closed-cell foam structure and dimensional stability under sustained wet conditions.
Green roof systems
Foamex manufactures StyroRoof specifically for green roof applications. StyroRoof uses the same closed-cell XPS chemistry but is engineered for rooftop conditions, including drainage, root-resistance considerations and the loading associated with landscaping build-ups. StyroRoof is specified for green roof installations rather than for inverted roof systems.

Civil and engineered fill applications
Lightweight civil fill, void fill beneath bridges and roadworks, and similar engineered applications typically specify a different Foamex product family. For these projects, GeoFoamX and StyroBloc are usually the more appropriate specifications, selected against the engineered load and density requirements of the design.
Sustainability, recycled content and Australian manufacturing
StyroTherm is manufactured in Australia under a closed-loop production model. Clean polystyrene recovered through construction offcuts, factory surplus and post-consumer EPS packaging collected through StyroCycle is reprocessed and returned to new product. StyroTherm can contain up to 90% recycled polystyrene from EPS packaging without affecting the published thermal or compressive performance values.
The manufacturing process is free from chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs) and other ozone-depleting substances. The product carries Australian-Made certification. For projects targeting waste-diversion or circular-economy outcomes, the take-back recycling pathway and the recycled content can be referenced in the specification alongside the thermal performance.
Test methods, certification and specification confidence
Once XPS is built into a slab, perimeter detail or roof assembly, the published performance data carries the same weight in compliance review as the material itself. Nominal R-values, generic product descriptions and unsourced product claims are not sufficient for specification or certification review.
Foamex tests StyroTherm in accordance with AS/NZS 4859.1 and ASTM C518 for thermal performance, and AS 2498.3 and ASTM D1621 for compressive stress. The product is supported by Australian-Made certification, published warranty, material safety data and material handling documentation. For specifiers, that combination provides measurable, comparable, sourced data and a clear chain of accountability through to the technical documentation if questions arise during certification, audit or project review.
Contact the Foamex specification team to confirm StyroTherm XPS for the project, or to request the current technical specifications, material safety data and Framework for Sustainability whitepaper.

Frequently asked questions
Are extruded polystyrene foam sheets suitable for Australian conditions?
Closed-cell XPS retains its rated thermal performance under moisture exposure and supports sustained compressive load. Both properties suit positions common in Australian construction, including ground contact, slab applications and exposed perimeter detailing. Local manufacturing in accordance with Australian Standards adds further consistency through the supply chain.
How do XPS insulation panels contribute to energy efficiency?
XPS reduces conductive heat transfer through the building envelope. The continuous closed-cell foam structure resists water absorption that would otherwise raise thermal conductivity, supporting retained R-value performance and more predictable heating and cooling demand across the year. Specific contributions to NCC, NatHERS or BASIX outcomes should be confirmed with the project designer or energy assessor.
What distinguishes extruded foam board insulation from EPS?
The manufacturing route and resulting cell structure. XPS is produced by extruding polystyrene polymer with a blowing agent into a continuous closed-cell foam. EPS is produced by expanding and fusing polystyrene beads. XPS typically delivers lower water absorption, higher compressive stress and more stable retained R-value, particularly at moisture-exposed positions.
Can closed-cell insulation foam be specified below ground?
Yes. The low water absorption and dimensional stability of XPS support specification at under-slab, slab-edge, retaining wall and other below-ground positions where moisture exposure is part of the design condition. Water absorption performance should be confirmed against AS/NZS 4859.1 Appendix.
What thicknesses are available for StyroTherm XPS?
StyroTherm XPS is manufactured in 30 mm, 40 mm, 50 mm, 60 mm and 75 mm thicknesses, at a sheet size of 2400 mm x 600 mm, with published R-values from 0.94 to 2.15 (tested to AS/NZS 4859.1 / ASTM C518).
Where can extruded polystyrene foam sheets be sourced in Australia?
Foamex manufactures StyroTherm XPS in Australia and supplies builders, specifiers, engineers and wholesalers nationally. Technical specifications, warranty, material safety data and Australian-Made certification documentation can be requested through the Foamex specification team.

#### Extruded Polystyrene the victor in the fight against mould
Mould is a problem that not only affects the appearance of your home, but it can also have severe effects on the occupants living within. Mould is typically found in dark, damp, warm spaces and can start growing within 24-48 hours of the right conditions being present.
The most important element that mould needs to grow is moisture. Even if your home is well ventilated, if it has been raining for several days in a row, mould may be able to take hold due to the constant moisture in the air.

#### Fire rating of polystyrene used in EXPOL Underfloor Insulation
Foamex has been a long time member of EPSA, the peak body for manufacturers of expanded polystyrene (EPS) in Australia and as such supports their recent media statement surrounding the materials used in the devastating Grenfell Tower building fire in the UK.

#### Foamex ‘Shapes’ Rooftop Green Gardens Into The Future
About 20 years ago, a green roof garden was something of a novelty. Today there are literally hundreds in our major cities, a trend driven by environmental awareness and moves by many local authorities to require such features in major projects.
This remarkable growth has brought with it greatly improved expertise in the area; making it more than just ‘gardening in the sky’. Key to the success of a roof top garden, is the long term interaction of the garden with the building; including critical issues such as drainage, stability, waterproofing and insulation.

#### Foamex EPS at core of Casafico building system finalist nomination in innovation award
Casafico is a Victorian based construction company focused on manufacturing innovative building products with sustainable building practices at the forefront. These sustainable practices include the use of recycled raw materials, utilising locally sourced materials and saving materials from landfill. For over eight years, Casafico have been using Foamex recycled polystyrene in its coating formulations. Over the last 12 years, this practice has saved over 5,700 cubic metres of polystyrene from landfill.
Casafico have recently launched the Polystat Wall construction system, a pre-fabricated wall system that uses Foamex’s Styroboard EPS expanded polystyrene as the core of this innovation construction system.  The use of EPS in between the steel framework helps give the Polystat wall system 90/90/90-minute fire rating and the thermal efficiency is 4.17R -Value on all external walls.

#### Foamex Expanded Polystyrene helps wall system achieve highest BAL rating
Unfortunately, many Australian homes are in areas prone to bushfire attack, and these homes and property are rated in terms of Bushfire Attack Levels, which in turn set minimum building guidelines. These guidelines are intended to reduce the risk of loss of life or damage to property in bushfire prone areas.

#### Foamex partners with luxury retailer to launch new products
Expanded polystyrene is one of the most versatile and cost-effective materials for both packaging and building/construction applications due to it being lightweight, easy to handle, durable, strong, flexible, and recyclable.
Foamex recently completed a job that demonstrates just how creative they can get with polystyrene foam. Hunter Lab, a premium Melbourne-based all-natural skin care brand for men, was organising a product launch event at the Jackalope Hotel & Winery on the Mornington Peninsula and required signage for the event.
Being a luxury, experiential brand, Hunter Lab sought a signage solution that would exude the prestige that’s synonymous with the brand. The launch event would be attended by 50 VIPs, including Hunter Lab’s brand influencers.
Having previously engaged Foamex to deliver other inventive polystyrene solutions such as point of sales collateral, gift set packaging, selling kits for sales managers, as well as CNC cutting the shape of their product bottles, Hunter Lab tasked the Foamex team with researching, designing and delivering stunning signage for the launch event. The signage required a high-end finish to support the premium positioning of the Hunter Lab brand and to help sell the event.

#### Foamex pledges support for EPSA’s new Pod Code of Practice
At Foamex we’re great supporters and contributors to our industry body, Expanded Polystyrene Australia (EPSA). EPSA is the peak national body for manufacturers and distributors in Australia, and our own General Manager Justin Kelsey is an EPSA Board Member.
You can read the revised code, now known as the 2019/20 Airpop Pod Code of Conduct, on the EPSA website. For those not familiar with the name, Airpop is the product descriptor that is now being used throughout Europe for EPS, the term Airpop and is also being adopted in Australia.
At Foamex we’ve been instrumental in developing this code, and unsurprisingly we already adhere to the requirements set out in it. We’re fully committed to maintaining professional standards in the EPS industry, as well as leading the industry in our commitment to environmental impacts.

#### Foamex pledges support for EPSA’s new Pod Code of Practice
At Foamex we’re great supporters and contributors to our industry body, Expanded Polystyrene Australia (EPSA). EPSA is the peak national body for manufacturers and distributors in Australia, and our own General Manager Justin Kelsey is an EPSA Board Member.
You can read the revised code, now known as the 2019/20 Airpop Pod Code of Conduct, on the EPSA website. For those not familiar with the name, Airpop is the product descriptor that is now being used throughout Europe for EPS, the term Airpop and is also being adopted in Australia.
At Foamex we’ve been instrumental in developing this code, and unsurprisingly we already adhere to the requirements set out in it. We’re fully committed to maintaining professional standards in the EPS industry, as well as leading the industry in our commitment to environmental impacts.

#### Foamex Polystyrene features in Sydney Biennale Artwork
Showcasing unique work using unique shapes and forms, the 18th Biennale of Sydney art festival opened today, exhibiting the works of 100 artists from 44 countries.
One of the largest displays is by artist Peter Robinson and features Foamex Styroboard EPS expanded polystyrene shapes and blocks. The display is called Snow Ball Blind Time. Foamex supplied the cut chain links to size that link the pieces together in the instillation.

#### Foamex responds to latest Victorian Building Authority ban of cladding products
The latest decrees for cladding systems used in the residential building market recently issued by the Victorian Building Authority (VBA) have taken the building industry by surprise. These new regulations will only add to the confusion for builders, specifiers and customers of these types of products. There needs to be increased clarity around cladding products to ensure that lingering confusion is cleared up.
The VBA, which regulates Victoria’s building sector, issued an alert in February this year stating that CertMark International had withdrawn nine certifications for cladding systems which are commonly used on low-rise residential housing. CertMark International is the agency that the Australian Building Codes Board (ABCB) relies upon to determine whether building products are compliant.

#### Foamex response to Victorian ban on EPS for high rise buildings
Last month, the Victorian Cladding Taskforce delivered an interim report calling for bans on certain cladding products for multi-storey buildings.  Aluminium Cladding Panels with a polyethylene core of more than 30 per cent, like what was found in the Grenfell and Melbourne Lacross building fires, will be banned on all multi-storey buildings in Victoria.  The polyethelene bears no relationship to the expanded polystyrene (EPS) products manufactured by Foamex.  However, the Taskforce have concluded that expanded polystyrene will be banned on multi-storey buildings.
Expanded Polystyrene (EPS) manufactured by Australian company Foamex complies with Australian building standards, it has never been linked to the horrendous outcomes mentioned above of using polyethylene in high rise buildings. Yet it has been put into the same category as polyethylene, a material with different combustible qualities than expanded polystyrene.

#### Foamex Styroboard XPS contributes to Canberra’s first Passivhaus project
The Jerrabomberra Tennis Facility is a showcase of Passive House (German: Passivhaus) and Low-e technologies encapsulated within a factory pre-fabricated high-performance building.
Laros Technologies completed the tennis facility, affectionately known as the architectural esky, as a pro-bono project and showcased the complete suite of Passivhaus solutions. As such, they invited Foamex to assist with the supply of 200-m2 of 50mm high-performance Foamex Styroboard XPS rigid insulation board as seamless under-slab insulation solution for this simple but special building.

#### Foamex supports Moomba Birdman Rally competitor raising funds for melanoma research
Peter participated in the iconic rally to raise money for the Morgan Mansell Fund which was established to carry on his daughter Morgan’s mission to do what she could to support research into finding a cure for the diseases that not only afflicted her but many others throughout the world.
Peter and Julie Mansell’s bright and vivacious 25-year old daughter, Morgan, passed away in October 2018 after a long and valiant battle against melanoma.
“Through the Morgan Mansell Fund, we aim to undertake one major fundraising event each year. We actually entered the Moomba Birdman Rally last year but it was cancelled due to COVID, so we’re very happy that it went ahead this year.
“Our daughter Morgan had a great sense of fun and she’d be laughing to hear that I’m participating in the rally. She’d also be embarrassed, but overall happy that I’m carrying on her legacy,” said Peter.
The Birdman Rally is a competition for home-made gliders, hang gliders and human-powered aircraft, and all participants nominate a charity. Competitors who are categorised as ‘fly’ or ‘flop’, leap off a platform into the Yarra River, aiming to be the victor and ‘fly’ furthest into the drink of the awaiting river.

#### Foamex supports national audit into cladding materials
In the wake of the Grenfell disaster in London and similar Melbourne Lacrosse building fire in 2014, the Australian media and local and state Government bodies have been driving investigations into potential buildings in Australia that could face the same dangers.
The material in question in the Grenfell disaster and the Melbourne Lacrosse building was aluminium sheeting bonded to a polyethylene core (PE). The use of polyethylene core (PE) has been linked to major building fires in other countries.
Not to be confused with polyethylene, all Foamex polystyrene building products have a fire retardant component built into them; which means when the panels are exposed to a small flame source, they will shrink away from the naked flame.
Structured Project Management director Peter Blair spoke at a recent strata fire safety forum in Sydney. “For every 10 apartment blocks in Australia with aluminium cladding, around eight face the risk that they’re covered in the highly combustible materials that caused the Grenfell fire in London.” he said.
The dangerous cladding usually comes in from overseas, isn’t well understood, and is sometimes even certified fraudulently.
Foamex expanded and extruded polystyrene are manufactured locally to stringent Australian building standards, and approved by BRANZ.
Foamex have supplied polystyrene for insulation material to the building and construction industry for over 30 years, and fully warrants its products to have a fire-retardant additive polymerised into the raw material formulation.
What’s being done?
A Senate committee has been set up to investigate the use of cladding material on Australian buildings in the wake of the deadly Grenfell tower fire.
The committee chair, Labor senator Chris Ketter, said the Grenfell tragedy was a “timely reminder” that the Parliament had a responsibility to stop a similar disaster in Australia.
He said the main risk was that some construction companies used cladding products which were not meant to be used for high-rise buildings.
“I’m very concerned by the lack of progress in this area. We do have a patchwork of regulations in this country … so there’s always a possibility that something slips through the cracks,” Senator Ketter said.
In Victoria alone, planning and fire experts estimate there are more than 5,000 buildings that contain non-compliant cladding similar to the cladding that was on the Grenfell Tower .
The Victorian Government has appointed a taskforce to fast-track the investigation into flammable cladding on the state’s buildings in the wake of the deadly London tower fire.
The taskforce — co-chaired by former Liberal premier Ted Baillieu and former Labor deputy premier John Thwaites — will audit buildings to ensure they adhere to safety standards.
Mr Thwaites said the State Government was concerned the building codes were not working and action was not happening fast enough.
“The advice from various fire authorities is that there is, right around Australia, widespread non-compliance with the building code.
“There has to be a system of compliance or people aren’t going to be safe.”
The specific material in question in the Grenfell Tower disaster was Reynobond PE which contains a polyethylene core between two aluminium sheets, which has limited fire retardant qualities.

#### Foamex supports responsible waffle pod practices
As a long-time member of EPSA, Foamex strongly supports recent EPSA messaging regarding the requirements for the safe storage, transportation and onsite management of EPS waffle pods in line with the EPSA code of conduct.

#### Foamex takes another step towards sustainability as a member of StyroCycle for expanded polystyrene recycling
Foamex, the leading provider of expanded and extruded polystyrene building products, is thrilled to announce its partnership with EPSA’s (Expanded Polystyrene Australia) new expanded polystyrene recycling initiative, StyroCycle, where expanded polystyrene (EPS) is recycled and used to manufacture new products like building insulation.
Through StyroCycle, and its network of drop-off bins, households and small businesses now have a genuine option to responsibly dispose of expanded polystyrene packaging waste to be recycled back into useful products. This significant step marks Foamex’s commitment to a circular economy, supporting environmental responsibility and sustainable practices within the industry.
 

#### Foamex’s EPE sheets used for Melbourne White Night Festival
Melbourne-based artist Joe Blanck is a huge fan of expanded polyethylene sheets (EPE sheets) supplied by Foamex after using them to craft a large-scale art installation for last year’s White Night Festival in Melbourne.
Joe used Foamex EPE sheets to create The Guardian, a large (10m x 4.5m) creature reminiscent of a giant lion, which he calls his, “largest and most ambitious creature to date”. Impressive in both size and intricate detail, The Guardian was a showstopper at White Night Melbourne 2019.
Festival organisers approached Joe with a very open brief. They wanted the wow factor and it had to be bigger and better than the previous creature called The Messenger, featured in the 2018 White Night Festival.
“I actually discovered EPE foam sheets a few years ago when I unwrapped an electronics product that was packaged in it,” he explains. “It appeared to be lightweight, flexible, and strong.
“For these types of large-scale puppets like The Guardian we’d previously used fibreglass, which is heavy, hard to work with, and gives off nasty chemicals.”
 

#### From Insulation to Architectural Profiling: How Recycled Polystyrene is Redefining Sustainable Design
Australia’s building and design industries are proving that sustainability and innovation can go hand in hand. Through a shared commitment to recycling and circular manufacturing, Foamex, StyroCycle, and The Cornice Store are showing how expanded and extruded polystyrene (EPS and XPS) can live multiple lives — from protective packaging to high-performance insulation and now, decorative interior products.
This collaboration demonstrates that recycled polystyrene has far more potential than waste management alone. It can be reshaped, repurposed, and reimagined into materials that perform, protect, and beautify Australian homes.

#### Graphite insulation for under floors in colder climates
Foamex has been manufacturing and selling the popular Expol White polystyrene underfloor insulation for over 15 years. It suits the cool temperatures of most Australian climate zones, but some areas need a little more. That’s where Expol Black thermal floor insulation comes into play.
Expol Black is 30 percent more efficient and has a higher thermal resistance, making it better for climates with extreme temperatures. Its R-value (thermal resistance rating) increases from R1.4 for Expol White to R1.8 for Expol Black.
It earned its name because it contains graphite, which is added to the expanded polystyrene (EPS), giving it a charcoal colour. Expol Black has been sold in New Zealand for many years, so adding it to the range and manufacturing it in Australia makes sense.

#### High compressive strength of polystyrene confirmed
The use of building materials has changed from one material to another over time thanks to ongoing technological advancements. This has led to the production and use of polystyrene blocks in building construction.
One of the most important properties of Expanded Polystyrene (EPS) as a building product is its resistance to compressive stresses, which increase as the density becomes higher. [1]
The compressive strength of expanded polystyrene is high which has been confirmed in numerous studies and reports. Specifically, the findings of a 2013 study on the compressive strength of expanded polystyrene via axial loading[2] revealed, “that the strength of an expanded polystyrene slab is good and can carry both the dead and live load of a building which is basically what every building should strive for.”.”
The findings also indicated that the compressive strength of expanded polystyrene block either through axial loading or crushing was high which means that it is a good material to specify in the construction industry as it meets the basic requirements of building material.

#### How Can EPS Insulation Be Used in Walls, Roofs and Floors?
 
When builders specify insulation, the real question is how it performs once the building is lived in. Foamex manufactures EPS insulation that integrates into wall, roof and floor systems with consistency across the envelope. This guide answers ‘What Are the Main Applications of EPS Insulation in Buildings?’,  and explains how the same material supports comfort, durability and safety when detailed correctly.

Wall systems that stabilise internal temperatures.
Roof assemblies that reduce heat gain and loss.
Floor applications that limit thermal leakage below.
Lightweight panels that simplify handling.
Durable boards designed for long service life.

Step inside many Australian homes and a familiar problem appears.
Floors feel cold underfoot.
Roof spaces overheat by midday.
Internal rooms swing between extremes.
These issues rarely come from one failure. They build from gaps across the structural envelope. EPS insulation, when used correctly, closes those gaps with a material that behaves predictably across different assemblies.
Expanded polystyrene boards work because they trap still air within a closed-cell structure. That structure limits heat transfer, resists moisture uptake and maintains shape under load. In practical terms, builders gain a lightweight insulation material that suits multiple zones without forcing separate products for every surface.
EPS Insulation in Wall Systems 
Walls form the largest exposed surface area of a building. Poorly insulated walls bleed comfort continuously. EPS boards installed within framed walls, cavity systems, or external insulation assemblies reduce that transfer and stabilise internal conditions.
In external wall applications, StyroSheet EPS Panels act as durable building panels that support continuous insulation lines. This continuity matters. The NCC highlights that insulation performance depends on uninterrupted installation rather than nominal R-values alone.
EPS also contributes to acoustic insulation solutions by dampening sound transmission through wall cavities. Traffic noise softens, internal echoes reduce and rooms feel calmer and more controlled.
Reducing Heat Stress, Top Down
Roof spaces absorb brutal heat loads during Australian summers. Without proper insulation, that heat drives downward all afternoon. EPS insulation boards installed above ceilings or within roof assemblies limit radiant and conductive heat flow before it reaches living spaces.
Because EPS remains dimensionally stable, it resists sagging and compression that reduce real-world performance over time. That stability supports fire-resistant insulation system design when combined with compliant linings and finishes specified under Australian Standards.
YourHome guidance reinforces that insulation must retain thickness and placement to maintain effective performance over decades, not seasons.
Floor Systems and Under-Slab Performance
Heat loss does not stop at walls and roofs. Floors leak energy constantly, especially in suspended timber homes and slab-on-ground construction without perimeter insulation.
EPS insulation installed beneath slabs or between floor joists reduces thermal leakage downward. The result feels immediate with warmer surfaces, reduced drafts and far less reliance on mechanical heating. In engineered floor systems, EPS boards also handle compressive loads without deformation when specified correctly.
Installation Principles That Protect Performance
Homeowners often ask ‘How Is EPS Insulation Installed in Residential and Commercial Projects?’ The answer stays simple but strict. Correct installation protects performance; shortcuts erode it.
Key principles include:

Maintain full board contact with framing or substrates.
Seal joints to prevent air movement.
Protect exposed edges from UV and weather.
Follow system specifications for fixings and coatings

EPS insulation rewards care. A clean install preserves thermal, acoustic and structural benefits for decades.
Durability, Safety and Long-Term Value
What makes EPS insulation durable and long-lasting comes down to material behaviour:

EPS does not rot.
It resists moisture absorption.
It retains shape under sustained load.
And, when incorporated into compliant systems, it supports building safety and performance without degradation.

Fire-resistant insulation performance depends on system design rather than raw material myths. EPS products manufactured to Australian Standards include flame retardant additives and rely on protective layers to meet code requirements. Correct specification aligns performance with compliance, not marketing claims.
FAQs on EPS Insulation
What Are the Main Applications of EPS Insulation in Buildings?
The main applications of EPS insulation in buildings include wall systems, roof and ceiling assemblies and floor or under-slab insulation where consistent thermal control is required.
Can EPS Insulation Be Used for Wall, Roof and Floor Systems?
EPS insulation can be used for wall, roof and floor systems when specified to suit load conditions, moisture exposure and installation requirements under Australian building standards.
How Does EPS Insulation Contribute to Building Safety and Performance?
EPS insulation contributes to building safety and performance by maintaining thermal stability, resisting moisture, supporting acoustic control and performing reliably within compliant system designs.
Call the Foamex team for EPS insulation guidance on walls, roofs & floors today.

#### How Do Custom EPS and XPS Foam Solutions Support Sustainable Construction in Australia?
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.

#### How EPS Panels Can Simplify Prefabricated Home Construction
On most prefab jobs, the pressure shows up in the program first. Foamex supplies EPS panels (StyroSheet EPS sheets) that help prefabricated home construction move with more control, less weight and fewer surprises once components arrive on site. This article:

Looks at speed, handling and factory-ready accuracy.
Connects panel choice to thermal performance and running costs.
Shows where lighter materials reduce pressure on site teams.
Explains why panel performance still matters after handover.

Prefabricated homes only save time when the parts arriving on site are easy to handle, consistent to install and reliable once the build is closed in. When they are not, installation takes longer and the time advantage starts to disappear. That is where EPS panels earn their keep. As a lightweight rigid foam, they are easy to move, position and cut accurately, which helps factory output and site installation stay aligned. Foamex manufactures Australian-made EPS and XPS in-house and supplies precision-cut solutions for construction applications across Australia.
Why Panel Weight Changes the Build
Heavy materials slow down prefab work in practical ways. They take longer to move, take more effort to place and adjust on site, and they affect transport loads and lifting requirements, which can complicate sequencing. Foamex describes Styroboard EPS as a closed-cell material made from about 98 per cent air and 2 per cent polystyrene. That mix explains why it is light but still rigid enough for building use, easier to handle in the factory and easier to work with during installation.
Thermal Performance Needs to Be Built In Early
Prefab homes still rely on a well-performing building envelope. If insulation is weak, heating and cooling demand rise and indoor temperatures become harder to control after handover. Thermal insulation boards slow heat moving through the building, and the right selection depends on climate zone and how the building will be used. These decisions are best locked in before panels are manufactured, not adjusted later.
For a prefab project, this usually involves:
Confirming the panel build-up suits the climate zone and energy target.
Checking that joints and service penetrations will not interrupt the insulation layer.
Selecting materials that can be cut accurately in the factory and installed cleanly on site.
Matching panel placement to areas with higher thermal load.
Where EPS Panels Help Most
Prefab jobs run more smoothly when prefabricated building panels arrive consistent in size, density and performance, which reduces on-site adjustment and helps installation stay on sequence. Foamex StyroSheet EPS sheets are used for lightweight insulation in wall and roof builds, supporting thermal performance while holding their shape during installation.
There is also an acoustic side to consider. EPS on its own is not a complete soundproofing material, but it contributes to how the full wall or roof system performs alongside the right linings and cladding. This becomes relevant for prefab homes near roads, schools or denser suburban areas. EPS should be specified as part of a system, not as a stand-alone solution.

Durability, Recycling and Low-Carbon Thinking
Lightweight materials still need to last. Foamex EPS and XPS are recyclable through Foamex recovery programs, and the business supports closed-loop recycling by using recovered material in new products where product-specific evidence supports it. On energy, Australian Government guidance (yourhome.gov.au and energy.gov.au) indicates insulation in roofs, walls and floors can significantly reduce heating and cooling costs. By slowing heat moving through the envelope, EPS panels reduce how much energy a prefab home needs before solar is added, helping keep long-term running costs under control.
FAQs on EPS Panels
How do EPS panels reduce noise in buildings?
EPS panels contribute acoustic performance within the wider wall or roof assembly, especially when paired with the right linings and cladding.
Can EPS panels be used in green roof installations?
EPS panels are more common in walls and prefabricated assemblies. For green roofs, Foamex positions XPS products such as StyroRoof, which offer the moisture resistance and compressive strength those assemblies need.
What makes EPS panels suited to prefabricated homes?
They are lightweight, easy to cut accurately and effective in insulation-focused building systems, which keeps factory output and site installation aligned.
How long do EPS panels last in commercial buildings?
EPS panels can last for the life of the assembly when it is designed and installed correctly for load, moisture and exposure conditions.
Can EPS panels improve energy efficiency when combined with solar systems?
Yes. Lowering heat flow reduces energy demand first, so solar covers a smaller remaining load.
Speak to Foamex about EPS panels that keep prefab construction moving on site.

#### How is Expanded Polystyrene manufactured?
Expanded polystyrene (EPS) is made by expanding small polystyrene beads with steam, allowing them to stabilise, then fusing them in a mould. The mould produces either a finished shape or a block that can be cut into sheets and profiles. The result is a lightweight, rigid foam with air held inside its closed cells.
The five stages
1. The raw bead
The process starts with expandable polystyrene beads. Polystyrene is produced by polymerising styrene monomer, and the beads contain pentane as a blowing agent. Pentane helps the beads expand when heated. EPS production does not use CFCs, HFCs or HCFCs.
Raw beads are compact granules. Their cellular foam structure develops during the next stage.
2. Pre-expansion
Steam heats the beads in a pre-expander. As the polystyrene softens and the pentane vaporises, each bead expands to form a network of small, closed cells.
Controlling expansion helps the manufacturer achieve the required density. Greater expansion produces a lower-density material; less expansion produces a denser material. Density strongly influences performance, but the finished grade must also meet its specified physical properties.
3. Maturing
The expanded beads are held in ageing chambers to cool and stabilise. Air diffuses into the cells as internal pressure equalises, preparing the beads for moulding.
Drying and conditioning prepare the beads for consistent moulding.
4. Moulding
The conditioned beads are loaded into a mould and heated with steam again. They expand further and fuse together, taking the shape of the mould.
Block moulding produces large blocks for cutting into sheets, insulation boards and custom profiles. Shape moulding produces items such as waffle pods, protective packaging and boxes directly in a shaped mould.
After moulding, the EPS is cooled and allowed to dry and stabilise before further processing.
5. Cutting and finishing
Hot wires cut blocks into sheets and boards. Profile cutting creates shaped components for specific applications. Depending on the product, further processing may include lamination, coating or assembly. Production offcuts are recovered for recycling.

How EPS grades relate to manufacturing
EPS is specified by grade because different applications require different physical properties. Nominal density is a useful reference, but it does not replace the grade’s performance data.
AS 1366.3-1992 sets minimum properties for six EPS classes: L, SL, S, M, H and VH. Foamex describes Styroboard EPS as manufactured to meet the requirements of this standard. VVH 32, VVH 36 and VVH 38 are additional Foamex grades outside those six classes.

Grade
Nominal density (kg/m³)
Compressive stress at 10% deformation, min. (kPa)
Thermal resistance at 50 mm, min. (m²K/W)

L
11
50
R1.0

SL
13.5
70
R1.20

S
16
85
R1.22

M
19
105
R1.25

H
24
135
R1.40

VH
28
165
R1.41

VVH 32
32
250
R1.43

VVH 36
36
300
R1.45

VVH 38
38
350
R1.50

The table gives Foamex’s published Styroboard EPS figures. Compressive stress at 10% deformation is tested to AS 2498.3. Thermal resistance is reported for a 50 mm sample at a mean temperature of 23°C under AS/NZS 4859.1:2018. These specifications apply to StyroSheet and StyroBloc, not automatically to every moulded EPS product.
A compression-test result is not an allowable design load. The data sheet also lists results at 1% and 5% deformation, but those figures should not be adopted as working loads without an engineering assessment. For load-bearing applications, ask the structural engineer to confirm the grade and request the relevant data from Foamex.
Choosing grade and thickness together
In the table, minimum compressive stress at 10% deformation rises from 50 kPa for L grade to 350 kPa for VVH 38. Minimum R-value at 50 mm also rises, from R1.0 to R1.50. Grade therefore affects both compression performance and thermal resistance.
For an insulation specification, check the required R-value against the selected grade and thickness. For a loaded application, check compression performance as well. Increasing thickness can provide more thermal resistance, but it does not remove the need to select a suitable grade.
Waste and recycled content
Foamex recovers and reprocesses offcuts generated during manufacture into new polystyrene products. Recovered EPS can also be used as a feedstock, with recycled-content options depending on the product. Confirm the recycled content of the product being ordered rather than applying one percentage across the range.
Fire performance
Foamex’s Styroboard EPS building products use fire-retardant raw material. This does not make EPS non-combustible or give a completed wall or roof a fire-resistance rating. The data sheet reports flame-propagation testing to AS 2122.1; the specified building system must meet the fire requirements of its intended use.
What this process produces at Foamex

polystyrene sheets and boards, cut from moulded blocks
EPS foam blocks for cutting and custom profiling
EPS waffle pods, moulded for waffle pod slab construction
geofoam civil void fill for lightweight fill applications
EPS boxes for protective and temperature-sensitive transport

Contact Foamex with the application, dimensions and required performance to discuss the appropriate product. Use the product-specific documentation when preparing a specification.

Frequently asked questions
What is EPS made from?
EPS is made from polystyrene beads containing pentane as a blowing agent. Steam expands the beads before they are fused in a mould. The finished foam contains air within its closed cells.
Are ozone-depleting blowing agents used to make EPS?
EPS production does not use CFCs or HCFCs. EPSA also states that the process is HFC-free. Pentane is used to expand the beads.
What does the EPS grade mean?
Grade identifies a set of physical properties, including compression performance. Foamex’s technical data lists nominal densities from 11 kg/m³ for L grade to 38 kg/m³ for VVH 38. Specify the required grade and performance, not density alone.
What is the difference between EPS and XPS?
EPS is made by expanding and moulding beads. XPS is produced by extrusion as a continuous foam board. Both are rigid, closed-cell insulation materials, but their thermal and compression performance must be checked for the specific product and thickness.
Is EPS recyclable?
Yes. Clean EPS can be collected and reprocessed into new products. Keep offcuts separate from other waste and confirm the recycler’s acceptance requirements before arranging collection.
How is EPS density controlled?
Density is controlled through the expansion process. The amount of expansion changes how much polystyrene is present in a given volume of foam. Finished-product performance must still be checked against the specified grade.

Sources

Foamex Styroboard EPS Technical Data Sheet 2025
EPSA How expanded polystyrene is made
Foamex Styroboard EPS brochure
Foamex recycling services and acceptance requirements
Foamex manufacturing and offcut recovery
EPS Industry Alliance Properties Performance and Design Fundamentals

#### How to Choose the Right Custom Foam Manufacturer for Your Project in Australia
Bottom line: Choosing a custom foam manufacturer in Australia comes down to five practical checks: the right material (EPS or XPS), proven in-house manufacturing capability, documented Australian Standards and National Construction Code compliance, a product range that matches your application, and reliable quality control and delivery. Foamex is a family-owned Australian manufacturer of EPS and XPS, operating across five states, with in-house CNC and precision cutting, an Australian delivery fleet and a partnership with the StyroCycle EPS recycling scheme.
EPS vs XPS at a Glance

Feature
EPS (Expanded Polystyrene)
XPS (Extruded Polystyrene)

Best for
Wall and underslab insulation, civil void fill, waffle pods, packaging and custom cut shapes.
Slab edge insulation and applications with higher load or moisture exposure.

Strength range
Low-density insulation grades through to high-strength engineered grades.
Generally higher compressive strength at equivalent density.

Moisture
Resists liquid water. Specify drainage and vapour-permeable detailing in cool climates.
High moisture resistance suitable for slab edges and in-ground applications.

Standard
AS 1366.3 (rigid cellular polystyrene, moulded).
AS 1366.4 (rigid cellular polystyrene, extruded).

Foamex range
StyroSheet, Styroboard EPS, StyroPod waffle pods, GeoFoamX, StyroPak, Insulclad (NSW only).
Styroboard XPS, including StyroTherm, StyroRoof, StyroLink.

Not sure whether EPS or XPS suits your project? Speak with the Foamex team or call 1300 AU FOAM (1300 283 626) for product selection and specification support.
1. Match the Foam Type to the Application
Before shortlisting a manufacturer, define the material (EPS or XPS), the end use (insulation, void fill, geofoam, packaging or load-bearing applications) and the performance brief (density, compressive strength, moisture resistance and R-value).
Best for: EPS suits cost-effective insulation, lightweight void fill and packaging. XPS suits slab edges and load-bearing or moisture-prone applications where higher compressive strength is the deciding factor.
2. Look for In-House Manufacturing Capability
A reliable custom foam manufacturer should be able to demonstrate:

CNC precision cutting for complex shapes and tight tolerances.
Hot-wire cutting and moulding for bespoke profiles and one-off panels.
Multiple Australian production sites for scale and lead-time control.

Foamex has been family-owned and manufacturing in Australia since 1982 and operates production sites across five states, with in-house CNC and precision cutting for both large production runs and one-off requirements.
3. Confirm Australian Standards and NCC Compliance
Foam products used in Australian construction need to align with the relevant Australian Standards and the National Construction Code (NCC):

AS 1366.3 covers moulded rigid cellular polystyrene (EPS).
AS 1366.4 covers extruded rigid cellular polystyrene (XPS).
NCC 2025 introduces tightened thermal performance and condensation management provisions.
Project-specific NatHERS, BASIX (NSW) and fire compliance pathways still apply.

Reputable manufacturers supply product data sheets and material certifications. Confirm specifics with the project designer, energy assessor, certifier or fire engineer.
4. Assess Product Range Across Your Applications
A capable manufacturer should cover more than one application. The Foamex product range includes:

StyroSheet and Styroboard EPS: versatile EPS sheets for wall, roof, slab and general insulation.
Styroboard XPS: XPS sheets, including the StyroTherm range, for slab edges, perimeter insulation and load-bearing applications.
StyroPod: EPS waffle pod system for efficient slab construction.
GeoFoam and GeoFoamX: lightweight EPS blocks for civil engineering void fill and landscape works.
StyroPak: EPS boxes for fresh, fragile or temperature-sensitive packaging.
Insulclad: rendered EPS wall cladding system, manufactured by Foamex NSW and available in NSW only.

5. Check Quality Control and Delivery
Specification is only half the picture. Confirm how the manufacturer controls quality and gets product to site.

Quality factor
What to ask for

In-house testing
Records for density, thermal resistance and compressive strength.

Batch traceability
Quality documentation tied to each production batch.

Logistics
Manufacturer-controlled fleet versus third-party freight, plus lead-time visibility.

Foamex maintains in-house quality testing and operates its own delivery fleet across Australia to support project timelines.
6. Prioritise Sustainable Manufacturing
Look for manufacturers that:

offer EPS recycling drop-off or take-back options.
use recycled EPS content where product-specific evidence supports it.
participate in industry recycling initiatives.

Foamex is a member of the StyroCycle EPS recycling scheme, with drop-off points in Victoria and South Australia for clean EPS recovery and reprocessing into new products. Several Foamex sites also draw on wind and solar power.
7. Focus on Long-Term Value, Not Just Price

Value factor
What good looks like

Material recommendations
Performance-based product selection, not just stock availability.

Technical support
Consultation, prototyping and panel sizing for non-standard requirements.

Project support
Specification, installation and on-site coordination through the project.

Long-term performance
Documented compliance, durability and a clear end-of-life pathway.

Work With Foamex
Looking for a custom foam manufacturing partner for your next project? Contact Foamex to discuss material selection, custom sizing and Australian-made EPS and XPS solutions, or call 1300 AU FOAM (1300 283 626).
Frequently Asked Questions
Should I choose EPS or XPS for my project?
EPS suits wall, roof and slab insulation, void fill, waffle pods and custom panels. XPS suits slab edges and load-bearing or moisture-prone applications. The right choice depends on the assembly, the R-value target and any moisture exposure.
Are Foamex EPS and XPS products Australian-made?
Yes. Foamex has been family-owned and manufactured in Australia since 1982, with sites across five states. Insulclad is supplied in NSW only; the wider EPS and XPS range is available nationally.
Do Foamex products meet Australian Standards and the NCC?
Foamex EPS and XPS products are manufactured to align with AS 1366.3 (moulded EPS) and AS 1366.4 (extruded XPS). NCC, NatHERS and BASIX outcomes depend on the assembly. Confirm with the project designer, energy assessor or certifier.
Can Foamex deliver custom shapes and sizes?
Yes. Foamex offers CNC and hot-wire cutting for custom EPS and XPS shapes, panels and profiles across multiple Australian sites.
Are Foamex EPS products recyclable?
Yes. Foamex is a member of the StyroCycle EPS recycling scheme and operates drop-off points in Victoria and South Australia for clean EPS recovery.

#### How Waffle Pod Suppliers Are Adapting to Australia’s Extreme Weather Conditions
Quick answer: A waffle pod supplier provides the expanded polystyrene (EPS) void formers used to build a stiffened raft slab. The pods sit in a grid on a prepared base, concrete is poured around and over them to form reinforced ribs and a top slab, and the result uses around 25 to 40 per cent less concrete than a traditional slab of equivalent footprint. Foamex manufactures StyroPod EPS waffle pods in Australia in a 1090 mm by 1090 mm format, in 150 mm, 225 mm, 300 mm and 375 mm heights. Pod height is set by the structural engineer to suit the site classification and slab design under AS 2870-2011, not chosen from a default. A good supplier matches the pod to the engineered design, delivers consistent product that holds geometry through the pour, and provides the specifications builders and certifiers need.
Slab performance is set before the pour, by how the site is prepared and which materials are specified. Heat affects curing, rainfall changes ground moisture, and reactive soils move over time. Choosing a waffle pod supplier is part of managing that risk: the pods have to suit the engineered slab and perform once installed.
What does a waffle pod supplier provide?
Builders and engineers rely on a supplier to deliver pods that suit the site and hold up through construction. In practice that means EPS pods that stay stable during setup, support an accurate reinforcement layout and keep their geometry through the pour. Consistent manufacture is what makes the finished slab predictable.
How Australian site conditions shape slab decisions
Site conditions vary across Australia. The National Construction Code sets climate zones, and AS 2870-2011 classifies sites by soil reactivity, from Class A (stable) through to Class E (extremely reactive) and P (problem sites). Soil classification, moisture behaviour and temperature range all influence how the slab is designed and how the pods perform. Pod height and slab design follow the engineered classification, not a default specification.
How EPS waffle pods support the slab
EPS waffle pods are lightweight void formers. Laid in a grid on a prepared base, they create a ribbed raft slab while replacing non-structural concrete volume. Foamex manufactures StyroPod EPS waffle pods in Australia in a 1090 mm by 1090 mm format, in 150 mm, 225 mm, 300 mm and 375 mm heights, so the pod can be matched to the site classification and slab design rather than forced from a standard size.
Do waffle pods add thermal performance?
By forming insulated voids beneath the slab, EPS waffle pods reduce heat transfer between the ground and the floor. They contribute up to around R1.0 of under-slab thermal resistance, depending on pod height and configuration. Australian Government guidance (yourhome.gov.au) recommends slab-edge and under-slab insulation in colder climates, and wherever in-slab heating or cooling is installed. The pod contribution is part of a whole-of-building envelope, assessed alongside wall, roof and glazing performance under NatHERS or BASIX.
How waffle pods reduce material use and embodied carbon
A waffle pod slab uses around 25 to 40 per cent less concrete than a traditional slab of equivalent footprint and classification. Less concrete lowers material demand, eases handling on site and can reduce the embodied carbon in the slab. Foamex can incorporate recycled content where product-specific evidence supports it, and runs an offcut take-back program so clean EPS is reprocessed into new product rather than sent to landfill.
How to choose a waffle pod supplier
For builders and specifiers, on-site performance drives the choice. The pods need to install cleanly, align with the engineered slab design and hold geometry through the pour. Look for an Australian manufacturer that supplies consistent product, matches the pod to the site, and provides the specifications your engineer and certifier need. Pod height and layout are always confirmed by the structural engineer under AS 2870-2011.

Frequently asked questions
Which waffle pod suppliers in Australia offer the most durable EPS pods?
Durability comes from consistent EPS density and dimensional accuracy. Look for an Australian manufacturer producing to a controlled grade and format, like StyroPod’s 1090 mm by 1090 mm pods in 150 to 375 mm heights, so the pods hold shape during reinforcement placement and the pour.
How do I choose the right waffle pod supplier for my project?
Match the supplier to the engineered slab design. The pods should suit the AS 2870-2011 site classification, stay stable during installation, and come with the product specifications your engineer and certifier need to sign off the slab.
What are the benefits of buying waffle pods from Australian suppliers?
Local manufacture means reliable supply, pods built for Australian site classifications and standards, and shorter lead times than imported product. Australian-made StyroPod also carries an offcut take-back path for clean site waste.
Where can builders find good-value waffle pod suppliers?
Value sits in reduced concrete volume, around 25 to 40 per cent less on an equivalent slab, plus cleaner installation and fewer slab issues later. Compare delivered cost across pod supply, concrete saving and labour, not headline pod price alone.
Why are waffle pod systems used instead of traditional concrete slabs?
On reactive, engineered sites a waffle pod raft spreads ground movement across the footprint and uses less concrete than a traditional slab of equivalent classification. The structural engineer confirms whether a waffle pod slab or a traditional slab suits the site under AS 2870-2011.

Contact Foamex for StyroPod specifications and pod height guidance for your slab design.

#### How XPS Insulation in Australia Can Help Reduce Your Energy Bills
Foamex manufactures durable XPS insulation boards engineered for slabs, roofs and moisture-prone areas. When XPS insulation is specified and installed correctly in key junctions, it can help steady indoor temperatures and reduce heating and cooling demand. If you ask, “Can XPS insulation help reduce heating and cooling costs in Australia?”—it can, particularly when it limits heat flow through slab edges and other detailing where energy commonly leaks.

Reduces thermal bridging at slab edges and perimeter detailing.
Holds performance in damp zones with closed-cell water resistance.
Supports tighter, more predictable indoor comfort across seasons.
Supports NCC-aligned detailing and predictable thermal performance when specified correctly.

In Australia, energy bills can climb quickly when heat moves through the building envelope, especially at slab edges, junctions and other thermal bridges. If insulation is poorly detailed, compressed, or exposed to moisture, gaps form and HVAC systems work harder to maintain a stable indoor temperature.
That’s why engineers, architects and specifiers often turn to XPS insulation, Australia for high-demand areas: it delivers reliable thermal performance with closed-cell moisture resistance and compressive strength, helping maintain continuity where weaker materials can be compromised.

What XPS Brings to the Job
When used as part of a well-detailed insulation system, Extruded Polystyrene (XPS) insulation can help lower heating and cooling demand by reducing heat transfer through concrete and masonry junctions. It is also specified in performance-focused roof assemblies where continuity matters – for example, XPS purlin roof spacers.
The National Construction Code (NCC) sets expectations for insulation performance and installation. Under the NCC 2022 Housing Provisions – Building Fabric, where insulation is required, the build must comply with AS/NZS 4859.1 and be installed to abut/overlap adjoining insulation and maintain continuity of the thermal barrier — avoiding gaps that undermine performance.
Where StyroTherm XPS Sheets Fit Best
StyroTherm XPS Sheets are designed for high-demand parts of a build where moisture, compression and long service life matter. Common slab applications include perimeter edge insulation, where the exposed slab edge can become a major pathway for heat loss in winter and heat gain in summer if it is not insulated and detailed for continuity.
StyroTherm is also well suited to under-slab applications, including sheets installed over prepared soil pads (and beneath membranes and reinforcement as specified). In these zones, XPS is chosen for its compressive strength and closed-cell moisture resistance, helping it maintain shape and thermal performance under load and in contact with damp ground conditions.

Beyond slab work, XPS is also used in commercial roofing systems as purlin roof spacers on metal deck roofing, helping improve insulation continuity and reduce thermal bridging at roof support points.
This is where energy-efficient materials earn their reputation: they deliver more predictable performance when conditions are tougher. StyroTherm XPS can also support sustainability goals when you specify Australian-made boards with recycled content and arrange approved recycling pathways for clean offcuts (availability can vary by location and project logistics).
Installation Details That Protect the Result
Install with tight tolerances and continuous coverage to protect the thermal performance. Cut boards cleanly, run tight joints and avoid leaving exposed edges that invite water or UV damage. Seal penetrations, keep adhesive and tapes compatible with the system and protect below-ground boards with appropriate membranes as your designer specifies.
Use a simple on-site check before you close anything up:

Joints tight, no daylight gaps.
Edges protected from UV and water exposure.
Penetrations sealed and compatible with the assembly.
Continuity maintained at slab edge, corners and junctions.

If you are unsure on R-values, the Australian Government Your Home guide explains how R-value relates to heat flow direction and why continuity matters.
The Payoff You Feel Daily
Good insulation does more than shave a bill. It steadies internal temperature, reduces drafts and takes the aggression out of peak summer afternoons. A strong XPS layer at the slab edge and critical junctions can cut the hidden losses that keep systems running longer than they should. The result reads as comfort first, then lower running costs that keep showing up in the monthly statement.
FAQs on XPS Insulation, Australia
What are the benefits of XPS insulation in Australia?
Benefits include stable R-values, compressive strength and water resistance in damp or load-bearing zones.
How does XPS insulation improve energy efficiency in homes?
XPS improves energy efficiency when it closes thermal bridges at slab edges and junctions, reducing heat flow.
Which XPS insulation products are best for Australian climates?
Choose XPS boards rated to AS/NZS criteria and suited to the assembly; StyroTherm XPS Sheets fit foundations and rooftops.
Can XPS insulation reduce heating and cooling costs in Australia?
It can help—when it’s detailed and installed with good continuity, it reduces heat loss and heat gain at thermal bridges, which can lower HVAC run time and peak demand.
How do I install XPS insulation in Australian residential buildings?
Install boards with tight joints and maintained continuity, seal penetrations and protect exposed edges from prolonged UV and site damage. Follow the project documentation (architect/engineer details) and manufacturer instructions to meet NCC intent for a continuous thermal barrier.
Use Foamex specs for XPS insulation in Australia: specify right, install tight.

#### Increase the thermal efficiency of metal deck roofing with Foamex PurlinK
Minimising energy usage in buildings has become one of the most widespread goals in the commercial, industrial, and residential construction industries. Efforts to reduce building energy usage are typically focused on the mechanical, electrical, and glazing systems and not the structural system.
However, one area where engineers can reduce energy consumption is thermal bridging. Thermal bridging refers to the loss of building energy through thermal conductivity of elements that “bridge” across the insulation of a wall or roof enclosure of a conditioned space when the outside temperature is warmer or cooler than the interior space.

#### Innovative Council using waffle pods to address construction cost challenges
The job of maintaining and upgrading local roads, bridges and waterways is a constant challenge for local Councils, a balance between delivering good services for their community while working within budgets and timeframes.

#### Insulate yourself, winter is coming!
Now that the sun has almost set on summer, the predictions for the upcoming winter have started to trickle in like the first cool breaths under the door and through the floorboards. But it doesn’t have to be like that.
It has been said that Australia is headed for one of the coldest winters on record. This forecast, made by amateur meteorologist David Taylor, predicts that we will experience extremely low temperatures, and more than our fair share of snowfall[1]. Mr Taylor claims the extremely cool weather will impact most of the country. Known to have correctly predicted major weather events in the past, Mr Taylor uses a special formulaic method based on sunspot activity, Global Forecast System modelling and the European Centre for Medium Range Weather Forecast.
Therefore with the oncoming winter snap about to blanket the country, now is a good time to discuss how best to make your home as warm as possible. Of course there is always the solutions involving heaters and ducted air-conditioning for when the deep cold sets in. However, one of the first concerns for most owners is the cost of electricity. Many people become afraid to turn on their heating because they believe they can actually hear the money being drained from their account as their home is being warmed.

#### Inventive garage insulation with expanded polystyrene
The reality for many Australian families and homeowners is that a garage is no longer merely a slab of enclosed concrete for storing vehicles and other miscellaneous household items that we don’t want to keep inside our house proper.
The humble garage is now a functional, multi-use living space in many Aussie homes. It can double as a gym, a home office, a man cave, a workshop, an indoor golf practice facility, a rumpus room, or a spare bedroom. It can house billiard tables and pool tables, washing machines, second refrigerators, and homebrew kits.
As the way we use our garages changes, so too does the amount of time we spend in them. As such, it is no longer acceptable for our garages to be so susceptible to the at-times harsh Australian climate – whether it’s steaming in summer or freezing in winter. Like the rest of the home, the garage is now a functional space, so it needs to be suitably insulated like the other functional areas in our homes.

#### Inventive ways of repurposing EPS
An inside look at efforts by University of Technology Sydney students to find creative ways to repurpose expanded polystyrene.
In a recently published article on The Conversation (1), Tom Lee, a lecturer in the Faculty of Design and Architecture Building at the University of Technology Sydney, outlined potential design opportunities for waste expanded polystyrene (EPS) to be repurposed instead of going into landfill.
In the article, Lee and his colleagues discuss the mounting challenge of dealing with unwanted EPS – 12,000 tonnes of which is sent to landfill every year in NSW alone – and why finding ways to repurpose EPS can flip the narrative on EPS from a waste crisis to a design opportunity.
As a proud, long-time member of the EPSA, Foamex is a vocal and active supporter of EPS recycling. Our recycling facilities serve EPS end-users, building, and road construction sites, as well as other EPS manufacturers.
Justin Kelsey, General Manager of Foamex Group, has been closely following the efforts of Lee and his Master of Design students at UTS.
“As a community, we all need to be thinking of creative ways of keeping EPS waste out of landfill,” Mr Kelsey said. “Recycling and repurposing of EPS waste should be a top priority for all EPS producers. At Foamex, our granulating machines reduce molded EPS into beads that are reformed into new products.”
In the below Q&A, Lee outlines the impetus for the University of Technology Sydney (UTS) design project and why EPS need not simply end up in the landfill.

#### Lightweight Expanded Polystyrene Insulation Panels with High R-Value
Australian construction asks two things of insulation: meet the NCC 2022 thermal targets, and avoid loading up the structure. Lightweight expanded polystyrene insulation panels are built for that brief – high R-values for walls, floors and slab systems without adding significant structural mass.
Foamex manufactures EPS sheets and boards in Australia in thicknesses from 10 mm to 600 mm, with grades from SL (70 kPa) through to VVH 38 (350 kPa) at 10 per cent deformation, tested to AS 1366.3. EPS is around 98 per cent trapped air, so a relatively thick panel can match much heavier insulation systems on thermal performance while staying easy to handle, cut and install. Used widely as slab insulation panels and across energy-efficient insulation systems, EPS helps specifiers lift total R-values – provided the full assembly and the project’s climate zone are accounted for.
Why lightweight insulation matters
EPS is produced through a steam-expansion process that locks air inside a closed-cell structure, resisting heat transfer while keeping density low. Foamex EPS is manufactured without CFCs or HCFCs.
Lightweight EPS panels simplify site work – easier transport, lifting and cutting across large wall and floor areas. EPS suits prefabricated assembly, retrofits with limited structural loading, and installations over suspended structures.
Where are high R-value EPS panels commonly used?
EPS panels are used across the building envelope, from rendered wall systems to under-slab insulation. Grade and thickness depend on loading, climate zone and the compliance pathway.

Application
Where it’s used

External wall insulation
Used within rendered wall systems and behind compatible cladding to lift total wall R-values under NCC 2022. In Type A and Type B construction, EPS external wall systems require an approved performance pathway and have been restricted in some jurisdictions following AS 5113 testing – confirm with your certifier and fire engineer.

Under-slab and slab-edge insulation
Used beneath slabs and at slab edges to lift thermal performance, particularly in cooler zones (CZ6–CZ8). Under-slab and slab-edge insulation is now widely required under NCC 2022 and BASIX. Higher-density grades suit applications carrying significant compressive load.

Suspended floor insulation
Lightweight EPS panels such as Expol are well-suited to insulating suspended timber and concrete floors where structural loading is limited. Low panel weight simplifies installation in retrofits and over existing framing.

Cool rooms and temperature-controlled environments
Stable thermal performance and low moisture absorption make EPS suitable for cool rooms, refrigerated stores and other temperature-controlled spaces where consistent envelope performance reduces operating energy.

What contributes to R-value performance?
R-value measures resistance to heat flow. The figure on a panel is the material R-value – installed total R-value depends on the rest of the assembly. EPS material R-values are determined under AS/NZS 4859.1:2018, which requires a statistically adjusted average across 10 specimens tested at 23 °C in Australia.
Total R-value is influenced by EPS thickness and grade, thermal bridging, membrane selection, air sealing, climate zone and installation quality. Specify thickness from the project energy assessment.
Under NCC 2022, new Class 1 and Class 2 buildings must meet a minimum 7-star NatHERS rating plus a Whole of Home rating of 60 out of 100. BASIX in NSW aligns with this – external wall insulation has lifted to around R2.5, ceiling insulation to around R6.0, and under-slab or slab-edge insulation is widely required.
Choosing the right EPS grade
Foamex EPS spans the AS 1366.3 grade range (L, SL, S, M, H, VH) plus three Foamex-specific higher-density grades – VVH 32, VVH 36 and VVH 38 – for higher-compressive applications. Lower-density grades typically suit wall insulation and similar non-loadbearing uses. Higher-density grades suit floors, under-slab insulation, trafficked surfaces and civil applications such as void fill.
Specify EPS on thermal and compressive requirements together. Confirm compressive strength with the project engineer to avoid over-specifying density and cost.
Compliance, fire and standards
Several standards and provisions sit behind any EPS specification: AS 1366.3 (physical properties of moulded rigid cellular polystyrene), AS/NZS 4859.1:2018 (thermal performance testing and R-value declaration), NCC 2022 Volume One Section J and Volume Two Part 13.2 (total R-values, condensation management and energy efficiency), and AS 5113 (fire propagation testing of external wall systems).
Fire-retardant EPS does not automatically satisfy NCC non-combustibility provisions. Rendered EPS systems on Type A or Type B construction have been restricted in some jurisdictions following AS 5113 testing outcomes. Where EPS is used in those external walls, a performance-based fire pathway and certifier sign-off are required.
The largest sustainability benefit from EPS comes from operational energy saved over the building’s life. Foamex manufactures locally, and clean EPS offcuts can be recovered through suitable recycling programs to support circular-economy outcomes.
Talk to Foamex about lightweight EPS insulation panel solutions. Call 1300 283 626 to discuss insulation thickness, panel grades and the right EPS specification for your project, or request product specifications and technical data sheets.

Frequently asked questions
Do thicker EPS panels provide higher R-values?
Generally yes – greater EPS thickness lifts material R-value. Final building performance depends on the full assembly, so thickness should be set by the project energy assessment.
Can EPS insulation be used in external walls?
Yes, in rendered wall systems and behind compatible cladding. Type A and Type B construction require a performance-based fire engineering pathway and certifier approval, and EPS has been restricted in some jurisdictions – confirm requirements before specifying.
What EPS grade should I specify?
SL and S grades suit walls and non-load bearing uses. Higher-density grades (H, VH and Foamex VVH 32–38) suit floors, under-slab insulation and civil applications. Confirm with your engineer.
How does EPS compare with XPS for slab insulation?
Both are closed-cell polystyrene. XPS has a slightly higher R-value per millimetre and very low water absorption, which suits below-slab use. EPS is lighter, more cost-effective at thickness and holds a stable R-value over time. Foamex supplies both.
Does EPS comply with NCC 2022?
EPS can contribute to NCC 2022 total R-value, 7-star NatHERS and Whole of Home requirements when specified and installed correctly. Compliance is set at assembly level based on climate zone and the energy assessment.

#### Long term cost benefits of polystyrene insulation
Expanded Polystyrene or EPS is a highly durable building and insulation material, designed to offer superior, constant insulation performance over their entire service life of more than 50 years.
The exceptional R Value of polystyrene used as insulation maximises your energy savings and level of comfort in your home. The higher the R value, the more effective the insulation is in reducing heat flow in or out of your home. Foamex polystyrene sheets and blocks will not deteriorate with age, delivering constant R values for the life of the building or home.

#### Long term performance and durability of Expanded Polystyrene for civil engineering projects confirmed
Expanded Polystyrene blocks have been used in construction and building projects for over forty years, uses ranging from civil engineering applications such as bridges, roads, and carparks to their use as insulation in residential and commercial buildings as well as cold storage.

#### Make a meal of it – growth of prepared meal delivery sector
A quick scan of delivery vans in suburban streets shows the vast array of food businesses who have tapped into the delivery of prepared meals. Lite n’ Easy, Marley Spoon, You Foodz, Menu Log, Fresh Meals 2 u and the list goes on.

#### Mind the Gap – Fill floorboard gaps to keep the hot air out this summer
Did you know that many of the materials used in the construction of your house expand and contract over time due to seasonal changes and moisture levels? And, gaps in your floorboards can occur when wooden floors lose their moisture content due to changes in relative humidity. According to many floorboard manufacturers and installers, substantial gapping in the floorboards is a result of flooring that was installed during periods of higher humidity or simply age.

#### Over the life of a building, efficient insulation will more than pay for itself
The upfront costs of insulation can be unappealing, but over the life of a building, insulation will pay for itself and end up saving you in the long run!

#### Placeholder Benefits of Polystyrene Packaging
Polystyrene has long been regarded as the ideal choice for packaging material due to its light weight and thermal insulation properties – coupled with the ability to custom mould to fit. Expanded polystyrene is the ideal inexpensive, lightweight packaging material, making it not only an economical way to pack products but also to transport products. The use of polystyrene for packaging for goods has seen the cost of packaging and transportation significantly reduced. This is because the energy required to manufacture and transport EPS is much less than conventional packaging materials such as timber, straw, cork or cardboard.
The benefits of polystyrene packaging are numerous:

Superior insulation which protects produce from temperature changes
Dimensional stability and recovery
Light weight and easy to stack
Water resistant
Ideal for hydro cooling
Excellent shock absorption qualities
Resistant to bacterial growth
More visually appealing to customers
Easier to handle
Less expensive
Environmentally sound & recyclable

A wide size and density range of produce packaging is available and Foamex can custom design and create packaging for your specific needs.
Please check with your state sales representative on available options.

#### Polystyrene Compressive Strength – EPS vs XPS
It’s not just a letter that separates EPS (Expanded Polystyrene) and XPS (Extruded Polystyrene). When you’re selecting your polystyrene you need to evaluate the importance of key factors such as compressive strength, moisture retention, and insulating capability to ensure that you’re making the most cost-effective decision and material choice for the job.

#### Polystyrene Giant Gorilla Skulls promotes Kong: Skull Island at Melb Train Station
A giant skull made from polystyrene is currently on display at Melbourne’s Southern Cross Station for the entire month of March

#### Polystyrene helps to make movie magic
Make up and costumes are all part of creating the theatre of special effects that goes hand in hand with making movies and television. The set and props are also a major feature in creating the right setting and often transporting the viewer into far away lands and times.
Polystyrene has long been used as an ideal material for building movie sets and TV props. Its lightweight and moisture resistant nature makes it long lasting, easy to transport and easy to work with (shame the same can’t be said about working with children or animals!).

#### Polystyrene Recycling
Foamex is dedicated to maintaining a sustainable environment for the next generations. That’s why our manufacturing process has been designed with the environment in mind.At Foamex, all our polystyrene manufacturing waste is recycled or converted into other products. In fact, virtually all of our expanded polystyrene manufacturing waste is reused for products that serve expanded polystyrene end-users, building and construction sites, and other expanded polystyrene manufacturers. By doing so, we minimise the waste in the environment and keep it sustainable for the generations to come.

#### Polystyrene Recycling in Australia: Where and How to Recycle
Can Polystyrene Be Recycled in Australia? Yes, and Here’s How You Can HelpExpanded polystyrene packaging is 100% recyclable, and it can be recycled repeatedly. What it cannot do is go in your kerbside bin. That gap is why Foamex runs free drop-off across Victoria, New South Wales and South Australia. We have partnered with StyroCycle, Australia’s leading initiative for recycling polystyrene packaging, to ensure that EPS waste is diverted from landfills and transformed into new, sustainable building materials

#### Polystyrene to drive housing insulation improvements in Australia
The Australian building industry needs to get better at insulating homes
Australians on the whole aren’t the best at insulating houses. Our residential buildings are notorious for ‘leaking air’, allowing the uncontrolled flow of heat into and out of our dwellings. Our answer has been to install more and more heating and cooling in the form of air-conditioning.
Europeans, who have to deal with much more extreme temperature, are far more concerned about energy efficiency and have developed better standards, such as Passive House certification.
Green building trends
According to the World Green Building Trends 2018 Report [1], Australia has a relatively mature green building market. 94 per cent of survey respondents do at least “some” green building projects, and 67 per cent reported a “moderate” level of green activity. But despite this, air-conditioning sales continue to rise, and electricity providers are struggling to keep up with peak load requirements.[i]
The aim of sustainable home construction is to create a comfortable home with low impact on the environment, which is economical to run, healthier to live in, and adaptable to your changing needs.

#### Polystyrene Wall Cladding in Australia: Is It Right for Your Home?
Polystyrene wall cladding is often used on Australian Class 1 homes as part of an external wall insulation system to reduce hot-and-cold spots and help the wall line perform more consistently across seasons. The biggest difference comes from specifying the full wall system (board, fixings, reinforcement and finish) and detailing it properly around openings and junctions.
Because external wall requirements can change depending on building class, construction type and state/territory rules, EPS-based cladding should be treated as a residential solution unless a qualified practitioner confirms an appropriate compliance pathway for other building types.
What is polystyrene wall cladding, exactly? 
When most Australians search “polystyrene wall cladding,” they’re usually talking about EPS (expanded polystyrene) boards used on the outside of a home, then finished with reinforcement mesh and a rendered coating. You might also hear it described as an insulated render-style wall build-up.
The key point is this: EPS is not “the cladding” on its own. It’s one part of a wall system. The performance you get (and whether it’s suitable for the project) comes from the full build-up — including how the boards are fixed, how joints are treated, how openings are detailed, and what protective finish is applied.
How polystyrene cladding makes a real difference to comfort
Most people don’t notice “thermal resistance” — they notice the lived experience of a home that’s hard to keep comfortable. One room overheats every afternoon. Another always feels colder than the rest. Heating and cooling seems to run more than it should.
External insulation can help because it supports a more consistent thermal layer across the wall line. When insulation is placed outside the structure, it can reduce the impact of thermal bridging and smooth temperature swings. The result, in many homes, is simply that the indoor temperature feels steadier and the system doesn’t have to work as hard just to maintain a set point.
How EPS Wall Panels Improve Home Insulation
EPS wall panels  improve comfort in a simple way: they hold pockets of still air inside a rigid board. When that air can’t move around, it slows heat transfer — which helps your home stay cooler in summer and warmer in winter.
What matters most isn’t just the material, though. It’s how continuous the insulation layer is once it’s installed. Gaps at sheet joins, weak detailing around window and door returns, and messy penetrations can reduce the real-world benefit far more than people expect.
That focus on continuity aligns with the NCC’s installation intent for insulation: where insulation is required, it must comply with AS/NZS 4859.1 and be installed so it abuts or overlaps adjoining insulation and forms a continuous barrier with adjoining building elements.
In practical terms, EPS boards used within a specified external wall system can make insulation performance more consistent across the wall line — particularly when junctions and transitions are detailed properly and the finished system protects the boards as intended.
Moisture and condensation: What “moisture-resistant” actually means 
It’s common for homeowners to search for moisture-resistant wall cladding after dealing with mould, a persistent damp smell or paint and plaster that never seem to stay right. That’s understandable, but it’s also where the wrong assumptions can lead to expensive problems.
EPS is not a waterproof skin by itself, and it isn’t a substitute for correct weatherproofing. Moisture performance depends on the full system build-up: the coatings and reinforcement, the integrity of flashings, the way joints and penetrations are sealed, and whether the wall is detailed to manage bulk water while still allowing the wall to dry as intended.
This is why “good cladding” isn’t just a product choice. It’s a specification and workmanship issue. If moisture management is a primary reason for considering external cladding, the safest approach is to treat the system details as non-negotiable and make sure they suit your wall type and local conditions.
Choosing the right cladding product for the Australian climate 
Australia is tough on external walls. UV exposure, heavy rain events, coastal salt air and sharp temperature swings don’t forgive poor detailing. Before choosing thickness or finishes, it’s worth grounding the decision in a few real-world factors: what your existing wall type is, what problem you’re trying to solve (comfort, condensation, a facade refresh), and how the system will be detailed around the parts of the wall that usually fail first — openings, junctions and penetrations.
It’s also worth stating clearly: performance comes from the system, not the board. The right fixings, the correct reinforcement and coatings, and disciplined installation are what make the difference between a cladding upgrade that performs for years and one that creates problems.
FAQs on Polystyrene Wall Cladding in Australia
What are the advantages of polystyrene wall cladding in Australia?
On eligible homes (typically Class 1), polystyrene wall cladding can improve comfort by supporting a more consistent insulation layer across external walls, helping reduce hot-and-cold spots and temperature swings. The outcome depends on using a correctly specified wall system and installing it with proper detailing.
Is polystyrene wall cladding the same as foam cladding?
“Foam cladding” is a broad term. Polystyrene wall cladding usually refers to EPS boards used within an external insulation and finish system (board, fixings, reinforcement mesh/base coat and a protective finish). It’s the full system — not the foam alone — that determines durability and performance.
How do I install polystyrene wall cladding safely?
Follow the specified wall system instructions and treat detailing around openings, penetrations and junctions as critical. Poor joint treatment and sloppy flashing/penetration detailing are common causes of weather and moisture issues, regardless of the insulation material used.
Can polystyrene wall cladding be used on apartments or commercial buildings?
It depends on the building’s class, construction type and state/territory requirements. External wall fire performance requirements are typically more stringent for Class 2–9 buildings, and EPS-based external wall systems may be restricted or require a different compliance pathway. Always seek project-specific compliance advice for multi-residential or commercial applications.
Foamex advice: talk to us about EPS wall cladding thickness and system build-up for a Class 1 home.

#### Port of Melbourne Project uses Foamex StyroBloc to deliver lightweight fill solution
The Port of Melbourne Port Capacity Project is redeveloping Webb Dock to be able to operate as an international container handling facility. The project, with an estimated cost of $1.6 billion, includes construction of new roads to Webb Dock Drive and Kooringa Way located below the West Gate Bridge.
 

#### Progress in polystyrene recycling for XPS Board
As manufacturers around the globe grapple with climate change and other environmental dilemmas, they are being called upon to take responsibility for their impact on the planet.
Australian manufacturers of recycled building materials like Foamex aim to establish and maintain a circular economy in which their polystyrene products are made from 100 per cent recycled material.
Polystyrene is infinitely recyclable, making this entirely possible. It begins with product stewardship, which forms the foundation for responsible manufacturing.

#### Properties of Expanded Polystyrene
Expanded polystyrene is widely used in building and construction as its inherent strength, durability, and thermal insulation properties make it an ideal choice for energy efficient buildings.
Foamex polystyrene building products make a major contribution to the quality, safety, and cost-effectiveness of construction as well as contributing to the sustainability of completed projects.

#### Recycling and reuse across the supply chain for Foamex StyroPod
Did you know that buildings and their users are responsible for almost a quarter of Australia’s greenhouse emissions?
The energy embodied in existing buildings in Australia is equivalent to ten years of energy consumption for the nation, and the choice of materials and design principles has a large, but previously unrecognised, impact on the energy required to construct a building.
Embodied energy is one measure of the environmental impact of construction and of the effectiveness of recycling, particularly for CO2 emissions.   The contribution that the re-use and recycling industry can make to lower the embodied impacts of buildings is significant.
Building materials account for about half of all materials used and about half the solid waste generated worldwide. A total of 19.0 million tonnes of construction and demolition (C&D) waste was generated in Australia in 2008-09. Of this total waste stream, 8.5 million tonnes was disposed to landfill while 10.5 million tonnes, or 55%, was recovered and recycled.
One challenge on the recycling and reuse of Foamex StyroPod waffle pod offcuts is to educate end users, such as builders and concreters, on the correct use of the pod scrap bags to ensure the EPS offcuts are segregated without contamination from other building site waste.

#### Retrofitting to increase your home’s energy efficiency
The National Construction Code contains within it a 6 Star Standard in relation to thermal performance of a home or its renovation. 6 Star’s is the baseline for any new construction to achieve a high level of thermal energy performance and to be deemed energy efficient. The challenge for existing home owners is to make their home more energy efficient to meet this 6 Star Standard.
Polystyrene can play a major role in retrofitting an existing home in order to achieve the performances that new houses feature, and become 6-star energy rating compliant.
Heating and cooling can account for more than 40% of a household’s annual energy consumption and has a significant impact on a household’s energy use and greenhouse gas emissions.
Proper insulation allows you to cool or heat your home to a comfortable temperature, turn off your heating or cooling appliance, and keep that temperature steady by preventing the air from leaking out.
Building insulation is the most cost-effective way for households to significantly reduce the global warming effect of greenhouses gases by drastically reducing their household CO2 emissions.
Sustainable insulation should be integrated into building projects at an early stage, ensuring solutions are durable and energy efficient. Polystyrene is the most cost effective insulation solution, yielding high energy efficiency potential and therefore seriously mitigating climate-changing CO2 emissions.
Polystyrene is a natural insulator against temperature and noise. Not only does polystyrene insulation stop heat from entering the home, it also regulates the temperature inside the home by not allowing the heated or cooled air to escape.

#### Safe and Quality Features of Expanded Polystyrene Foam Blocks by Foamex
Foamex StyroBloc expanded polystyrene foam blocks are a versatile alternative popular within the building and construction industry for their ergonomic trademark. Consisting of almost 98% air, EPS blocks are easy to handle, carry, and install, which can help in minimising construction time. It is also an eco-friendly CFC-free material with thermal and acoustic insulation benefits that help conserve energy. This polystyrene is made from fire retardant raw material that automatically ceases when in direct contact with flam

#### Setting the record straight with EPS Waffle Pods
For more than a decade, expanded polystyrene (EPS) waffle pods have enhanced the construction of domestic housing concrete slabs, making them safer and more cost-effective. EPS pods have revolutionised slab construction by enabling stronger, better-engineered slabs to be built more quickly and economically than traditional methods. They have also significantly reduced the labour-intensive manual work typically associated with conventional concrete slab construction.
But some people have got the story wrong, and myths abound about polystyrene waffle pods and their pros and cons. That’s why the industry body Expanded Polystyrene Australia (EPSA) is working hard to educate the construction industry and the broader population about the benefits of waffle pods for concrete slabs.
EPSA represents Australia’s EPS manufacturers, and its members include makers of products ranging from packaging for fresh produce to a wide variety of building and construction applications, including insulated sandwich panels, domestic wall cladding systems and under slab void former pods.

#### Shining a light on the sustainable nature of the manufacturing of expanded polystyrene
In the world of building and construction, careful consideration must be given to every element of the build to ensure stringent environmental standards are adhered to.
Everything, from the building plans and design through to the very materials used in the build, needs to be examined to ensure it meets the long list of guidelines set out by the relevant governing bodies.
Some building products stand head and shoulders above the pack when we consider the environmental impact of producing them and their sustainable characteristics. One such product is expanded polystyrene (EPS).

#### Six unusual ways to use Foamex polystyrene
Polystyrene has been around for nearly 200 years, having first been discovered in 1839 by German apothecary Eduard Simon when he isolated a substance from natural resin. So, there has since been plenty of time to find many different uses for polystyrene. And while there’s plenty of obvious examples, there are also a few you might not have thought of

#### Slab Structural Integrity with StyroPod
Providing your concrete slabs with structural integrity is vital, and nothing is quicker or more cost-effective than Foamex’s StyroPod waffle pods for providing your slabs with insulation and support.
According to Expanded Polystyrene Australia (EPSA), expanded polystyrene waffle pods have revolutionised under slab construction methods which have enabled stronger, faster, and more cost effective slabs to be constructed. Foamex has taken this one step further with our uniquely diamond shaped StyroPods, which offer optimal support for foot traffic during construction due to their thicker foam deck. This deck supports a concreter’s boot and allows for load to be spread across a minimum of four support pillars.

#### StyroBloc EPS foam blocks: cut-to-size and custom profiling
StyroBloc is a rigid EPS foam block built to be cut. It machines cleanly on CNC and hot-wire equipment, holds a crisp profile, and is light enough to handle and install by hand, which is why it is used for props, signage, formwork, landscaping shapes and custom packaging as well as construction fill. It is manufactured in Australia to AS 1366.3 and can contain recycled content. Grade is selected for the job, so confirm the density grade for the application.
When a project needs a shape rather than a sheet, EPS foam blocks earn their place. A block can be cut, carved, hot-wired and profiled into almost any form, then finished, coated or rendered. StyroBloc is the Foamex block product for this work.
This is the fabrication side of StyroBloc: custom-cut shapes for the trades that need a light, workable, dimensionally stable material. Its civil and road-embankment use is a separate application with its own guidance.
What StyroBloc is
StyroBloc is a rigid block of expanded polystyrene, produced by fusing pre-expanded beads with steam into a closed-cell block. It is manufactured to meet AS 1366.3 and supplied in large blocks that are cut down to the sizes and shapes a job needs.
The properties that make it useful for fabrication are consistent density, dimensional stability and low weight. It cuts cleanly, holds an edge, and does not sag or shift once shaped, so a profile machined today matches the drawing.
Sizes and grades
StyroBloc is supplied in blocks and cut down to the size and shape a job needs. Custom sizes are available on request.
Standard block dimensions
Width – 1200 mm
Length – 2400 mm to 5000 mm
Thickness – 600 mm
Compressive strength, density and design stress by grade
Two compressive figures matter, and they are not interchangeable. The figure at 10 per cent deformation is the one quoted on data sheets, tested to AS 2498.3 and set as a minimum in AS 1366.3. It is a material comparison figure, not a working load. The figure at 1 per cent deformation, tested to ASTM D1621, is the one to design to, because EPS behaves as a linear elastic material only up to around 1 per cent strain, and keeping sustained loads inside that limit is what controls long-term creep. Foamex publishes the 1 per cent values as maximums, so treat them as a ceiling rather than a guaranteed floor.
L Grade – 11 kg/m³ – 50 kPa min at 10 per cent – up to 14 kPa at 1 per cent
SL Grade – 13.5 kg/m³ – 70 kPa min at 10 per cent – up to 23 kPa at 1 per cent
S Grade – 16 kg/m³ – 85 kPa min at 10 per cent – up to 31 kPa at 1 per cent
M Grade – 19 kg/m³ – 105 kPa min at 10 per cent – up to 42 kPa at 1 per cent
H Grade – 24 kg/m³ – 135 kPa min at 10 per cent – up to 58 kPa at 1 per cent
VH Grade – 28 kg/m³ – 165 kPa min at 10 per cent – up to 60 kPa at 1 per cent
VVH 32 – 32 kg/m³ – 250 kPa min at 10 per cent – up to 63 kPa at 1 per cent
VVH 36 – 36 kg/m³ – 300 kPa min at 10 per cent – up to 65 kPa at 1 per cent
VVH 38 – 38 kg/m³ – 350 kPa min at 10 per cent – up to 70 kPa at 1 per cent
L to VH are the grades set out in AS 1366.3. VVH 32, VVH 36 and VVH 38 are Foamex grades that sit above the range the standard covers, so they are specified against the Foamex data sheet rather than against a grade letter in the standard.
StyroBloc can also be laminated where a job needs more than the standard block thickness.
Cut-to-size and custom profiling
Foamex provides CNC and hot-wire cutting, contract manufacturing and architectural services to turn StyroBloc into finished shapes. CNC cutting handles complex three-dimensional profiles; hot-wire cutting handles clean straight and curved sections at volume.
Custom-cut blocks also cut waste. Supplying a shape ready to install removes on-site cutting, offcuts and the labour that goes with them, which matters where the same profile is repeated across a job.
Where custom EPS blocks are used

Film, television and event props, sets and theming, where a light, carvable material can be shaped and finished quickly.
Signage and three-dimensional letters, cut to profile and coated or painted.
Formwork and void formers for concrete, shaped to create recesses, curves and profiles in a pour.
Landscaping and feature shapes, and custom packaging formers for protecting irregular products in transit.

Choosing the right grade
Work back from the load, not from the grade. Calculate the sustained load the piece will carry in kilopascals, then choose the grade whose 1 per cent figure sits above that load with a margin. Selecting against the 10 per cent figure produces a grade that looks more than adequate on paper and then creeps under a load it holds for months.
A worked example. Wet concrete weighs roughly 24 kN per cubic metre, so a 300 mm pour bearing on a void former imposes about 7.2 kPa before you add reinforcement, screed boards and the crew working over it. Allow for those and call it 15 kPa. S Grade, at 31 kPa at 1 per cent deformation, carries that with room to spare. L Grade, at 14 kPa, does not, even though its 10 per cent figure of 50 kPa is more than three times the load.
Two things move the choice beyond the arithmetic. Duration is the first: creep accumulates under load held for weeks or months, so a permanent load needs more margin than a load applied for an afternoon. Machined detail is the second: density affects how finely the block holds an edge, so fine detail, sharp corners and lettering usually justify a higher grade than the load alone would call for.
As a starting point, display, prop and signage work that carries nothing beyond its own weight sits at the light end, L to S. Landscaping and feature shapes generally sit mid-range. The worked example above is a shallow pour carried for a day or two; void formers under deep pours, or under load held for weeks rather than days, sit at H and above. Confirm the grade with Foamex against the actual loading for the job rather than defaulting to one grade across every use.
Fire and compliance
StyroBloc is manufactured as a flame retardant grade EPS. The fire-retardant additive is polymerised into the raw material formulation rather than applied as a surface coating, and Expanded Polystyrene Australia requires its members to use flame retardant material in all EPS manufactured for the building industry. A flame retardant grade resists ignition from small sources such as sparks, and self-extinguishes once the ignition source is removed.
That is not the same as non-combustible. EPS is a combustible material, and a flame retardant grade is not a fire rating. For props, sets and event work the distinction matters, because venues and productions commonly set their own fire requirements for materials brought on site, and a finished piece is assessed as a coated assembly rather than as bare foam. Confirm what the venue, production or building surveyor requires before you specify, and coat or treat the finished piece accordingly.
Finishing, coating and durability
StyroBloc takes a range of finishes, from hard-coat renders and protective coatings to paint systems, depending on whether the piece is display, exterior or structural. EPS beads are closed-cell, but water can travel through the spaces between the fused beads, so EPS absorbs more moisture than extruded polystyrene does. Exposed StyroBloc should be coated wherever it will see weather, wear or handling.
One material note: EPS is attacked by petroleum-based solvents, so coatings and adhesives should be checked for compatibility before use on a finished piece.

Frequently asked questions
What are StyroBloc EPS blocks used for?
StyroBloc is used for cut-to-size and custom-profiled work, including props and theming, signage, formwork and void formers, landscaping shapes and custom packaging, as well as construction fill. It is manufactured to meet AS 1366.3.
Can EPS blocks be cut to a custom shape?
Yes. Foamex provides CNC and hot-wire cutting to turn StyroBloc into custom two- and three-dimensional profiles, supplied ready to install.
What density grade of EPS block do I need?
It depends on the sustained load. Work the load out in kilopascals, then choose the grade whose compressive stress at 1 per cent deformation sits above it with a margin, rather than the headline figure at 10 per cent deformation. On that basis StyroBloc runs from L Grade at 14 kPa through to VVH 38 at 70 kPa. Lighter grades suit display, prop and signage work; higher grades are specified where the piece carries load, such as void formers under a deep pour, or anything holding load for weeks rather than days. Confirm the grade with Foamex against the actual loading for the job.
Can StyroBloc be rendered or painted?
Yes. StyroBloc takes hard-coat renders, protective coatings and paint systems. Check coating and adhesive compatibility, as EPS is attacked by petroleum-based solvents.
Is StyroBloc made in Australia and does it contain recycled content?
Yes. StyroBloc is manufactured in Australia to AS 1366.3 and can contain recycled content. Foamex holds Australian Made certification across its core Styroboard range.

#### Styroboard blocks for road embankments
Expanded Polystyrene (EPS) blocks may be used as a light fill material in road embankments or behind retaining structures in order to solve both stability and settlement problems due to soft subsoil conditions.
Expanded Polystyrene blocks have been used in construction and building projects for over forty years, with uses ranging from civil engineering applications such as bridges, roads, and carparks, through to wall insulation in residential and commercial buildings, including cold storage.
One such project well monitored and reported has been the adopted use of EPS as a super light filling material in road embankments across Norway since 1972. The study of the effects of time on the performance of the EPS concluded that no deficiency effects are to be expected from EPS fills placed in the ground for a normal life cycle of 100 years. [Read more on the long term performance and durability of EPS for civil engineering projects]

#### StyroPod saves time, money and the environment
Did you know that concrete is one of the world’s most widely used building materials, and has literally been used for thousands of years? During the 700 years of The Roman Empire, concrete was used extensively, with many structures still surviving today.
But it wasn’t until the 1850s that reinforced concrete was developed in both Europe and the US, and more recently the concrete slab became a staple building technique in the post World War II building boom.
In more recent years, reinforced concrete slabs have benefited from the use of polystyrene, which has led to innovations like Foamex’s StyroPod product. According to Expanded Polystyrene Australia (EPSA), EPS waffle pods have contributed to a revolution in slab construction methods, enabling stronger, better-engineered slabs to be constructed faster and cost-effectively over traditional methods.

#### Supporting EPSA on expanded polystyrene cladding for housing
As a leading manufacturer of expanded polystyrene cladding (EPS), we feel it’s important to help our customers and the wider building industry to better understand the key difference between common cladding materials.
We support our industry body, the EPSA, which in a recent statement noted that, “the use of expanded polystyrene as a cladding material for domestic housing up to two storeys is legal and safe under the National Construction Code”.
EPS foam has been used in the Australian construction industry for many years due to its many appealing traits (strong, lightweight, durable) and that it ticks many sustainability boxes for both commercial and residential construction. But despite its longevity, there are several myths that perpetuate. So, let’s set a few things straight.

#### Sustainability Benefits of EPS Panels in Energy-Efficient Buildings
Energy-efficient buildings stand or fall on thermal continuity, material recovery and long-term performance. Foamex supplies EPS Panels that strengthen envelope efficiency while addressing a core question: Are EPS panels environmentally friendly and recyclable?

Reduces operational energy demand through improved insulation.
Supports material efficiency via lightweight design.
Enables cleaner recycling streams when managed correctly.
Assists compliance with Australian insulation standards.

A building can meet energy targets on paper and still underperform once construction shortcuts interrupt insulation lines or compromise junctions. Thermal gaps increase heat gain and heat loss. Mechanical systems compensate. Energy bills climb quietly over time.
When designers specify expanded polystyrene panels (EPS) with disciplined detailing and proper sequencing, the envelope performs as intended and sustainability outcomes become measurable rather than theoretical.
Where EPS Panels Fit in Energy-Efficient Design
EPS Panels operate as thermal insulation boards that slow heat flow through roofs, walls and floors. Expanded polystyrene panels create a stable insulating layer when installers maintain continuity at corners, slab edges and wall-to-roof connections. That continuity reduces thermal bridging and stabilises interior temperatures.
Builders frequently select insulated wall panels and lightweight construction panels because they simplify handling while supporting envelope performance. Reduced structural load lowers transport impact and site strain. In larger commercial projects, that reduction influences logistics planning and embodied energy associated with material transport.
A Sustainability Case That Goes Beyond Green Claims
Sustainability in construction demands quantifiable outcomes. EPS building materials contribute strongly during the operational phase of a building’s lifecycle. Lower heat transfer means lower heating and cooling demand. Lower demand means reduced energy consumption across decades of occupancy.
The Australian Government’s Your Home guidance confirms that insulation installed in Australia must comply with AS/NZS 4859 and that effective insulation improves energy efficiency across the building fabric. 
Linking EPS Panels to Global Sustainability Goals
Responsible property owners increasingly align project decisions with broader global benchmarks. The United Nations Sustainable Development Goals identify Climate Action (Goal 13) and Responsible Consumption and Production (Goal 12) as priorities tied directly to construction and energy use.
Climate Action focuses on reducing greenhouse gas emissions and strengthening resilience. Buildings account for a substantial portion of global energy consumption, so envelope efficiency becomes a direct lever. Responsible Consumption and Production addresses material efficiency, waste reduction and circular resource flows. 
EPS panels support these global goals through performance and recoverability. When insulation reduces lifetime energy demand, operational emissions fall. When clean offcuts remain segregated and recyclable, projects reduce landfill pressure and conserve raw material inputs. Sustainability shifts from marketing language to practical implementation.
Recycling and Circularity in Practice
Recyclability only succeeds when site management treats EPS as a recoverable resource. Contamination from wet trades or mixed waste can undermine recovery pathways. A structured approach strengthens circular outcomes:

Designate a clean storage area for EPS offcuts only.
Keep material dry and separate from render, adhesives and general waste.
Brief subcontractors on correct segregation practices.
Coordinate removal before offcuts mix with other debris.

Foamex outlines an expanded polystyrene recovery and reuse process that collects clean EPS waste and reprocesses it into new products, reinforcing circular construction practices. 
Compliance and Specification Integrity
Sustainability claims only carry weight when performance aligns with regulation. The National Construction Code requires insulation to comply with AS/NZS 4859.1 and to form a continuous barrier with adjoining elements.
That continuity requirement protects effective R-value. Gaps at junctions or penetrations reduce thermal performance and undermine the operational energy savings that support long-term sustainability goals.
Continuity protects performance. Small gaps erode insulation value long before the building reaches midlife. Correct installation preserves thermal outcomes and ensures design intent translates into real-world efficiency.
Durability and Long-Term Impact
How long do EPS panels last in buildings? Service life depends on protection and detailing. When EPS panels remain shielded within properly constructed assemblies and protected from prolonged moisture or ultraviolet exposure, they can maintain thermal performance across long building lifespans. Durable insulation reduces replacement cycles, which lowers material turnover and associated environmental impact.
FAQs on Polystyrene Wall Cladding
What are EPS panels used for in construction?
EPS panels are used for insulating walls, roofs and floors in residential and commercial projects where teams require stable thermal performance and manageable installation weight.
How do EPS panels improve thermal insulation?
EPS panels improve thermal insulation by reducing heat transfer through the building envelope, particularly when installed as a continuous layer across junctions and edges.
Are EPS panels suitable for external wall cladding?
EPS panels can be suitable for external wall cladding when integrated into compliant systems that address fire performance, moisture control and fixing requirements.
How long do EPS panels last in buildings?
EPS panels can last for extended building lifecycles when protected within wall assemblies and installed according to relevant standards.
Are EPS panels environmentally friendly and recyclable?
EPS panels can support environmental goals when they reduce operational energy demand and when clean offcuts are recovered for recycling in Australia.
Contact Foamex today for EPS panels that are designed for long-term sustainable performance.

#### Sustainable home construction and polystyrene
The aim of sustainable home construction is to create a comfortable home with low impact on the environment which is economical to run, healthier to live in, and adaptable to your changing needs.
Sustainable home design and construction has put a new emphasis on the use and benefits of expanded polystyrene insulated homes.  The demand for more efficient, energy saving and sustainable homes has led to great innovations using expanded polystyrene.

#### The Esky: History & Evolution
The Esky is pretty much a standard piece of equipment for every house in Australia. In some families, there may even be an Esky that has been passed down through the generations. You know the one…
While we have all been in contact with one at some point in our lives, very few know about the history of the humble Esky, so here is a brief history our best friend in summer.

#### The forgotten art of style – polystyrene architectural mouldings
With most new builds and renovation projects use rendering to give a modern finish to your home, architectural mouldings can add a welcoming layer of style, class and curb appeal to your home’s exterior.
Architectural mouldings can provide a design focal point by contouring or outlining edges and surfaces such as a cornice, architrave, capital, arch, base, or jamb. The surface of a moulding is modelled with recesses and reliefs, which either maintain a constant profile or are set in rhythmically repeated patterns.
One of the many benefits of using polystyrene to create interesting architectural profiles is the precision that the hotwire cutting technique brings to detail the shape and the base of the moulding. Its inherent lightweight and moisture resistant nature means that your architectural profiles will be easier to move, safer to handle and highly durable.
With Foamex expanded polystyrene, you can add a touch of your own personality to the exterior of your home ensuring long term durability with unmatched style and sophistication.

#### The role of XPS insulation in passive house design
Passive design is an approach that harmonises with the local climate to maintain comfortable indoor temperatures. Passive House or Passivhaus is a design standard from Germany that achieves high levels of thermal comfort and energy efficiency by utilising insulation, airtightness, window and door design, and ventilation systems.
Effective passive design minimises or eliminates the need for additional heating or cooling, depending on the location. A home based on passive principles can provide long-term thermal comfort, lower energy costs, and reduce greenhouse gas emissions.
It is most effective to incorporate passive design principles when designing and building a new home, but some passive design features can be added through renovations or home improvements.
One of the fundamental principles of passive design is to seal the building envelope, which is the physical interface between the conditioned interior environment and the unconditioned outside environment of a building, also known as thermal bridging.
Insulation is a vital part of any passive-designed home, helping to keep heat inside in winter and outside in summer. The performance of insulation products is measured by how well they resist heat flow, known as their R-value. The higher the R-value, the higher the level of insulation.
XPS foam has excellent thermal resistance, keeping its R-value stable throughout its life. It is, therefore, outstanding underslab insulation and slab edge insulation due to its high compressive strength, moisture resistance, and durability.

#### The Ultimate Upcycling: Foamex Supports Diego Faivre’s Playful Transformation of Polystyrene
Expanded Polystyrene (EPS) has long been a staple in construction, packaging, and insulation, but its potential for reinvention goes far beyond its conventional uses. At Foamex, we champion sustainability and circularity, ensuring that EPS continues its lifecycle well beyond its first use. That’s why we were proud to support Diego Super Bonza Store, an immersive and interactive exhibition by renowned French designer and artist Diego Faivre, in collaboration with Melbourne artist David Wadelton, hosted by Useful Objects.

#### This Halloween, save a pumpkin!
When you mention ‘Halloween’, most people associate the holiday with being American only, specifically North American. However, while it is celebrated strongly in the US, its origins go back further than you would expect to ancient Celtic times in the UK. While this holiday is not as big in Australia as it is in the US, Halloween has started to gain traction, and each year it’s getting a little bigger.

#### Top tips on using Foamex Styroboard XPS to theme your Halloween house with oversized props
Love it or hate it, Halloween has been gaining popularity in Australia over the past decade. While many pundits claim this is the work of evil American TV shows and their influence over Australia’s youth, Halloween parties and trick or treating can be great fun.
This year, the official Halloween night falls on a Monday, which can limit the trick or treating or parties being held, but that shouldn’t really stop you from enjoying Halloween perhaps a few days early.

#### Under Slab Insulation Australia: What Builders Need to Know Before the Pour
Under slab insulation is one of the few thermal decisions on a build that is permanently locked in once concrete is placed. The board type, compressive grade, perimeter detailing and continuity across the slab footprint all need to be confirmed before reinforcement and the pour. StyroTherm XPS is the standard selection for under-slab, slab-edge and perimeter insulation in Australian residential and commercial slabs; high-density StyroSheet EPS suits some flat under-slab applications at a lower price point. Required thickness and grade are set by the project energy assessment and structural design, and need to be confirmed with the energy assessor, certifier or structural engineer.
Slab insulation is not a finish-trade decision. Board selection, sequencing and continuity affect the thermal performance of the floor for the life of the building, and once concrete is placed the access window closes. This piece covers the practical pre-pour checks builders use to keep the floor system performing as designed.

Why under slab insulation matters in Australian conditions
A concrete slab in direct contact with the ground tracks ground temperature year-round. Without insulation, the slab pulls heat out of the conditioned space in winter and stores heat against the building in summer. Under-slab and slab-edge insulation interrupt that heat path. NatHERS whole-of-home modelling captures slab thermal performance as part of the heating and cooling load calculation, and NCC 2022 (retained in NCC 2025) treats the floor as part of the regulated envelope.
Two materials carry the under-slab and slab-edge load in current Australian practice. StyroTherm XPS is a continuous closed-cell board with high compressive strength and very low water absorption, suited to under-slab, slab-edge, perimeter and damp-exposed details. High-density StyroSheet EPS suits some flat under-slab applications where load and moisture exposure are lower. Both are certified to Australian Standards: XPS under AS 1366.4, EPS under AS 1366.3.
Pre-pour checklist: what to confirm before reinforcement
The following checks come up before every slab pour where under-slab insulation has been specified. They are the difference between an insulation specification that performs and one that underperforms despite the right board on the truck.

Board grade against slab load. Compressive strength is grade-dependent. StyroTherm XPS grades carry different kPa ratings; the structural engineer confirms which grade matches the design slab load, including any point-loads from columns or footings.
Installed thickness against the thermal calculation. The energy assessment (NatHERS or BASIX in NSW) sets the required R-value for the floor. If the installed thickness deviates from the assessment, the thermal resistance changes, and the overall envelope performance changes with it.
Perimeter and slab-edge coverage. Slab edges are one of the largest sources of heat loss in a slab-on-ground floor because the edge is exposed to outside air. StyroTherm XPS is commonly used at slab edges for that reason. Confirm coverage continues to finished ground level, not stopping short at the formwork line.
Continuity across the slab footprint. Gaps, broken corners and overlaps create localised heat-transfer paths through the slab assembly. Each gap is a thermal bridge that the assessment did not account for.
Protection during reinforcement and services. Reinforcement bars, mesh tying, conduit pulls and service penetrations damage insulation boards if movement is allowed during the install. Lock boards down before reo goes in.
Vapour control alongside insulation. The vapour barrier sequence around the insulation needs to match the slab detail. Damaged or punctured vapour barriers carry moisture into the assembly regardless of the insulation board choice.
Clean offcut handling. All construction site EPS and XPS waste generated from Foamex products is collected and managed by EPS Sheets. Clean offcuts (free of tape, food, paint or plastic wrap) are 100 per cent recyclable through the Foamex collection and reprocessing system. Plan separation on site at the same time the insulation goes in.

XPS or high-density EPS: which board for which detail
Material selection is driven by the slab detail, not by a default preference. Three practical decisions cover most jobs.

Under-slab on grade with moderate loads: high-density StyroSheet EPS can suit flat under-slab applications where the structural design supports it. Confirm compressive grade against the slab design.
Under-slab with higher loads, slab-edge, perimeter or damp-exposed details: StyroTherm XPS is the standard selection. Continuous closed-cell structure, very low water absorption, retained R-values long-term.
Foamex: Foamex StyroPod EPS waffle pods are a separate product, not an under-slab board. They sit within the slab to form voids that reduce concrete consumption. A waffle pod slab can still need under-slab or perimeter insulation depending on the energy assessment.

How under slab insulation interacts with NatHERS and BASIX
The energy assessment is where the insulation thickness and R-value get nailed down. For most new residential builds, that is a NatHERS whole-of-home assessment driving a 7-star thermal target and a Whole-of-Home score (60 for Class 1 dwellings, 50 for Class 2 apartments). In New South Wales, BASIX captures both the 7-star thermal target and the Whole-of-Home assessment through the same NatHERS engine.
What that means on site: the assessor specifies a board thickness, the structural engineer confirms a compressive grade, and the builder needs both numbers to align with the boards on the delivery. A swap to a thinner board to fit a tolerance changes the assessment outcome. Confirm any substitution before it goes in the ground.
Where the decision goes wrong on site
Three failure patterns repeat across slab pours where the insulation specification did not survive contact with the build.

Thickness drift. Boards arrive in the specified thickness, but a packer or sub-base correction effectively reduces installed thickness in part of the footprint. The slab is poured at full assessment-specified depth, but a portion of the insulation layer is no longer at the assumed R-value.
Perimeter cut-off. The under-slab board stops at the formwork, leaving the slab edge exposed. The thermal performance of the assembly is determined by the weakest path; the bare slab edge becomes that path.
Late discovery of incompatible grade. The structural engineer requires a higher compressive grade than the assessor specified for thermal. The site receives the thermal-grade board and only catches the mismatch during installation. Stopping a pour at that point is expensive; catching it at delivery is not.

Each of these is preventable with a pre-pour walk and a checklist against the assessor and engineer specifications. Insulation is the only envelope element where the build sequence locks the result in permanently.
Sustainability and recycled content
Foamex Styroboard XPS (including StyroTherm XPS) carries up to 90 per cent recycled content, depending on feedstock availability. StyroPod waffle pods carry up to 50 per cent recycled content when possible. Styroboard EPS sheets and blocks (including StyroSheet) can contain recycled content. All clean offcuts from these products are 100% recyclable. The largest lifetime sustainability contribution from under-slab insulation, however, is operational: heating and cooling demand reduced across the life of the building.
Talk to Foamex about under-slab and slab-edge insulation for your next slab. Call 1300 AU FOAM (1300 283 626) to discuss board selection, compressive grade, thickness against the energy assessment, and offcut collection on site.

Frequently asked questions
What is the best under slab insulation for Australian conditions?
There is no single best product. StyroTherm XPS is the standard selection for under-slab, slab-edge, perimeter and damp-exposed details because of its high compressive strength, very low water absorption and retained R-values long-term. High-density StyroSheet EPS can suit some flat under-slab applications at a lower price point where load and moisture exposure are lower. The right specification is determined by the energy assessment, the structural design and the slab detail.
How thick should under slab insulation be?
Required thickness is set by the project energy assessment (NatHERS or BASIX in New South Wales) for the target R-value, then cross-checked against the structural design for compressive grade. Both numbers come from the project specification, not from a default. Confirm with the energy assessor and structural engineer before ordering.
Can EPS be used for under slab insulation in Australia?
Yes, where the slab design supports it. High-density StyroSheet EPS suits some flat under-slab applications where compressive loads and moisture exposure are within the product’s certified range under AS 1366.3. For slab edges, perimeter insulation and higher-load conditions, StyroTherm XPS is the more common specification.
Does under slab insulation help meet NatHERS 7-star and Whole-of-Home compliance?
Yes, when correctly specified inside the complete 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. Under-slab and slab-edge insulation contribute to the assessment through reduced heat flow at the floor.
What happens to insulation offcuts on a Foamex slab job?
Foamex collects and manages all construction site EPS and XPS waste generated from its products. Clean offcuts are 100 per cent recyclable through the Foamex collection and reprocessing system and are returned to manufacturing as recycled feedstock. Plan site separation before the insulation goes in.

#### Under Slab Insulation in Australia: Building Sustainable, Low-Carbon Floors
Quick answer: Under-slab insulation is a layer of rigid polystyrene board laid beneath a concrete slab to slow heat transfer between the slab and the ground. It keeps internal floor temperatures more stable and reduces heating and cooling demand over the life of the building. Two boards are used in Australian slabs: StyroTherm XPS for slab edges, below-ground details and damp or higher-load positions, and high-density StyroSheet EPS where the structural design and moisture conditions allow. Compressive grade is matched to the slab load, from SL grade (70 kPa) to VVH 38 (350 kPa) at 10 per cent deformation, and confirmed against the structural design and the project energy assessment. Under-slab insulation is not the same as a waffle pod slab: the board insulates, while StyroPod EPS pods are void formers that create the ribbed slab system under AS 2870-2011.
Once a slab is poured, its thermal behaviour is largely fixed, so under slab insulation is a decision that affects energy use and floor comfort for the life of the building. Foamex manufactures Australian-made rigid insulation, StyroTherm XPS and high-density StyroSheet EPS, for under-slab and slab-edge applications. This article:

Explains how under slab insulation works in Australian conditions.
Sets out when XPS suits the detail and when high-density EPS is the cost-effective option.
Shows how insulation supports energy-efficient slab systems and lower operational carbon.
Clarifies the difference between under-slab insulation and waffle pod slabs.

How under-slab insulation works in Australian conditions
A slab in direct contact with the ground acts as a heat sink, losing heat to cooler ground in winter and gaining heat in warmer periods. Without insulation, the slab tracks ground temperature and pulls energy out of the building before the internal environment stabilises. When thermal floor insulation is included at the design stage, indoor temperatures hold for longer and heating and cooling systems cycle less often.
Australian Government guidance (yourhome.gov.au) is clear that thermal mass only performs when it is insulated. A slab in direct ground contact loses heat to the ground rather than storing and releasing it usefully, so Your Home recommends slab-edge and under-slab insulation in colder climates and wherever in-slab heating or cooling is installed. The floor’s contribution sits within whole-of-home performance assessed under NatHERS or BASIX, confirmed with the project energy assessor.
Consistent coverage matters. Subfloor insulation panels must remain continuous, because gaps create localised cold zones and uneven performance across the slab.
XPS or high-density EPS for under-slab insulation
Two rigid polystyrene boards are used beneath and around slabs, and they behave differently under load and moisture. StyroTherm XPS has an extruded continuous closed-cell structure, very low water absorption and compressive strength of approximately 200 to 350 kPa at 10 per cent deformation, which suits slab edges, below-ground details and damp or higher-load positions. High-density StyroSheet EPS is graded from SL (70 kPa) to VVH 38 (350 kPa) at 10 per cent deformation, with low water absorption and a more economical cost at equivalent thickness, and suits under-slab insulation where the structural design and moisture conditions allow. Match the compressive grade to the slab load, not just the thickness, and confirm against the structural design and the project energy assessment.
Does under-slab insulation improve energy efficiency?
Thermal floor insulation reduces heat transfer through the slab, which lowers demand on heating and cooling systems. Specified at design stage and detailed for continuity, it helps a building meet the energy requirements that apply under the National Construction Code across residential and commercial projects. Confirm the target and pathway with the project energy assessor.
When should under-slab insulation be installed?
Under slab insulation must be installed before the concrete pour to achieve full coverage beneath the slab. Gaps or movement during installation create thermal bridging that reduces performance. Foamex supplies boards that stay stable during reinforcement placement and pouring, so the insulation layer remains consistent across the floor. Rigid foam is not a substitute for a damp-proof membrane, so insulation and waterproofing should be detailed as separate functions.
How under-slab insulation performs in coastal and variable conditions
Coastal and variable sites introduce changing ground moisture. Both XPS and EPS are closed-cell and resist water uptake, so their thermal performance stays stable rather than drifting over time. XPS is the more moisture-tolerant of the two and is often preferred where boards sit against damp ground for extended periods. With correct detailing, both continue to perform across changing ground conditions.
How under-slab insulation supports lower operational carbon
Under slab insulation reduces heat transfer through the floor, which lowers operational energy demand and, over time, operational carbon. Foamex manufactures EPS and XPS in Australia, can incorporate recycled content where product-specific evidence supports it, and operates an offcut take-back program so clean material can be reprocessed into new products rather than sent to landfill.
Under-slab insulation and waffle pod slabs are not the same
It is worth being precise about products. Under-slab insulation is a board (StyroTherm XPS or high-density StyroSheet EPS) laid beneath the slab. StyroPod EPS waffle pods are different: they are void formers used to create a ribbed waffle pod slab system, with pod height set by the structural engineer under AS 2870-2011. A project may use one, the other, or both.

Frequently asked questions
How does under slab insulation work in Australian homes?
It forms a thermal barrier beneath the concrete, reducing heat transfer between the ground and the building so indoor temperatures stay more stable.
Is XPS or EPS better for under slab insulation?
Neither is universally better. XPS offers higher compressive strength and very low water absorption for slab edges and damp or higher-load conditions, while high-density EPS is more economical under the slab where the design allows.
Can under slab insulation improve home energy efficiency?
Yes. By limiting heat loss and heat gain through the floor, it reduces reliance on heating and cooling, contributing to whole-of-home energy performance.
How long does under slab insulation last in coastal areas?
Closed-cell EPS and XPS are designed to perform for the life of the building when installed and detailed correctly, including in coastal conditions.
Should under slab insulation be installed before pouring concrete?
Yes. Installing before the pour ensures continuous coverage and prevents thermal gaps.

Contact Foamex for under slab insulation that performs during installation and after the pour. Ask the team to confirm the right StyroTherm XPS or high-density StyroSheet EPS option for your slab design.

#### Underfloor Insulation – Keep the heat under your feet
With winter fast approaching, your thoughts are probably turning towards how to keep your house warm, without breaking the bank.
There are many options you could choose. If you are wanting to heat a small room, you could use a portable electric heater. Their efficiency lays in being able to heat small areas quickly, however they can be expense to run.
If you’re looking to heat a larger area, then a portable gas heater is the way to go. Most are electric/gas hybrids that just require a power outlet to run, removing the need of a complicated installation. Also, being portable, you can move it to another room depending your needs.
However, if you’re looking for an option to heat your entire house, you can’t go past ducted/central heating. Using a compressor (installed outside the house or in the roof), warm air is distributed throughout the house through ducted vents located in selected rooms. Temperatures can be easily controlled and monitored through a central control panel.

#### Underfloor insulation for the whole house – not just under floorboards
Underfloor insulation is ideal to stop drafts coming up from floorboards, but did you know that you should also consider underfloor insulation under carpeted floors to add layers of insulation to your home?

#### Unique diamond grid for high strength void former pod design
The unique shape of Foamex’s StyroPod has many benefits; not only does it give this waffle pod void former system heightened strength and flexibility, it is also durable, lightweight, and easy to handle.
The size and shape of the foam pillars that form the diamond offers optimum support for the foot traffic necessary for setting out the pods, placing the reinforcing steel, and pouring the concrete.

#### Unsure of the differences between polyethylene and EPS?
The NSW Government has followed its Victorian counterpart and introduced a building product use ban that prohibits the use of aluminium composite panels with a core comprised of greater than 30 per cent polyethylene. Such products were found in the tragic Grenfell Tower and Melbourne Lacrosse building fires.
Announcing the NSW ban, which came into effect on August 15, NSW Commissioner for Fair Trading, Rose Webb, said she considered a broad range of sources, including public submissions, expert advice, national and international reports, and NSW Cladding Taskforce data.
Commenting on the ban, Foamex Group General Manager Justin Kelsey issued support for the NSW Government’s stance on flammable products in building projects, while underscoring the significant difference between the banned polyethelene products and expanded polystyrene (EPS) products manufactured by Foamex.
 

#### Using polystyrene solutions to beat the summer heat
Find yourself sticking gel packs in between your bed mattress and fitted sheet this summer when trying to get to sleep? Good housing insulation can help regulate the indoor temperature of your home so it doesn’t feel like a sweat box each summer evening.
Polystyrene is a natural insulator against temperature and noise. Not only does polystyrene insulation stop heat from entering the home, it also regulates the temperature inside the home by not allowing the cooled air to escape.

#### Versatile Extruded Polystyrene Sheets for Energy Efficient Homes from Foamex
The increasing emphasis on sustainability transforms the way industry players are specifying building materials, including versatile extruded polystyrene sheets. It is common knowledge that the energy-efficiency of a building structure depends on the materials utilised in creating its envelope. Hence, choosing the right insulating material is crucial in achieving the required insulation performance of a building project.
With a track record spanning more than three decades, Foamex remains one of the respected industry leaders responsible for the innovation, creation, and distribution of expanded and extruded polystyrene.
Product Focus: Styroboard® XPS Versatile Extruded Polystyrene Sheets
Created for Australians by Australians, Styroboard® XPS provides numerous advantages that come from the way the versatile extruded polystyrene sheets are manufactured. Styroboard® is developed through extrusion, a continuous process that produces its unique closed cellular structure. The extrusion process also results in a smooth skin on the top and bottom side of the polystyrene panel.
The closed cell matrix of versatile extruded polystyrene sheets blocks water from infiltrating through the insulation materials. Hence providing long-term strength, durability, and resistance against vermin attacks, premature deterioration, and rot.

#### Waffle Pod Slab vs Traditional Concrete Slab: Which Foundation Suits Your Australian Build?
Quick answer: A waffle pod slab uses polystyrene void formers to create a grid of reinforced concrete ribs over a shallow, prepared base. A traditional slab pours a thicker continuous slab tied into deeper edge and internal beams. On reactive Australian sites, waffle pod systems typically reduce concrete volume by 25 to 40 per cent, contribute up to R1.0 of under-slab thermal resistance, and respond well to soil movement when designed under AS 2870-2011. On stable sites or where unusual loading or access constraints apply, a traditional slab can still be the better choice. Your structural engineer makes the final call based on soil classification, loadings and site conditions.
Slab selection is one of the earliest decisions that shapes the cost, programme and long-term performance of an Australian residential build. It also sits where geotechnical conditions, structural design and material choice meet. Get it right, and the slab supports the home for decades. Get it wrong, and you can spend the rest of the build chasing cracking, movement or callbacks.
In this guide, we compare the two systems most commonly specified in Australian housing: the traditional reinforced concrete slab on ground, and the waffle pod slab system that uses expanded polystyrene (EPS) pods as void formers within a stiffened raft. We cover construction sequence, cost drivers, soil reactivity, programme impact, thermal performance and the situations where one system wins out over the other.
Foamex manufactures StyroPod EPS waffle pods in Australia for residential slab design. Pod height and layout are always confirmed by the structural engineer responsible for the slab.
At a Glance: Waffle Pod Slab vs Traditional Slab
The summary below is a starting point for comparison, not a substitute for an engineered slab design.

Factor
Traditional concrete slab
Waffle pod slab

Excavation depth
Deeper, with perimeter and internal beam trenches
Shallower, pods sit above a prepared, level base

Concrete volume
Higher
Approximately 25 to 40 per cent less

Reinforcement
Bars in beams plus mesh in slab
Trench mesh in ribs plus top mesh over pods

Setup time
Less pre-pour preparation
Adds a pod placement stage before pour

Pour duration
Standard
Reduced by roughly 20 to 40 per cent on equivalent floor area

Under-slab thermal contribution
Minimal unless extra insulation specified
Up to R1.0 from EPS pods, depending on pod height and configuration

Best suited to
Stable Class A or S sites, unusual loading, restricted access
M, H1, H2 and E sites where engineered raft action is needed

How Does a Waffle Pod Slab System Work?
A waffle pod slab is a stiffened raft. Lightweight EPS pods sit on a level, compacted base in a regular grid. Trench mesh runs in the gaps between the pods, forming the reinforcement for the concrete ribs. A layer of mesh sits over the top of the pods to reinforce the thin top slab. Concrete is poured across the whole layout in one operation, filling the rib trenches and forming the slab above.
Once the concrete cures, the slab and ribs work as a single stiff plate. Load transfers through the ribs into the ground, and the raft action helps the slab respond to soil movement evenly across the footprint, rather than concentrating stress at one point.
Foamex StyroPod EPS pods are manufactured in a 1090 mm by 1090 mm format with standard heights of 150 mm, 225 mm, 300 mm and 375 mm. Pod height is selected by the structural engineer to suit the soil classification, the slab loading and the design under AS 2870-2011.
How a Traditional Concrete Slab Compares
A traditional slab on ground also sits at the base of the home, but it works through depth and mass rather than ribbed raft action. Beam trenches are excavated around the perimeter and internally where required by the engineer. Reinforcement is placed in the trenches and across the slab area. Concrete fills the trenches and forms the slab in a single pour.
Structural performance comes from the depth of concrete in the beams, the reinforcement layout and the strength of the slab itself. The system suits straightforward sites with limited soil reactivity, sites with unusual loading paths and projects where access or sequencing favours a simpler form.
Soil Reactivity, AS 2870-2011 and Why Classification Drives Slab Design
Most Australian residential slabs are designed under AS 2870-2011 Residential Slabs and Footings. The standard sets out site classes based on the reactivity of the soil to moisture changes, and links each class to slab and footing design requirements.
Reactive clays expand when they take on water and shrink when they dry. The bigger the moisture-driven movement, the more the slab has to be designed to accommodate it without distress in the structure above. Foundation choice and detailing follow from there.

Class
Site reactivity
Typical movement
Slab design implications

A
Stable, non-reactive (sand or rock)
Little to none
Standard slab design

S
Slightly reactive
Slight ground movement
Standard design with light reinforcement

M
Moderately reactive
Moderate movement from moisture changes
Deeper ribs or beams typically required

H1
Highly reactive
High ground movement
Engineered stiffened raft, increased rib depth

H2
Highly reactive (upper range)
Very high movement
Increased rib depth and reinforcement, engineer-specific

E
Extremely reactive
Extreme movement
Specialised engineered design and deeper sections

P
Problem sites (soft soils, fill, mine subsidence)
Variable, site specific
Geotechnical and structural engineering required

Tip for builders and homeowners: Ask your designer or engineer for the geotechnical report and the AS 2870 site classification before you sign off on a slab type. Pod height, rib depth and reinforcement should all flow from that classification, not from a default specification.
Construction Sequence and Site Preparation
Both systems start with site preparation, levelling and a suitable base. From there, the sequences split:
Traditional slab sequence

Set out and excavate beam trenches around the perimeter and internally as designed.
Place vapour barrier and trench mesh.
Tie reinforcement, set service penetrations and inspect.
Pour concrete, screed and finish.

Waffle pod slab sequence

Prepare and level a clean compacted base over the building footprint.
Lay vapour barrier and set out the pod grid.
Place EPS pods to plan, then trench mesh between pods.
Lay top reinforcement mesh, set penetrations and inspect.
Pour concrete in a single operation, filling rib trenches and forming the top slab.

On the ground, the trade-off is clear. A traditional slab usually has less pre-pour set-up but requires more excavation and concrete on the day. A waffle pod slab adds a pod placement stage but reduces excavation and concrete volume, with a faster pour for the same floor area.
Cost Drivers Across Both Systems
Slab cost is rarely a single line item. It is made up of excavation, formwork, reinforcement, concrete, labour and transport. Each system shifts those line items in different directions.
Waffle pod slab systems typically reduce concrete volume by around 25 to 40 per cent compared with a traditional slab of equivalent footprint and engineering classification. That reduction tends to offset pod supply and labour on projects over roughly 100 m² of slab area, although the exact crossover depends on pod cost, concrete pricing in your area and the site classification.

Concrete supply: Lower for waffle pod slabs because non-structural volume is replaced by EPS pods.
Transport and pump time: Typically lower for waffle pod slabs, with fewer truck movements for the same footprint.
Excavation: Typically lower for waffle pod slabs because the slab does not require deep beam trenches across the footprint.
Labour and set-up: Pod placement and reinforcement add a defined preparation stage to the waffle pod slab build-up.
Engineering: Design fees are similar, since both systems require a slab design under AS 2870-2011.

Get a quote from your concreter for both options once you have a soil classification. The cheapest system on paper is not always the cheapest delivered slab.
Ground Movement and Structural Behaviour
Reactive soils are the main reason waffle pod slabs are so common in Australia. The stiffened raft action of a waffle pod slab spreads movement across the full footprint, which helps the slab respond to soil expansion and contraction without concentrating stress at a single point.
A traditional slab also resists movement, but does it through mass and the depth of beams. On stable Class A or S sites, this works well. On reactive M, H1, H2 or E sites, the engineer will usually favour a more uniformly stiff system. Both systems can be designed for any of those conditions, but pod-based rafts are often the more economical engineered solution as reactivity increases.
Whichever system is selected, the structural design must adjust rib depth, pod height and reinforcement to suit AS 2870-2011 and the site-specific geotechnical report. Pod height is not a homeowner choice. It is an engineered output of the slab design.
Installation Time and Program Impact
Program impact is project specific, but the patterns are consistent.
On a typical Australian residential slab, reduced concrete volume in a waffle pod system can shorten the pour itself by about 20 to 40 per cent compared with the equivalent traditional slab. Pod placement and reinforcement add roughly one to two days of preparation on smaller projects, depending on crew size and slab complexity. On larger or more reactive sites, the saving on the day of the pour usually outweighs the extra set-up.
On constrained sites, lower pour volume can be an advantage when concrete truck access is limited or when the pour window has to fit within site rules. On open sites with simple geometry, a traditional slab can sometimes match or beat a waffle pod slab on program. Talk this through with your concreter and engineer before locking in the system.
Thermal Performance Beneath the Slab
Concrete slabs are good thermal mass, but they are also a heat loss path if they sit directly on cold ground or against external air at the edge. Adding an under-slab insulation layer slows that heat loss and helps maintain stable indoor temperatures.
EPS waffle pods provide a contribution to under-slab insulation, typically up to R1.0 depending on pod height, configuration and the share of slab area covered by ribs. That contribution is part of a building envelope strategy, not a standalone solution. NatHERS or BASIX assessments evaluate the whole envelope, so wall, roof, glazing and floor insulation all matter together.
Under the National Construction Code 2022, the minimum NatHERS performance for new homes increased from 6 stars to 7 stars in most jurisdictions. Slab edge insulation, sub-slab insulation and waffle pod contribution all sit within that conversation. A NatHERS or BASIX assessor working from your plans will tell you how the slab system fits the overall pathway.
When is a Traditional Slab Still the Better Option?
A waffle pod slab is not always the right answer. Consider a traditional slab where any of the following apply.

The site is Class A or S with limited reactivity and a straightforward design.
Loading paths or unusual structural conditions require continuous mass beneath specific areas.
Access is too tight to set out and place pods efficiently.
A heritage or planning consent specifies a different system.
A slab heating system or specific edge detail is easier to integrate without pods.

Both systems can deliver a sound slab. The right choice is the one that fits the site classification, the engineering design and the project conditions.
How to Choose Between a Waffle Pod Slab and a Traditional Slab
Use this short checklist to guide the decision with your designer and structural engineer.

Confirm the AS 2870-2011 site classification from a recent geotechnical report.
Ask your engineer to compare a traditional slab and a waffle pod raft for the same site classification and loadings.
Get a concrete and reinforcement quote for both options from your concreter.
Discuss thermal performance with your NatHERS or BASIX assessor, including how the under-slab contribution fits the energy target.
Confirm pod height, rib depth and reinforcement before procurement.

Why Builders Choose Foamex StyroPod EPS Waffle Pods
Foamex manufactures StyroPod EPS waffle pods in Australia for residential slab design. Pods are produced in a 1090 mm by 1090 mm format in 150 mm, 225 mm, 300 mm and 375 mm heights. Foamex also operates an offcut collection service for clean site waste, returning material to manufacturing for reprocessing into new EPS and XPS products.
Specifying StyroPod EPS waffle pods supports a stiffened raft slab design that meets the engineering requirements set out under AS 2870-2011. The product is part of a system. The system performs when it is engineered, supplied and installed correctly.
Speak with the Foamex Team Before You Lock in a Slab System
A waffle pod slab is a strong choice on reactive Australian sites when designed correctly. A traditional slab still has a role on stable sites or where structural conditions favour mass over ribbed action. Either way, the engineer makes the call based on AS 2870-2011, the geotechnical report and the project loadings.
Talk to the Foamex team about waffle pod slab systems. Contact us for product specifications, pod height guidance and offcut recycling support for your next residential slab.

Frequently asked questions
What is a waffle pod slab system?
A waffle pod slab system is a stiffened raft slab that uses expanded polystyrene (EPS) pods as void formers in a regular grid, with a network of reinforced concrete ribs running between the pods and a thin top slab over the layout. It is designed under AS 2870-2011 and is widely used on reactive Australian residential sites.
Is a waffle pod slab cheaper than a traditional concrete slab?
A waffle pod slab typically reduces concrete volume by 25 to 40 per cent for the equivalent slab area, which lowers concrete supply, transport and pour cost. Pod supply and placement add a preparation stage. On most projects over 100 m² of slab area, the concrete saving offsets pod and labour cost, but exact pricing depends on local concrete rates and your site classification.
What thermal performance does a waffle pod slab provide?
EPS waffle pods contribute approximately R0.5 to R1.0 of under-slab thermal resistance, depending on pod height and configuration. This contribution sits inside a complete building envelope strategy. NatHERS or BASIX outcomes depend on the whole envelope, including wall, roof, glazing and floor systems.
How do I know what waffle pod height I need?
Pod height is selected by the structural engineer based on the AS 2870-2011 site classification, the slab loadings and the engineered design. Common heights are 150 mm, 225 mm, 300 mm and 375 mm. Discuss your geotechnical report and slab design with your engineer before procurement.
Can a waffle pod slab be used on any soil class?
Waffle pod slabs are designed for a wide range of site classes from S through to E when the slab design suits the soil reactivity. Problem (P) sites generally require additional geotechnical and structural engineering. The engineer assesses suitability for each project.
How long does it take to install a waffle pod slab?
Installation time is project specific. On equivalent floor area, the pour itself is typically 20 to 40 per cent shorter because of the lower concrete volume, while pod placement and reinforcement add roughly one to two days of preparation on smaller projects. Crew size, slab complexity and access also affect the result.

#### Waffle pod slabs and the 7 star energy requirement
EPS waffle pods are more than efficient void formers – they also provide measurable thermal resistance beneath the concrete slab. Published research places this contribution at R0.57 to R0.65, depending on pod depth. A 7-star rating is achieved through the combined performance of the entire home, but EPS waffle pods give the floor system a valuable thermal head start. This page explains what the pods contribute, what additional floor insulation may be required, and how the complete system works together to support a comfortable, energy-efficient home.
What NCC 2022 requires
NCC 2022 lifted the minimum thermal performance standard for most new homes from 6 to 7 stars under the Nationwide House Energy Rating Scheme (NatHERS). It also introduced a separate Whole of Home assessment, which considers energy used by fixed services and appliances, together with any energy generated on site.
Implementation was staged across Australia. The higher BASIX standards commenced in New South Wales on 1 October 2023. The Australian Capital Territory introduced the new energy-efficiency provisions on 15 January 2024, followed by Victoria and Queensland on 1 May 2024. Because local variations and transitional arrangements applied, builders should always confirm the requirements for their jurisdiction and approval pathway.
For a waffle pod slab, the practical message is clear: the floor forms part of the home’s thermal envelope and can influence the NatHERS result. It should not be treated as thermally neutral. EPS waffle pods provide measurable thermal resistance beneath the concrete slab, helping the overall design work towards the 7-star target.

What a waffle pod slab contributes
CSIRO investigated the thermal resistance of waffle pod slabs and published additional R-values by pod depth, measured against a conventional 100mm slab on ground. These are the figures NatHERS assessors work from.

Pod depth
Additional R-value
StyroPod® size
Site class under AS 2870

170mm
R0.57
150mm, set-downs
Shower and garage set-downs

230mm
R0.60
225mm
Class M, moderately reactive

300mm
R0.63
300mm
Class H, highly reactive

370mm
R0.65
375mm
Class E, extremely reactive

What this table means:
The published R-value represents the complete slab system. It measures the additional thermal resistance delivered by the waffle pod slab as constructed, not simply the material R-value of EPS in isolation. For NatHERS modelling, the relevant figure is the system contribution: R0.57 to R0.65, depending on pod depth.
The thermal benefit is built into a structurally driven design. Pod depth is determined by the site classification under AS 2870-2011 and the engineer’s slab design; it is not selected as an energy-rating upgrade. A Class E site may require a 375mm pod because of the soil conditions, while a Class M site may use a 225mm pod. The difference in R-value is a consequence of the structural specification, not a reason to select a deeper pod.
The important point is that, whichever pod depth the engineer specifies, an EPS waffle pod slab makes a real and measurable contribution to the floor’s thermal performance. That benefit is already built into the slab system; it does not need to be added as a separate feature.
How a waffle pod slab manages heat flow 
Heat moves through a slab-on-ground floor by two main paths: downward through the underside of the slab and outward through its exposed perimeter.
EPS waffle pods address the first path by providing measurable thermal resistance beneath the concrete. Where additional performance is required, slab-edge insulation complements the pods by reducing heat flow through the perimeter. This is not a limitation of EPS waffle pods – it reflects how heat moves through any slab-on-ground floor.
Because the pods and slab-edge insulation address different heat paths, their R-values cannot simply be added together. For example, a pod contribution of R0.60 and a slab-edge board rated at R0.94 do not create a floor rated at R1.54. NatHERS assesses the underside and perimeter contributions separately.
Used together, EPS waffle pods and appropriately specified slab-edge insulation provide a more complete thermal strategy: the pods reduce downward heat flow, while the edge insulation addresses perimeter losses. This allows the waffle pod slab to make a stronger contribution towards the home’s overall 7-star result.
Slab-edge insulation: completing the floor system
Once the EPS waffle pods have reduced heat flow beneath a waffle pod slab, slab-edge insulation can address the exposed perimeter. It consists of rigid insulation board installed vertically against the outer edge of the concrete, either before or during the pour, depending on the specified construction detail.
StyroTherm XPS is manufactured for this application. Its compressive strength helps it withstand backfilling, while its closed-cell structure provides resistance to moisture in ground-contact applications. Depending on thickness, its thermal resistance ranges from R0.94 at 30mm to R2.15 at 75mm.
StyroTherm is also manufactured using up to 90 per cent recycled polystyrene recovered from EPS packaging, adding thermal performance while keeping valuable material in productive use.
Where the design requires even greater floor performance, high-density StyroSheet EPS or StyroTherm XPS can be installed beneath the slab as a continuous insulation layer. This is a separate construction detail that can affect the vapour barrier, penetrations and pour sequence. It should therefore be coordinated with the engineer and NatHERS assessor from the beginning rather than introduced late in the project.
Together, these options provide a flexible thermal strategy: EPS waffle pods beneath the concrete slab, StyroTherm XPS around the perimeter and continuous under-slab insulation where the modelling requires it.
Specifying a concrete slab as one system
A 7-star rating is achieved across the whole home, but the floor should be designed as one coordinated system. The EPS waffle pods, slab-edge insulation and, where required, continuous under-slab insulation each address a different part of the floor’s thermal performance.
Foamex manufactures all three components in Australia. This allows the complete waffle pod slab insulation system to be quoted through one supplier, with product selection, construction details and delivery coordinated together rather than resolved separately.
StyroPod® waffle pods are manufactured to AS 1366.3 and contain recycled material. StyroTherm® slab-edge and under-slab boards are manufactured using up to 90 per cent recycled polystyrene recovered from EPS packaging. StyroSheet EPS boards are also manufactured to AS 1366.3, with flame-retardant properties incorporated into the raw-material formulation.
The result is a locally manufactured and coordinated floor system that combines structural requirements, measurable thermal performance and recycled material content.
Talk to Foamex about the floor as a whole. We manufacture the pods, the slab edge and the under slab boards, and we can work through the details with your engineer or energy assessor. 
Frequently asked questions
Do waffle pods count towards a NatHERS rating?
Yes. A waffle pod slab is modelled as a concrete top layer with an additional insulation layer beneath it, at R0.57 to R0.65 depending on pod depth.
Will a waffle pod slab get my house to 7 stars on its own?
No. The pods contribute to the floor, but a 7 star result depends on the whole envelope, and within the floor the slab perimeter has to be addressed separately.
What R-value does a 300mm waffle pod add?
R0.63 as an additional insulation layer, based on CSIRO testing of a 300mm pod against a conventional 100mm slab on ground.
Can I choose a deeper pod to improve my rating?
Pod depth is determined by the site classification under AS 2870-2011 and the engineer’s slab design, not by the energy rating. The difference between the shallowest and deepest pod is 0.08 in additional R-value.
Is slab edge insulation required under NCC 2022?
Requirements vary by jurisdiction and by the compliance pathway used. Where a floor needs to contribute more, slab edge insulation is usually the most direct way to get it, because perimeter loss is concentrated and treatable.
Sources

Thermal resistance figures: CSIRO Australian Housing Data, thermal resistance of waffle pod slabs.
Star rating requirement and adoption dates: Nationwide House Energy Rating Scheme, NatHERS.
Site classification: AS 2870-2011, Residential slabs and footings.
Moulded EPS: AS 1366.3, Rigid cellular plastics sheets for thermal insulation.

#### Weigh Up The Savings Of Building With Lightweight Construction Materials
The benefits of building with lightweight construction materials may seem obvious but it really is worth looking closely at the differences that can be achieved in ease and speed of construction, cost savings, and results.

#### What Are the Best EPS Insulation Boards for Exterior Walls?
For exterior walls in Australia, Foamex offers two EPS-based options. StyroSheet is a versatile EPS sheet available nationwide. Insulclad is a complete rendered EPS wall cladding system, manufactured by Foamex NSW and available in New South Wales only. Both perform inside a complete wall system, not as a stand-alone board. For Type A and Type B construction, fire compliance must be confirmed by the certifier or fire engineer.
NSW only: Insulclad is manufactured by Foamex NSW and supplied in New South Wales only. Outside NSW, specify StyroSheet.
StyroSheet vs Insulclad at a Glance

Feature
StyroSheet
Insulclad

Product
Versatile EPS sheet from Foamex Styroboard EPS
Complete rendered EPS wall cladding system

Best for
EIFS-style systems, wall insulation, fabrication and custom panels
Rendered residential walls and selected low-rise commercial in NSW

Availability
Nationwide
NSW only (Foamex NSW)

Sizes
Widths up to 1.2 m, lengths 2.5 / 3 / 5 m, thickness 10 to 600 mm
1200 x 2500 mm and 1200 x 5000 mm panels, 50 / 60 / 75 / 100 mm

Grade range
SL Grade (70 kPa) to VVH 38 (350 kPa) at 10 per cent deformation
Configured as a complete certified system

 
Not sure which one fits your wall system? Speak with the Foamex team or call 1300 AU FOAM (1300 283 626) for product specification support.
When to Choose StyroSheet
Best for: nationwide projects, EIFS-style external wall insulation, wall insulation behind compatible cladding, and custom fabricated EPS panels.
StyroSheet is manufactured from Foamex Styroboard EPS in grades from SL Grade at 70 kPa through to VVH 38 at 350 kPa at 10 per cent deformation, in thicknesses from 10 mm to 600 mm. Use it when the wall system is being specified separately and the EPS layer needs to fit a defined size, grade and thickness brief.
When to Choose Insulclad
Best for: NSW residential and selected low-rise commercial projects that need a complete rendered EPS cladding system rather than a separate sheet.
Insulclad panels are available in 1200 x 2500 mm and 1200 x 5000 mm core panel formats, in 50, 60, 75 and 100 mm thicknesses. The system documentation covers fixing, render application and detailing as a complete cladding solution. For NSW projects only.
What Makes EPS Work in an Exterior Wall
EPS boards are part of a wall assembly. Performance comes from the complete build-up, including mechanical fixings or adhesive, reinforcing mesh, base coat, water control layer, drainage cavity, vapour-permeable membrane and the render or cladding finish. Specify the EPS to fit the system, not the other way around.

Consistent density and grade across the wall area.
Compressive strength matched to the system, especially under rendered finishes.
Thickness selected from the energy assessment, not a default specification.
Moisture-aware detailing with vapour-permeable membranes and drainage cavities in cool climates.
A confirmed compliance pathway for the building class, particularly for fire performance.

Compliance Snapshot: NCC, NatHERS and BASIX
External walls in Australia generally need to satisfy several pathways together. The summary below is a starting point. Confirm specifics with your designer, energy assessor, certifier and fire engineer.

NCC Energy Efficiency: total wall R-value applies in all states. NCC 2022 typically targets external wall R-values of R2.4 to R2.8 in many residential zones, with higher values in cooler climates.
NatHERS: whole-of-home energy modelling. NCC 2022 lifted the minimum to 7 stars in most jurisdictions.
BASIX (NSW residential): thermal, energy and water targets. EPS wall thickness is captured in the assessment but compliance depends on the whole envelope.
NCC Fire (Type A and B construction): external walls and their components must generally be non-combustible unless a permitted performance pathway applies. Fire-retardant EPS does not meet this automatically. Fire engineering assessment and certifier sign-off are required.

Moisture and Detailing in Brief
EPS resists liquid water uptake. The point that catches more projects out is condensation. In cooler climates, warm indoor air can condense at the back face of an EPS board. The fix sits in the detailing. Specify vapour-permeable membranes, a drained cavity behind the cladding, sealed penetrations and a coordinated approach to insulation and air control. Detail EPS as part of a moisture-aware wall, not a stand-alone layer.
Sustainability
Foamex manufactures EPS in Australia using a steam expansion process. EPS is produced without CFCs, HCFCs or other ozone-depleting blowing agents. Clean EPS offcuts and suitable EPS waste streams can be recovered through Foamex recycling programs, with an estimated recovery of 85 to 90 per cent of clean site offcuts. The biggest sustainability gain from EPS in an exterior wall is operational energy savings across the life of the building.
Talk to Foamex about EPS exterior wall solutions. Call 1300 AU FOAM (1300 283 626) or contact the Foamex team to discuss StyroSheet, Insulclad and the right EPS solution for your wall system, R-value target and compliance pathway.

Frequently asked questions
Can EPS boards be used on exterior walls in Australia?
Yes, when specified as part of a suitable wall build-up and installed against the relevant product documentation, NCC requirements and compliance pathway. Class 1 detached homes commonly use rendered EPS systems. Type A and Type B construction requires a performance-based fire compliance pathway.
Is Insulclad available outside NSW?
No. Insulclad is manufactured by Foamex NSW and available in New South Wales only. For projects outside NSW, specify StyroSheet.
What EPS thickness should I use?
Thickness is selected from the energy assessment for the project. StyroSheet is available from 10 mm to 600 mm. Insulclad panels are 50, 60, 75 or 100 mm. Speak with your NatHERS or BASIX assessor before locking in board thickness.
Does fire-retardant EPS meet NCC non-combustibility requirements?
No. Fire-retardant EPS does not automatically satisfy NCC Deemed-to-Satisfy non-combustibility requirements for external walls in Type A and Type B construction. A performance-based pathway requires fire engineering and certifier sign-off.
Are Foamex EPS boards recyclable?
Yes. Clean EPS offcuts can be recovered through Foamex recycling programs, with an estimated recovery of 85 to 90 per cent of clean site offcuts.

#### What happens to Expol in the case of a fire?
This is one question we get asked about a lot by our customers, and in light of recent overseas events, it is an important one.
Foamex’s Expol Underfloor Insulation has a fire retardant component built into every panel; which means when the panels are exposed to a small flame source, they will shrink away from the naked flame. When the flame is completely removed or extinguished, so too will the Expol Underfloor Insulation, meaning Expol does not add fuel to the fire.

#### What is the difference between EPS & XPS foam?
Expanded polystyrene (EPS) and extruded polystyrene (XPS) are both made from the same raw material, but where they differ is the manufacturing process which gives them different densities. As XPS has a higher cell density, it has a higher compressive strength and is more moisture resistant. However, there are many situations where EPS is a better option and others where XPS should be considered. Expanded polystyrene EPS is manufactured using foam beads that expand and fuse within a mould using heat or steam. Extruded polystyrene XPS is manufactured using an extrusion process. EPS and XPS provide efficient and effective insulation and guarantee excellent thermal conductivity. Choosing between the two will depend on the particular use. Foamex manufactures both EPS and XPS products in Australia.

#### Where polystyrene sheets are used in Australian building
Expanded polystyrene (EPS) sheets are used in Australian buildings for wall & floor insulation, including under-slab and slab-edge applications. They are also used in rendered wall cladding systems and cold rooms. Foamex manufactures polystyrene sheets from Styroboard EPS in thicknesses from 10 mm to 600 mm, with grades from SL to VVH 38 listed for StyroSheet.
The right sheet depends on where it will be installed, the thermal resistance required and any load it must carry. Moisture exposure and the requirements of the complete building system also need to be checked.
The applications

Where it goes
What the application asks of the sheet

Cavity and external walls
Thermal resistance within the specified wall system. Confirm sheet thickness, fixing, moisture-control details and fire requirements; the sheet alone does not establish wall performance.

Roofs and ceilings
Thermal resistance within the available depth. Check the roof build-up, service conditions and any loading before selecting the sheet.

Under slab
Thermal resistance and compression performance under the slab’s design loads. Both grade and thickness matter.

Slab edge
Continuous insulation at the perimeter. Check thickness, moisture exposure and protection within the slab-edge detail.

Rendered wall cladding
EPS used as part of a specified cladding system, with compatible fixings, reinforcement and render. General-purpose sheet is not a complete cladding system.

Cold rooms and cool stores
Thermal resistance and control of moisture movement through the complete enclosure, including joints and vapour-control details.

Void forming and protective packaging
A shape and grade suited to the task. Void formers require checks for construction loads; packaging requires cushioning and protection during handling.

Working back to a specification
Start with the project’s thermal and structural requirements, then check the sheet against both.
For thermal performance, select a grade and thickness that deliver the required R-value. Foamex’s StyroSheet range lists minimum R-values at 50 mm from R1.20 for SL grade to R1.50 for VVH 38. Increasing thickness can provide more insulation, while the grade also affects the result. Use the published value for the proposed product, not a single R-value for all EPS.
For compression performance, check the specified grade. Published minimum compressive stress at 10% deformation ranges from 70 kPa for StyroSheet SL grade to 350 kPa for VVH 38. These test figures describe material behaviour; they are not allowable working loads for a slab or other structure.
The broader Styroboard EPS grade table, including L grade, is set out in how expanded polystyrene is made. It brings together nominal density, compression-test results and thermal resistance.
AS 1366.3-1992 sets minimum properties for six EPS classes. Foamex describes Styroboard EPS as manufactured to meet this standard; its additional VVH grades sit outside those six classes. For load-bearing use, the structural engineer should confirm the grade. Check the insulation requirement against the project energy assessment.
Moisture and thermal performance
EPS has a closed-cell structure and resists moisture uptake, but it can absorb some water. The conditions around the sheet matter, particularly below ground or where condensation may occur.
Foamex’s Styroboard EPS data sheet gives maximum water absorption under total immersion from 4% by volume for L, SL and S grades to 1% for VVH 36 and VVH 38, tested to ASTM C272. These are laboratory test results, not predictions of moisture content in a particular building.
Assess the sheet as part of the moisture-control design. Specify any required drainage, waterproofing or vapour-control layers for that location; moisture-resistant insulation does not replace them. Do not assume that adding a vapour barrier is appropriate in every wall or roof.
Sizes and grades

Attribute
Value

Widths
up to 1.2 m

Lengths
2.5 m, 3 m, 5 m

Thickness
10 mm to 600 mm

Grades
SL, S, M, H, VH, VVH 32, VVH 36, VVH 38

Foamex publishes these sizes for StyroSheet and offers custom cutting. Contact Foamex with your required dimensions and grade to confirm supply and lead time. Custom sizes may have different availability from standard stock.
Fire performance
StyroSheet is made from fire-retardant Styroboard EPS. EPS remains combustible, so a flame-retardant formulation does not make the sheet non-combustible or establish the fire rating of a complete building system. Foamex publishes flame-propagation test data under AS 2122.1. Use the relevant system documentation when specifying walls, roofs or cladding.
Recycling and site offcuts
StyroSheet contains recycled material, and clean EPS offcuts can be reprocessed into new products. Keep them separate from general building waste and secure them against wind. Confirm acceptance with the recycler, especially for recovered sheets with render, paint or other attached materials. Recyclability does not mean every demolition offcut can be accepted.

For more information about our EPS Sheets, please visit our StyroSheet product page.  

Frequently asked questions
What thickness of polystyrene sheet do I need?
Check the R-value required by the project energy assessment, then select the grade and thickness together. StyroSheet’s published minimum R-values at 50 mm range from R1.20 to R1.50. Also check available space, loading and the installation detail.
What is the difference between the EPS grades?
EPS grades have different physical properties. In the StyroSheet range, SL grade has a published minimum compressive stress of 70 kPa at 10% deformation; VVH 38 has 350 kPa. Thermal resistance also varies. Grade selection should use the performance data, not nominal density alone.
Can polystyrene sheets be used under a concrete slab?
EPS is used for under-slab insulation, but the specified product, grade and thickness must suit the slab design. The structural engineer should confirm loading requirements. A general-purpose sheet should not be substituted without approval. For void-fill for concrete slab construction, consider EPS waffle pods.
Do polystyrene sheets absorb water?
They can absorb some water. Foamex publishes maximum total-immersion absorption figures of 1% to 4% by volume across the Styroboard EPS grades. Check the chosen grade and the project’s moisture-control details.
What sizes do polystyrene sheets come in?
Foamex lists widths up to 1.2 m, lengths of 2.5 m, 3 m and 5 m, and thicknesses from 10 mm to 600 mm. Custom cutting is available; confirm dimensions and supply with Foamex.
Are polystyrene sheets recyclable?
Yes. Clean EPS can be recycled through specialist collection and processing services. Keep offcuts free of contamination and confirm whether coated or recovered building material will be accepted before arranging recycling.

Sources

Foamex StyroSheet sizes grades and product information
Foamex Styroboard EPS Technical Data Sheet 2025
Foamex Styroboard EPS brochure and fire guidance
Foamex Insulclad system information NSW
Foamex recycling services and acceptance requirements
EPS Industry Alliance moisture and material properties

#### Where to Buy High-Density EPS Insulation Near Me?
It usually starts with a simple question. You are planning a build, maybe a renovation, or even fixing insulation issues that should have been sorted years ago. Somewhere between talking to a builder and scrolling late at night, you ask yourself, ‘Where can I buy high-density EPS insulation near me?’
It sounds like a small thing, but choosing the right insulation supplier can affect comfort, energy bills, and even structural performance. In Australia, where heat, cold, and energy efficiency rules all play a role, this question matters more than people realise. That is why many builders and designers turn to Australian-made EPS solutions such as StyroSheet EPS Sheets, which are designed specifically for local conditions.
What Is High-Density EPS Insulation and Why Is It Important?
High-density EPS insulation is a rigid foam material designed to handle pressure while still delivering reliable thermal performance. It is commonly used under concrete slabs, within wall systems, roof insulation applications, and civil projects where strength really counts. Many people assume all EPS insulation is the same. It is not. High-density EPS insulation products, like StyroSheet EPS Sheets, are manufactured to precise density grades to ensure consistency, durability, and compliance with Australian Standards. This is why builders and engineers across Australia rely on high-quality EPS sheets for long-term performance.
Where Can I Buy High-Density EPS Insulation Near Me in Australia?
If you are searching online for where to buy high-density EPS insulation near me, the best place to start is with local Australian manufacturers rather than generic importers. Buying locally ensures the product meets Australian standards and performs as expected in Australian climates.
High-density EPS insulation is commonly supplied by:

Australian EPS manufacturers such as Foamex
Construction and insulation suppliers
Building material distributors
Civil and commercial construction specialists

Products like StyroSheet EPS Sheets are manufactured in Australia and available nationally, making them a practical option when you need a reliable supply, technical support, and consistent quality.
Should I Buy High-Density EPS Insulation Direct from a Manufacturer?
Buying directly from an Australian manufacturer is often the smartest option. Manufacturers can supply consistent quality, verified density ratings, and products that comply with Australian building codes. Foamex, for example, manufactures StyroSheet EPS Sheets in a range of densities and thicknesses, suitable for under slab insulation, wall systems, and commercial applications. Many manufacturers also offer custom cutting options, which can help reduce waste and installation time on site.
How Do I Know If the EPS Insulation Is High-Density?
Not all EPS insulation is the same. When asking where to buy high-density EPS insulation near me, it is important to confirm the technical details. High-density EPS insulation is usually identified by:

Density ratings are measured in kilograms per cubic metre
Compressive strength values
Compliance with Australian Standards
Clear and accessible product data sheets

Reputable suppliers of products like StyroSheet EPS Sheets will always provide this information and guide you toward the correct grade for your project.
Is High-Density EPS Insulation Suitable for Residential and Commercial Projects?
Yes, high-density EPS insulation is widely used in both residential and commercial construction across Australia. In homes, it is commonly used for under-slab insulation, wall insulation, and energy-efficient flooring systems. In commercial and civil projects, EPS sheets are used for structural fill, roofing insulation, and applications that require load-bearing performance without excessive weight. The lightweight nature of EPS also makes handling and installation easier, saving labour time without compromising strength.
Why Should I Choose an Australian Supplier for EPS Insulation?
Choosing an Australian supplier ensures the insulation is designed for local conditions and complies with Australian building regulations. Australian manufacturers like Foamex also focus on sustainability, recycling programmes and responsible production methods.
When searching for where to buy high-density EPS insulation near me, selecting a trusted local supplier gives you access to expert advice, ongoing support, and products that are proven in Australian projects.
Final Thoughts
If you are looking for high-density EPS insulation that meets Australian Standards, delivers consistent thermal performance, and is readily available, StyroSheet EPS Sheets by Foamex are a reliable choice. By choosing a trusted Australian supplier, you improve your project outcomes and gain confidence that your insulation is engineered for local conditions. To learn more about product specifications, pricing or availability, contact our team today and let us help you select the right EPS solution for your application.
FAQs
What is high-density EPS insulation used for?

High-density EPS insulation is used under concrete slabs, in walls, roofs, and civil projects where strength and thermal performance are required.
Where can I buy high-density EPS insulation near me in Australia?

You can buy high-density EPS insulation from Australian manufacturers like Foamex, insulation suppliers, and building material distributors nationwide.
How do I know if EPS insulation is high-density?

High-density EPS insulation comes with clear density ratings, compressive strength values, and technical data sheets.
Is high-density EPS insulation suitable for residential homes?

Yes, it is commonly used in Australian homes, especially for under-slab insulation and energy-efficient designs.
Why should I choose an Australian supplier for EPS insulation?

Australian suppliers ensure compliance with local standards, suitability for climate conditions, and reliable product support.
Is high-density EPS insulation environmentally friendly?

EPS insulation is durable and recyclable, and many Australian manufacturers operate recycling programmes to reduce waste.

#### Which EPS Insulation Type Suits Your Home Best?
There is no single EPS product that is best for every part of a house. Standard EPS boards may suit selected wall systems, higher-density EPS grades are typically used where compressive strength matters, and slab applications should be assessed in relation to climate zone, engineering design and the relevant compliance pathway.
Choosing the right insulation is one of the most important decisions when building or renovating a home. If you are researching expanded polystyrene, or EPS, insulation for Australian homes, it is important to understand that not all EPS products are designed for the same application.
So which type of EPS insulation is best for your house? The answer depends on where it will be used, the compressive loads it needs to handle, your project’s climate zone, and the thermal performance you are trying to achieve. In residential construction, EPS may be used in wall systems, under-slab applications and waffle pod slab systems but the most suitable product grade will vary by application.
What Is Expanded Polystyrene Insulation?
Expanded polystyrene, or EPS, is a rigid, lightweight, closed-cell insulation material made by expanding and moulding polystyrene beads. Foamex manufactures a range of EPS products in Australia, including Styroboard EPS, for use across residential and commercial construction.
EPS is widely used because it offers:

Reliable thermal resistance
Low weight for easier handling and installation
Good dimensional stability
 Long service life when correctly installed and protected
Recyclability within suitable recovery programs

When specified correctly, EPS can contribute to improved thermal performance in Australian homes across a range of climate conditions.
6 Factors That Determine the Right EPS Product
Before selecting an EPS product, it is worth checking the six factors that most often determine what is appropriate for the project:

Where the insulation will be used
Wall systems, under-slab applications and waffle pod slabs do not require the same type of EPS.

Compressive strength requirements
Some applications need higher-density EPS to handle structural loads without deformation.

Required thermal performance
The target R-value will influence the product grade and thickness required.

Moisture exposure
Areas exposed to ground contact, damp conditions or higher moisture risk may need more careful product selection and detailing.

Climate zone and compliance pathway
NCC requirements, NatHERS assessments and BASIX considerations in NSW can all affect what is suitable.

Installation method and system design
The way the insulation is installed, detailed and integrated with the wider building system can change which EPS product is the best fit.

Best EPS Insulation for Wall Systems
Standard EPS Boards for Suitable Wall Applications
If you are choosing EPS insulation for wall systems, standard-density EPS boards such as Foamex Styroboard EPS may be suitable depending on the wall build-up, required R-value and moisture-management design.
EPS boards are commonly used in applications such as:

selected wall insulation systems
insulated panel construction
projects where lightweight, easy-to-fabricate insulation is required

Why EPS can work well in wall applications:

cost-effective thermal performance
lightweight handling and easier installation
stable long-term insulation performance when correctly installed
suitability for a wide range of fabricated building components

Rather than treating one board as the best solution for every part of the house, it is more accurate to assess whether a standard EPS board is the most suitable choice for the wall system being designed.
Best EPS Insulation for Concrete Floors and Slabs
Higher-Density EPS for Load-Bearing Applications
Where insulation is installed beneath or around a concrete slab, compressive strength becomes more important. In these applications, higher-density EPS grades may be specified to help manage structural loads while contributing to thermal performance.
Foamex structural EPS grades can assist in applications where the insulation needs to:

Resist compressive loads beneath the slab system
reduce unwanted heat loss or heat gain through the floor system
improve thermal comfort in cooler conditions
support slab edge detailing where required

The most suitable slab insulation solution depends on the slab type, climate zone and the project’s compliance pathway. Under NCC 2022, slab edge and under-slab insulation requirements vary by application, so the insulation should be selected and detailed accordingly.
Best EPS Solution for New Slab-on-Ground Homes

EPS Waffle Pod Systems for Residential Slab Construction
For new home builds, particularly slab-on-ground construction, EPS waffle pod systems such as Foamex StyroPod can offer both structural and thermal advantages.
These EPS pods are used within reinforced concrete slab systems to:

reduce the volume of concrete required
assist the thermal performance of the floor system
support efficient installation on site
contribute to a cost-effective slab design outcome

Waffle pod systems are widely used in Australian residential construction, but their suitability should still be assessed in relation to climate zone, slab design, engineering requirements and the applicable compliance pathway.
EPS Compared with Other Insulation Types
EPS, XPS and PIR (foil-faced rigid insulation boards) do not serve exactly the same purpose in every application. The most suitable product depends on where the insulation is being installed, how much compressive strength is required, how much thickness is available, and how important moisture resistance is in that part of the building.
In general:

EPS is often selected where lightweight handling, cost-efficiency and versatile fabrication are important
XPS may be preferred in applications where higher moisture resistance is critical
PIR (foil-faced rigid insulation boards) can provide higher thermal performance per unit of thickness, where space is limited

For residential projects, the best choice is not always the product with the highest R-value per millimetre. It is the product that best matches the wall, floor or slab application and the broader building design.
Does EPS Help Meet NatHERS or BASIX?
Yes, EPS insulation can contribute to the thermal performance of a residential building and may support energy-efficiency outcomes assessed under NatHERS. On NSW projects, it may also contribute to BASIX compliance when specified as part of the overall building fabric design.
It is worth keeping the terminology precise: NatHERS is used nationally as a pathway for assessing the thermal performance of homes, while BASIX is a NSW-specific planning requirement.
How to Choose the Best EPS Insulation for Your Home?
To choose the most suitable EPS insulation, start with the application rather than the product name. Check where the insulation will be installed, what loads it needs to carry, the climate zone, the target R-value, and whether the design includes any detailing considerations such as slab edges, moisture exposure or thermal bridging.
On most projects, the final product selection should be confirmed with the designer, builder, engineer or energy assessor so that the insulation works as part of the overall building system, not as an isolated material choice.
Final Thoughts
By choosing the right EPS insulation for each area of your home, you can enhance indoor comfort, reduce energy bills, and achieve long-term building performance. If you are unsure which solution is right for your project, contact us to discuss the best Foamex insulation options for your home.
Frequently Asked Questions
Is EPS insulation suitable for every part of a house?
Not necessarily. EPS can be suitable in a range of wall, slab and fabricated building applications, but the most appropriate product depends on the location, required performance and detailing conditions.
What is the difference between standard EPS and structural-grade EPS?
Standard EPS is often used where lightweight thermal performance is the priority, while structural grades are selected where higher compressive strength is needed, such as under or around certain slab systems.
Are waffle pods the same as under-slab insulation boards?
No. Waffle pods are used within a concrete slab system as void formers and can contribute to thermal performance, while under-slab insulation boards are separate insulation elements specified for particular floor or slab conditions.
Is EPS or XPS better for under-slab insulation?
That depends on the project. EPS may suit many applications, but XPS may be preferred where very high moisture resistance is required. The right choice depends on the design brief and the relevant detailing requirements.
Does EPS help meet NatHERS requirements?
Yes, EPS can contribute to the thermal performance of the building fabric and may support NatHERS outcomes as part of the overall design, but compliance is assessed at the whole-of-home level rather than by one product alone.
Does BASIX apply across Australia?
No. BASIX is specific to NSW. NatHERS and NCC energy-efficiency provisions apply more broadly across Australian residential projects.
Need Help Choosing the Right EPS Insulation?
Foamex can help you identify the most suitable insulation solution for wall systems, slabs and waffle pod construction based on your project type, thermal target and application requirements.

#### Why Geofoam polystyrene blocks are ideal for roads & bridges
GeofoamX EPS blocks are ideal for civil engineering applications, including road construction and bridge abutments, due to their exceptional weight-bearing load capacity, weather resistance and durability.
Using polystyrene blocks also reduces soil stresses and decreases the amount of concrete required to stabilise roads, roadmaking fill, embankments, bridge abutments, side hills, and retaining walls.
The high compressive stress resistance of Geofoam blocks makes them the perfect solution for new road construction or the widening of existing roads. They sufficiently support high traffic loadings, meaning that roads can be built faster, lighter, and more stable than similar fill materials. The high compressive resistance of polystyrene foam blocks also safely supports the loadings of bridge abutments without overstressing the underlying ground cover. Compared to traditional fill materials, EPS blocks reduce the lateral force on the abutment walls, foundations, and other retaining structures.

#### Why polystyrene is still the best for protective packaging?
Polystyrene has been the material of choice for protective packaging for many years due to its inherent qualities that make it ideal to protect goods in transit and storage.

#### Why underfloor insulation is key to draught proofing a home
It’s time to rethink how we insulate our homes against draughts. Expanded polystyrene insulation is one of the most effective materials for sustainably insulating draughty houses. Unlike many of our Northern Hemisphere counterparts, in Australia we tend to build houses with plenty of draughts.
In colder climates, it is essential to control draughts in housing because the heating costs would be prohibitive. But here in the Southern Hemisphere we’re still learning about the merits of insulating our draughty homes sustainably to cost-effectively reduce the amount of cool air that can enter.

#### Why well insulated homes start at the edge
Slab edge can be responsible for approximately 80% of the slab’s total heat loss1,  with further research showing that thermal resistance does not significantly improve by fully extending the insulation under the slab or by increasing the thickness of the insulation under the slab.  The reason being that, with no insulation on the perimeter foundations, most of the heat is conducted along the slab2 and out through the exterior face of the footing.
This suggests that insulating slab edges is far more effective for preventing heat loss than insulating the underside of the slab.
Styroboard XPS from Foamex is an ideal material for Slab Edge Insulation. Extruded polystyrene (XPS) is a rigid insulation that is formed with polystyrene polymer, but manufactured using an extrusion process. This rigid foam provides a strong, yet lightweight and flexible insulation solution which is resistant to water absorption, making it a long term, sustainable solution to reducing slab edge heat loss.

#### Why you should choose extruded polystyrene (XPS) underneath hydronic heating systems
Extruded polystyrene (XPS) is a type of rigid foam insulation material commonly used in construction and other applications.
XPS is characterized by its closed-cell structure, which makes it resistant to moisture absorption and provides high thermal resistance.
The properties of extruded polystyrene make it an effective insulation material, used to reduce heat transfer and provide energy efficiency in buildings. It is commonly employed in applications such as insulating walls, roofs, and foundations.
Using extruded polystyrene (XPS) insulation underneath hydronic heating systems can provide several benefits.

#### XPS Foam Board: 5 Critical Applications That Improve Building Performance
Quick answer: XPS (extruded polystyrene) foam board is a closed-cell rigid insulation that holds shape under load and resists moisture. In Australian construction, the five most useful applications are slab edge insulation, sub-slab insulation, below-ground walls, metal roof spacers and inverted or green roofs. Foamex StyroTherm XPS is available in grades that achieve 200 to 350 kPa compressive strength at 10% deformation, with R-values ranging from approximately R0.9 at 30 mm up to R3.0 plus at 100 mm and above. For Type A and Type B construction under the National Construction Code, fire compliance must be confirmed by the certifier or fire engineer, regardless of fire-retardant grading.
Insulation only performs at its rated R-value when the board stays in shape and stays dry. That is why slab edges, below-ground walls and roof junctions are the points where insulation choices matter most. Compress an insulation layer or let water find it, and the design R-value disappears.
XPS foam board is engineered to handle those conditions. Its closed-cell structure resists water absorption, the dense matrix holds shape under sustained load and the dimensional stability suits cutting and detailing on site. Foamex StyroTherm XPS is manufactured in Australia for slab insulation, perimeter detailing, below-ground protection and roof systems where long-term thermal performance has to hold.
Let’s take a look at what XPS is, the five applications where it earns its place over EPS or other materials, the technical numbers to use in specification, and the National Construction Code considerations that need a certifier in the loop.
What is XPS Foam Board & How Does It Differ from EPS?
XPS and EPS are both polystyrene insulation, but they are made in different ways and behave differently in service.
EPS (expanded polystyrene) is made from polystyrene beads that are expanded with steam and fused into a board. The structure is closed-cell at the bead level, but bead boundaries can absorb a small amount of water under sustained exposure. EPS is light, inexpensive and well suited to wall insulation, void forming and lightweight panels.
XPS (extruded polystyrene) is made by extruding molten polystyrene through a die, forming a continuous closed-cell matrix. The cells are smaller and more uniform, the density is higher and water absorption is lower under prolonged contact. XPS has a higher compressive strength at the same nominal R-value, which is why it suits slab edges, below-ground walls and roof systems where load and moisture are constants.
The choice between XPS and EPS is not about which one is better in general. It is about matching the board to the application. EPS waffle pods are appropriate beneath slab systems, while XPS is better suited to exposed perimeter slab-edge applications where moisture exposure and compressive resistance are more demanding.
XPS Performance: R-Values and Compressive Strength
Specifying XPS comes down to two numbers in most projects. R-value tells you how much resistance the board offers to heat flow at the nominated thickness. Compressive strength tells you how much load the board can take before deforming beyond its design limit. Both numbers matter at slab edges, below-ground walls and roofs.
Foamex StyroTherm XPS is available in grades that achieve roughly 200 to 350 kPa compressive strength at 10% deformation. R-value scales with thickness. Confirm specific values for the grade and thickness on the project drawings against the product technical data sheet.

XPS thickness
Approximate R-value (m²K/W)
Typical compressive strength
Common applications

30 mm
Approximately R0.9 to R1.0
200 to 300 kPa
Slab edge insulation, perimeter detailing

50 mm
Approximately R1.5 to R1.7
200 to 350 kPa
Slab edge, below-ground walls, roof spacers

75 mm
Approximately R2.2 to R2.5
200 to 350 kPa
Below-ground walls, sub-slab insulation

100 mm
Approximately R2.9 to R3.3
200 to 350 kPa
Inverted roofs, green roof systems, deep below-ground applications

Note: R-value declarations are based on a stable, dry board at a known temperature. Real-world performance assumes the board stays dry and in shape, which is exactly why XPS is selected over softer or more absorbent materials in exposed conditions.
Application 1: Slab Edge Insulation
A slab edge is one of the biggest heat loss paths in an Australian home. Concrete is a strong thermal mass, but it conducts heat to ground and outside air at the edge unless that edge is insulated.
XPS is the standard answer for slab edge insulation because it can resist moisture in contact with the ground, hold shape under backfill pressure and integrate with the slab pour or post-pour application. Closed-cell structure resists water uptake that would otherwise degrade thermal resistance over time.
Specify the XPS thickness based on the energy assessment and climate zone. R-values for slab edge insulation typically sit in the range of R1.0 to R2.5, depending on the project target and the wall and floor build-up.
Application 2: Sub-Slab and Below-Ground Insulation
Below the slab and below ground, insulation has to handle hydrostatic pressure, soil moisture and the weight of fill or paving above. Softer materials compress and absorb water in those conditions, which means the rated R-value drops in service.
XPS holds its closed-cell matrix under sustained load and resists moisture migration through the board. That makes it suitable for below-ground walls, sub-slab insulation in conditioned slabs and tanking-adjacent details where the board sits in contact with soil.
Detailing matters as much as the board specification. Drainage, waterproofing membrane choice and backfill compaction all affect long-term performance. Coordinate the XPS layer with the waterproofing system and the structural design.

StyroThem XPS Sheet Sub-Slab Install- Malvern, VIC
Application 3: Metal Roof Spacers and Thermal Bridging Control
Metal roofs over glasswool batts have a known performance issue. Where the batt passes under each purlin, the metal roof and the purlin compress the insulation. Compressed insulation has a much lower effective R-value, and the compression line runs along every purlin in the roof. The result is a thermal bridge that reduces the overall envelope performance.
Foamex StyroLink XPS Roof Spacers create a fixed separation point above each purlin. The spacer holds the metal roof off the purlin by a defined amount, which lets the glasswool batt recover its full installed profile. The batt continues at its design thickness across the purlin line, and the thermal bridge is reduced.

Without StyroLink XPS roof spacers
With StyroLink XPS roof spacers

Glasswool batt is compressed at every purlin contact, often to around 50% of its installed thickness
Batt sits at full design profile because the spacer creates a fixed separation point above each purlin

Effective R-value at the purlin can drop sharply, creating thermal bridges along every roof line
Effective R-value across the assembly tracks closer to the design value

Heat loss and heat gain occur predictably along the purlin lines
Thermal bridging through the purlin line is reduced

In a real-world example, a typical COLORBOND® roof on glasswool batts can lose roughly half the effective R-value at every purlin without spacers. That sets a ceiling on what the assembly can deliver, regardless of how thick the batt is. StyroLink XPS spacers address the cause rather than compensating with thicker batts.

Application 4: Inverted Roofs and Green Roof Insulation
Inverted roofs place the insulation above the waterproofing membrane, with paving, gravel or growing medium over the top. That layout protects the membrane from temperature swings and mechanical damage. The insulation has to resist water, hold shape under heavy overburden and last as long as the rest of the roof.
Foamex StyroRoof XPS is designed for those conditions. The board supports overburden loads from soil, pavers and drainage layers, and the closed-cell structure resists sustained moisture exposure. The insulation layer remains intact while the membrane sits protected beneath.
Green roof projects benefit from the same properties. The combination of mechanical load, moisture and biological activity above the membrane needs an insulation layer that can take the conditions for the life of the roof.

Image Credit: An Architect’s Guide To: Green Roofs
Application 5: Foundation and Basement Walls
Basement walls and foundation walls in below-ground or partially below-ground construction need insulation that can sit against the wall, resist soil moisture and survive backfill compaction. XPS handles all three conditions when detailed correctly.
Specify the right grade for the project loadings, integrate the board with the waterproofing system and confirm the assembly with the structural engineer. The insulation contribution to overall thermal performance is then captured in the energy assessment for the building.
XPS, Recycled Content and the Circular Production Model
Foamex StyroTherm XPS is manufactured with post-consumer and post-industrial recycled polystyrene content. Recycled content typically ranges from 70 to 90% depending on feedstock availability, with the manufacturing process tuned to maintain consistent thermal and structural performance across production batches.
Clean offcuts from EPS and XPS site work can be returned to manufacturing through the Foamex offcut collection service. Material is compacted, pelletised and reintroduced into new product, supporting circular-economy outcomes within the construction cycle. Manufacturing uses steam expansion rather than ozone-depleting blowing agents, which removes that historical environmental concern from XPS production.
Sustainability claims for any insulation product depend on more than recycled content. The biggest contribution insulation makes to long-term outcomes is reducing operational energy use across the life of the building. Specify the right product, install it correctly and detail it to last.
National Construction Code (NCC), Fire and Compliance
Insulation specification has to sit inside the compliance pathway for the building. For commercial, multi-residential and other Type A or Type B construction, the NCC Deemed-to-Satisfy provisions generally require external walls and their components, including cladding, insulation and related elements, to be non-combustible unless a permitted compliance pathway applies.
Fire-retardant XPS and fire-retardant EPS do not automatically satisfy non-combustibility requirements. A performance-based compliance pathway can be used, but it requires a fire engineering assessment and certifier sign-off. Before specifying XPS in a commercial or higher-risk application, confirm the compliance pathway with the project architect, certifier or fire engineer.
In residential Class 1 and 2 work, applications such as slab edge insulation, sub-slab insulation, basement walls and metal roof spacers are commonly used when detailed appropriately. The compliance pathway should still be recorded against the project documentation.
How to Specify Foamex XPS for Your Project

Confirm the application: slab edge, below-ground, roof spacer, inverted roof or green roof.
Read the energy assessment to identify the target R-value at each location.
Match thickness and grade to the R-value and the design loading.
Coordinate the XPS layer with the waterproofing, drainage and structural design.
Check the NCC compliance pathway with the certifier or fire engineer for Type A and Type B work.
Plan offcut collection ahead of installation to keep clean waste in the recycling stream.

Contact Foamex for StyroTherm XPS, StyroLink roof spacers and StyroRoof technical support on slab edges, below-ground, roof and green roof applications.

Frequently asked questions
What is XPS foam board used for?
XPS foam board is used in construction where insulation must resist heat flow, moisture and compression at the same time. The most common Australian applications are slab edge insulation, sub-slab insulation, below-ground walls, metal roof spacers and inverted or green roof systems.
Is XPS foam board better than EPS?
XPS has a denser closed-cell structure with higher compressive strength and lower water absorption than standard EPS. That makes XPS the better selection where insulation has to sit under sustained load or moisture, such as slab edges, below-ground walls and inverted roofs. EPS still suits wall insulation, void forming and lightweight panels where those conditions do not apply.
What R-value can I expect from XPS foam board?
XPS R-value scales with thickness. Approximate values are R0.9 to R1.0 at 30 mm, R1.5 to R1.7 at 50 mm, R2.2 to R2.5 at 75 mm and R2.9 to R3.3 at 100 mm. Confirm the exact value for the grade and thickness against the product technical data sheet.
What compressive strength does Foamex XPS provide?
Foamex StyroTherm XPS is available in grades that achieve approximately 200 to 350 kPa compressive strength at 10% deformation, suitable for slab edge, below-ground and roof spacer applications. Higher strength grades are available for specialised applications.
Is XPS suitable for commercial wall systems?
For commercial, multi-residential and other Type A or Type B construction, the National Construction Code generally requires external walls and their components to be non-combustible unless a permitted compliance pathway applies. Fire-retardant XPS does not automatically satisfy non-combustibility. Confirm the compliance pathway with the certifier or fire engineer before specifying XPS in those applications.
Can XPS be recycled?
Yes. Clean XPS and EPS offcuts can be returned through the Foamex offcut collection service. Material is compacted, pelletised and reintroduced into new EPS and XPS products. Foamex StyroTherm XPS is also manufactured with post-consumer and post-industrial recycled polystyrene content, typically 70 to 90% depending on feedstock.

#### XPS foam: what it is, where it is used and what it delivers
XPS is the rigid board that goes where the insulation is going to get wet, walked on or buried. It is extruded polystyrene, and it is a different material from the white expanded polystyrene most people picture, made by a different process and specified for different positions in a building. This page sets out what it is, where it belongs, and what it delivers at each thickness.
What is XPS foam?
Extruded polystyrene is made by melting polystyrene with a blowing agent and forcing it through a die as a continuous board. The result is a closed-cell foam with a uniform structure and a smooth skin on both faces.
Expanded polystyrene, EPS, is made a different way. Steam expands loose beads and fuses them together in a mould, which is why you can see the bead boundaries on an EPS board and why it breaks along them.
The practical differences that follow from that: XPS absorbs less water, holds its dimensions better in ground contact, and takes more compression at a given thickness. EPS is lighter, cheaper per square metre and available in far greater thicknesses, which is why it does the bulk work under slabs and inside panels. They are specified for different jobs.
Foamex manufactures XPS in Australia as StyroTherm®, made from Styroboard® XPS, and Styroboard® EPS as StyroSheet, StyroPod® and StyroBloc.

Where XPS is specified
XPS earns its place wherever moisture, load or ground contact would compromise a lighter board.

Slab edge insulation. A vertical board at the slab perimeter, in contact with soil and backfill. This is the single most common XPS application in Australian housing and it is what NCC 2022 energy provisions have pushed hardest.

Under slab, where loads are high. Car parks, industrial floors and cold store bases, where the board carries sustained load and sits against damp ground.

Inverted and protected membrane roofs. The insulation sits above the waterproofing, so it is permanently exposed to water. Closed cell structure is not optional here.

Cavity walls and internal linings. Where a thin board has to deliver a set R-value in a fixed cavity depth.

Cool rooms and refrigerated spaces. Continuous insulation with low water absorption, in a position that will see condensation.

Decks, balconies and planter boxes. Wet, loaded and hard to access once built.

StyroTherm® specification
StyroTherm® is supplied in five thicknesses. Thermal resistance, thermal conductivity and compressive stress by thickness:

Thickness

R-value
K-value (λ)
Compressive stress at 2%

Compressive stress at 10%

30 mm
0.94
$0.03
>90 kPa
>250 kPa

40 mm
1.29
0.031
>150 kPa
>350 kPa

50 mm
1.55
0.033
>230 kPa
>350 kPa

60 mm
1.82
0.033
>240 kPa
>350 kPa

75 mm
2.15
0.034
>280 kPa
 >350 kPa

How to read this table:

Both compressive figures are published for comparison, not as working loads. The 10 per cent figure is the value data sheets conventionally quote. The working load for a given position should be confirmed with the engineer, because sustained load behaves differently from a short term test.

R-value is a property of the board as installed. A board bridged by fixings, compressed at the joints or laid with gaps will not deliver its rated figure. Where a floor or wall has to reach a specific rating, the assembly is what gets assessed, not the product.

Moisture, and why it decides the material
The closed-cell structure is the whole argument for XPS. Water has no continuous path through the board, so it absorbs very little and keeps its thermal performance in positions where an open structure would not.
That matters in three places in particular: below ground, where the board is against soil that holds water; above a waterproof membrane, where it is deliberately outside the dry envelope; and anywhere condensation forms on a cold surface. In all three, insulation that takes up water stops insulating.
It is worth being precise about the claim. XPS resists water absorption. It is not a waterproofing layer and it does not replace a membrane or a damp proof course.
Specifying XPS in Australia
The material standard for extruded polystyrene is AS 1366.4. Thermal resistance is declared under AS/NZS 4859.1, which is the standard an energy assessor and a certifier will look for.
Three things to confirm before an order goes out. The position, because it sets everything else. The thickness, against the R-value the assessment requires rather than the space available. And the load, resolved with the engineer against the figures in the table above.
Residential slab using XPS foam – Malvern, Victoria

StyroTherm® is manufactured in Australia using up to 90 per cent recycled polystyrene recovered from EPS packaging, in a process free from ozone-depleting gases.
Talk to Foamex about the position you are insulating. We manufacture XPS and EPS in Australia and can work through the specification with your engineer, assessor or builder.
Frequently asked questions
What is XPS foam?
Extruded polystyrene: a rigid closed cell insulation board made by extruding polystyrene through a die as a continuous sheet, manufactured to AS 1366.4.
What is the difference between XPS and EPS?
XPS is extruded as a continuous board and EPS is moulded from expanded beads. XPS absorbs less water and takes more compression at a given thickness. EPS is lighter, available in far greater thicknesses and does the bulk insulation work.
What R-value does XPS give?
StyroTherm® runs from R0.94 at 30 mm to R2.15 at 75 mm, with R1.55 at 50 mm. The installed assembly is what gets assessed, so fixings, joints and gaps all affect the figure achieved.
Can XPS be used under a concrete slab?
Yes, and it is specified there where loads are high or the ground is wet. Confirm the thickness against the load with the engineer, and resolve the vapour barrier and pour sequence at the same time.
Is XPS waterproof?
XPS is special in that it resists water absorption because of its closed-cell structure, which is why it is used below ground and above membranes. It is not a waterproofing layer and does not replace one.
Sources

Material standard: AS 1366.4, Rigid cellular plastics sheets for thermal insulation, rigid cellular polystyrene, extruded (RC/PS-E).
Declared thermal resistance: AS/NZS 4859.1, Thermal insulation materials for buildings.
Specification figures: Foamex StyroTherm® product data.
Energy provisions: National Construction Code 2022.

#### XPS sheets in Australia: how to specify the right thickness, R-value and grade
XPS specification across Australian construction is driven by the position the board will occupy and the conditions it will see in service. Moisture exposure, sustained compressive load, available installation depth and the target R-value each push the selection. The following article sets out the variables that typically resolve an XPS specification in Australia, with reference to the Foamex StyroTherm published performance data and the relevant Australian Standards.Foamex manufactures StyroTherm extruded polystyrene (XPS) sheets in Australia in five thicknesses, with thermal performance tested in accordance with AS/NZS 4859.1 and ASTM C518 and compressive stress tested in accordance with AS 2498.3 and ASTM D1621. The product is supported by an Australian-Made certification and by published warranty, material safety data and material handling documentation.What XPS sheets areExtruded polystyrene (XPS) is a rigid cellular plastic insulation board produced by extruding polystyrene polymer with a blowing agent through a die into a continuous closed-cell foam. The cell structure is dense and uniform, with no bead boundaries, which distinguishes XPS from expanded polystyrene (EPS) in three measurable ways. Water absorption is low under sustained exposure (tested in accordance with AS/NZS 4859.1 Appendix), compressive stress at 10% deformation is high relative to most EPS density grades, and rated R-value is more likely to be retained where moisture is part of the operating environment.For these reasons, XPS is the typical specification at slab-edge, under-slab, perimeter, basement and selected rooftop positions across Australian construction. Foamex manufactures a product range that maps to position: StyroTherm for foundation and perimeter work, StyroRoof for green roof installations, and StyroLink as a purlin spacer for metal roofing assemblies.Positions where XPS is typically specified in Australian buildingsXPS is typically specified at positions where moisture exposure or sustained compressive load makes EPS or open-cell insulation unsuitable. Common positions include:Under-slab insulation beneath ground slabsSlab-edge and perimeter insulation around the building footprint, addressing thermal bridging at the slab edgeBelow-ground insulation against retaining walls and basement wallsGreen roof build-ups using a product engineered for the rooftop conditionsCool room, cold store and refrigerated floor systemsCommercial metal roofing, where an XPS purlin spacer provides a thermal break between the purlin and the roof sheetFoamex matches product to position. StyroTherm is specified for under-slab, slab-edge, perimeter and wall positions. StyroRoof is specified for green roof installations and uses the same closed-cell XPS chemistry, engineered for the loading, drainage and root-resistance considerations of a rooftop build-up. StyroLink is specified for metal roofing as an XPS purlin spacer.Specification variablesFour variables typically resolve an XPS specification. Each should be confirmed against the project documentation before order placement.Target R-value and NCC pathwayR-value targets are typically set by the project designer, accredited NatHERS assessor or building certifier against NCC 2022 Section J for Class 2 to 9 buildings, or against NCC 2022 Volume Two and the NatHERS pathway for Class 1 and 10a buildings. State-based requirements such as BASIX in New South Wales may also apply to residential work. The selected board thickness must be sufficient to deliver the required R-value within the available cavity or build-up depth, and should account for any thermal bridging at slab edges, junctions or purlins.Compressive stress at 2% and 10% deformationXPS at under-slab, slab-edge, rooftop or roof-spacer positions sits under sustained load through the design life of the assembly. Compressive stress should be reviewed at both 2% and 10% deformation in accordance with AS 2498.3 and ASTM D1621, and matched against the design load with appropriate allowance for compressive creep. Published nominal compressive stress is not a substitute for a load-specific check at the design stage.Moisture exposure and water absorptionAt positions exposed to ground moisture, hydrostatic pressure or external weather, XPS is preferred over EPS or open-cell insulation because the continuous closed-cell foam restricts water movement through the board. Water absorption performance for the product should be confirmed against the relevant test method in AS/NZS 4859.1 Appendix and assessed against the project’s hygrothermal design.Available installation depthThe available cavity, slab-edge, perimeter batten, roof-spacer or below-ground depth imposes a practical thickness limit. The combination of thickness selected and the as-installed condition of the board (including gaps, compression and continuity) determines the installed R-value.Caption: NewCold Storage Project in Truganina, using StyroTherm XPS Sheets.StyroTherm XPS published technical dataThe following thermal and compressive data is published by Foamex for StyroTherm XPS at a sheet size of 2400 mm x 600 mm.ThicknessR-value (m2.K/W)K-value (lambda, W/m.K)Compressive stress at 2% deformationCompressive stress at 10% deformation30 mm0.940.031>90 kPa>250 kPa40 mm1.290.031>150 kPa>350 kPa50 mm1.550.033>230 kPa>350 kPa60 mm1.820.033>240 kPa>350 kPa75 mm2.150.034>280 kPa>350 kPaTest methods: thermal performance is reported in accordance with AS/NZS 4859.1 and ASTM C518; compressive stress is reported in accordance with AS 2498.3 and ASTM D1621. Current values should be confirmed against the latest StyroTherm technical specification sheet before final design.XPS and EPS at a glanceConsiderationXPS (StyroTherm)EPS (StyroSheet)Cell structureContinuous closed-cell extruded foamFused expanded beadsWater absorptionLow under sustained exposureLow to moderate, density-grade dependentCompressive stress>280 kPa at 2% deformation, >350 kPa at 10% deformation at 75 mmUp to 350 kPa at 10% deformation in VVH grades per AS/NZS 1366.3Typical positionsSlab-edge, under-slab, perimeter, green roof, metal roof purlin spacerWalls, floors, ceilings, garage door panels, packaging, fabricationCustom-cut formatsAvailable within standard sheet sizesWide range of custom-cut and foil-faced optionsInternal, dry and protected positions are typically specified in StyroSheet EPS. Positions with moisture exposure, ground contact or external weather are typically specified in StyroTherm XPS, with StyroRoof or StyroLink selected where the position calls for the green roof or purlin-spacer variant.Australian manufacturing, recycled content and the StyroCycle recycling pathwayStyroTherm is manufactured in Australia using a process free from chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs) and other ozone-depleting substances. Under Foamex’s closed-loop manufacturing model, StyroTherm can contain up to 90% recycled polystyrene from EPS packaging recovered through construction offcuts, factory surplus and post-consumer streams collected through the StyroCycle take-back network. The product carries Australian-Made certification.Where a project is targeting waste-diversion or circular-economy outcomes, the take-back recycling pathway and the recycled content can be referenced in the specification alongside the thermal and compressive data.Contact the Foamex specification team to confirm StyroTherm XPS thickness, R-value and compressive stress for the project, or to request the current technical specification and material safety data.Frequently asked questionsWhat are XPS sheets specified for in Australia?Common positions include under-slab insulation, slab-edge and perimeter insulation, below-ground installations, green roof build-ups, cool room construction and metal roofing as an XPS purlin spacer. Selection by Foamex product depends on position: StyroTherm for foundation and perimeter, StyroRoof for green roofs, StyroLink for metal roof purlins.What thickness of XPS should be specified?Thickness depends on the required R-value, the available installation depth and the sustained compressive load. StyroTherm is manufactured in 30 mm, 40 mm, 50 mm, 60 mm and 75 mm thicknesses, with published R-values from 0.94 to 2.15 (tested to AS/NZS 4859.1 / ASTM C518). Final R-value selection should be confirmed against the relevant NCC pathway with the project designer or accredited NatHERS assessor.How does XPS compare to EPS for thermal applications?XPS uses a continuous closed-cell extruded foam structure with low water absorption and high compressive stress relative to most EPS density grades. EPS uses fused beads and is classified by density grade under AS/NZS 1366.3, with grades from SL through to VVH 38. EPS is typically specified for internal, dry, protected positions; XPS is typically specified for positions with moisture exposure or sustained compressive load.Can XPS be specified below ground or in wet conditions?Yes. The closed-cell extruded foam structure restricts water movement through the board, which supports use at under-slab, slab-edge, retaining wall and green roof positions. Water absorption performance should be confirmed against AS/NZS 4859.1 Appendix and against the project’s hygrothermal design.Is Foamex XPS manufactured in Australia?Yes. StyroTherm XPS is manufactured in Australia from Foamex Styroboard XPS, free from CFCs, HCFCs and other ozone-depleting substances, and carries Australian-Made certification.Where can XPS sheets be sourced in Australia?Foamex supplies StyroTherm XPS nationally through the Foamex specification team. Technical data, warranty, material safety data and Australian-Made certification documentation are published and can be requested at order stage.

### Pages

#### About Us
Foamex – Our Story				
				
				
				
							
			
						
		
						
				
					
				
		
				
				
							
			
						
		
						
				
				
		
					
		
		
				
				
					About Us				
				
				
				
								
				Who we are
Our Solutions
circular Economy
Sustainability
			
						
				Who we are
Our Solutions
circular Economy
Sustainability
			
						
				
				
				
		
		
		
		
		
				
				
							
			
						
		
						
				
				
				
					Australian-Made, Industry Trusted				
				
				
				
				
									Foamex is a leading Australian manufacturer & recycler of expanded (EPS) and extruded polystyrene (XPS), proudly family-owned since 1982. With over 250 employees across five states, we serve industries including construction, packaging, geotechnical, landscaping, and retail. Our high-performance, sustainable polystyrene insulation is trusted by builders, architects, specifiers, and businesses nationwide. As one of the largest EPS producers in Australia, Foamex is committed to:Energy-efficient building solutionsCircular economy and recycling initiativesLocal manufacturing excellence and quality assurance								
				
				
		
				
				
																														
				
				
				
		
				
				
							
			
						
		
						
				
				
				
		
		
		
		
				
				
							
			
						
		
						
				
				
				
					Engineered for Efficiency and Performance				
				
				
				
				
									Foamex delivers custom-engineered EPS and XPS products designed for performance, sustainability, and long-term efficiency. Lightweight yet strong, our polystyrene is ideal for waffle pods, under-slab insulation, slab-edge insulation, void formers, protective packaging, and more. These solutions help reduce structural load while improving thermal performance—supporting the design of energy-efficient, compliant buildings across residential, commercial, and industrial sectors. Many of our products also incorporate recycled content, aligning with green building goals and environmental certifications.Energy-efficient building solutionsCircular economy and recycling initiativesLocal manufacturing excellence and quality assurance								
				
				
				
									
					
						
						
							
									Our products
					
					
				
								
				
				
		
				
				
																														
				
				
				
		
				
				
							
			
						
		
						
				
				
				
		
		
		
		
				
				
							
			
						
		
						
				
				
				
					Recycling Programs				
				
				
				
				
									Foamex supports both public and commercial EPS recycling. In partnership with StyroCycle, we provide free public drop-off recycling via bins at Foamex sites across Australia. Additionally, Foamex enters into recycling agreements with local councils, retailers, and waste providers to recover and process expanded polystyrene packaging. All material is reprocessed into new EPS products—reducing waste and supporting a circular economy.								
				
		
				
				
							
			
						
		
						
				
				
				
					Responsible Practices				
				
				
				
				
									Our approach to circularity goes beyond standard recycling. Foamex collects and recycles EPS & XPS scrap directly from construction sites, helping reduce on-site waste and support greener building practices. Within our manufacturing facilities, 100% of offcuts generated during production are recovered and reprocessed into new polystyrene products. All sites are designed for maximum efficiency and minimal environmental impact.We are proud members of Expanded Polystyrene Australia (EPSA) and Operation Clean Sweep, working to uphold best-practice standards in safe manufacturing, waste reduction, and preventing plastic loss to the environment.								
				
				
				
									
					
						
						
							
									Learn More
					
					
				
								
				
				
		
				
				
																														
				
				
				
		
				
				
							
			
						
		
						
				
				
				
		
		
		
		
				
				
							
			
						
		
						
				
				
				
					Sustainability in Action				
				
				
				
				
									Sustainability is embedded in everything we do at Foamex. We invest in smarter, cleaner manufacturing to reduce emissions and environmental impact. Our EPS and XPS products are fully recyclable, and we actively close the loop by reprocessing used polystyrene into new, high-performance solutions. Local manufacturing, innovation, and sustainability work together in every part of our business.								
				
		
				
				
							
			
						
		
						
				
				
				
					Renewable Energy				
				
				
				
				
									Foamex is reducing emissions by shifting to renewable energy and improving energy efficiency. Our South Australian and Victorian facilities already run on wind and solar power. Since 2018, we’ve implemented energy-saving upgrades across multiple sites, lowering electricity use and emissions. Solar installations continue to expand as part of our national sustainability strategy.								
				
				
		
				
				
																														
				
				
				
				
				
					
				
		
					
		
				
				
					Why
Foamex?				
				
				
		
				
				
							
			
						
		
						
				
				
				
					100% Australian-owned and operated & trusted for over 40 years				
				
				
		
				
				
							
			
						
		
						
				
				
				
					Reliable delivery & serviceability nationwide				
				
				
		
				
				
							
			
						
		
						
				
				
				
					Sustainable & circular EPS and XPS manufacturing				
				
				
		
				
				
							
			
						
		
						
				
				
				
					Custom-engineered polystyrene building insulation solutions				
				
				
		
				
				
							
			
						
		
						
				
				
				
					Industry leader in polystyrene recycling & circular practices				
				
				
					
				
		
				
				
							
					
				
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
									
				
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### Applications
Applications				
				
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
							
							
											

											Home
											
									
								
											
													
										Applications
									
						
						
				
				
				
					Application Filter
		
		
		
						All
					
	

		
		
		
						Foundations
					
	

		
		
		
						Wall
					
	

		
		
		
						Roof
					
	

		
		
		
						Geofoam
					
	

		
		
		
						Underfloor
					
	

		
		
		
						Profiling
					
	

		
		
		
						Packaging
					
	

				
				
				
				
							
			
						
		
						
				
				
		
		
				
				
							
						
				
					 Brands 
							
			
			
		

						
				
				
				
					Brands Filter
		
		
		
							
					
	

				
						All
					
	

		
		
		
							
					
	

				
						Styroboard EPS
					
	

		
		
		
							
					
	

				
						Styroboard XPS
					
	

		
		
		
							
					
	

				
						QPOD
					
	

		
		
		
							
					
	

				
						Expol
					
	

		
		
		
							
					
	

				
						GeoFoamX
					
	

		
		
		
							
					
	

				
						StyroSlab
					
	

		
		
		
							
					
	

				
						Insulclad
					
	

				
				
				
					
						
				
					 Material 
							
			
			
		

						
				
				
				
					Material Filter
		
		
		
							
					
	

				
						All
					
	

		
		
		
							
					
	

				
						100% Recycled Polypropelene (PP)
					
	

		
		
		
							
					
	

				
						Expanded Polystyrene (EPS)
					
	

		
		
		
							
					
	

				
						Extruded Polystyrene (XPS)
					
	

		
		
		
							
					
	

				
						Graphite Expanded Polystyrene (GEPS)
					
	

				
				
				
					
						
				
					 Industry 
							
			
			
		

						
				
				
				
					Industry Filter
		
		
		
							
					
	

				
						All
					
	

		
		
		
							
					
	

				
						Agriculture & Aquaculture
					
	

		
		
		
							
					
	

				
						Commercial
					
	

		
		
		
							
					
	

				
						Landscaping
					
	

		
		
		
							
					
	

				
						Mega Projects
					
	

		
		
		
							
					
	

				
						Residential
					
	

		
		
		
							
					
	

				
						Retail
					
	

				
				
				
					
					
						
				
				
		
				
				
							
				
					
		
				
				
																														
				
		
				
				
					Expol Underfloor R1.8				
				
				
				
									Graphite-infused underfloor insulation that’s 30% more energy efficient.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroRoof®: Green Roofs				
				
				
				
									XPS Insulation for Green Roofs and Rooftop Applications								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroPod®: EPS Waffle Pods				
				
				
				
									The Smart Choice for Stronger, Energy-Efficient Waffle Pod Slabs								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					QPOD™ 300 Pods (VIC & SA)				
				
				
				
									100% Recycled Earth-Friendly Foundations								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroSheet: EPS Sheets				
				
				
				
									High-performance expanded polystyrene sheets for lightweight, & energy-efficient insulation solutions.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroTherm®: XPS Sheets				
				
				
				
									High-Performance XPS Insulation for Foundations and Green Roofs								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					GeoFoamX®: Geofoam				
				
				
				
									High-performance, extremely strong, lightweight EPS blocks for structural fill								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroBloc®: EPS Blocks				
				
				
				
									High-Quality EPS Foam Blocks for Custom Profiling								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					Expol Underfloor R1.4				
				
				
				
									Underfloor Insulation for New & Existing Floors								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroLink®: XPS Roof Spacers 				
				
				
				
									High-Strength XPS Purlin Roof Spacer for Metal Roofing.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroPak®: EPS Boxes				
				
				
				
									Recyclable foam packaging designed for thermal & protective transport.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					Insulclad (NSW Only)				
				
				
				
									High-Performance, Lightweight Cladding Solution								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
						
				
				
				
									
					
						
									Load More
					
					
				
								
				
				
				
					
				
		
				
				
							
					
				
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
									
				
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### Careers
Careers with Foamex				
				
		
					
				
				
					We regularly have jobs across Victoria, New South Wales, and South Australia. Please contact us on 1300 AU FOAM to talk to one of our friendly staff about current availabilities. 				
				
					
				
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
									
				
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
									New South Wales
									Victoria
									Queensland
									South Australia
									Western Australia
									Tasmania
									Northern Territory
									Australian Capital Territory
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### Cart
Cart				
				
				
				
						
		
			Return to shop

#### Checkout
Checkout				
				
				
				
					Your cart is currently empty.

#### Contact Us
Contact Us				
				
				
				
					Find your nearest Foamex sales office.				
				
				
				
							
			
						
		
						
				
					
				
		
					
		
		
				
				
							
			
						
		
						
				
				
				
					Contact Us				
				
				
				
				
									Please complete this form, and in the comments let us know which Foamex product you’re enquiring about.If you are contacting us about recycling, please read our updated information here.								
				
				
		
				
				
									
				
				
					
				
		
					
		
				
				
							
			
						
		
						
				
				
				
					Office Locations				
				
				
		
		
				
				
					VIC				
				
		
				
				
					Bayswater North				
				
				
				
							
							
										31 – 33 Gatwick Rd BAYSWATER NORTH VIC 3153
									
								
											

											P: 03 8739 5800
											
									
						
						
				
				
				
				
							
			
		
						
				
				
		
		
				
				
					COOLAROO				
				
				
				
							
							
										430 Barry Rd, COOLAROO VIC 3048
									
								
											

											P: 03 9219 6280
											
									
						
						
				
				
				
				
							
			
		
						
				
				
		
		
				
				
					WODONGA				
				
				
				
							
							
										22 Moloney Dr, WODONGA VIC 3690
									
								
										(Manufacturing Plant Only)
									
						
						
				
				
				
				
							
			
		
						
				
				
				
		
		
				
				
					NSW/ACT				
				
		
				
				
					REVESBY				
				
				
				
							
							
										31 Mavis St, REVESBY NSW 2212
									
								
										P: 02 9773 1655
									
						
						
				
				
				
				
							
			
		
						
				
				
		
		
				
				
					ORANGE				
				
				
				
							
							
										6 Colliers Ave, ORANGE NSW 2800
									
								
											

											P: 02 9773 1655
											
									
						
						
				
				
				
				
							
			
		
						
				
				
		
		
				
				
					WYONG				
				
				
				
							
							
										4 Donaldson Road, WYONG NSW 2259
									
								
										(Manufacturing Plant Only)
									
						
						
				
				
				
				
							
			
		
						
				
				
				
		
		
				
				
					SA				
				
		
				
				
					EDINBURGH NORTH 				
				
				
				
							
							
										15 Peachey Rd, EDINBURGH NORTH SA 5113
									
								
											

											P: 08 8393 5900
											
									
						
						
				
				
				
				
							
			
		
						
				
				
		
				
				
					QLD (Polyfoam)				
				
		
				
				
					DARRA				
				
				
				
							
							
										44 Bernoulli Street, DARRA, QLD 4076
									
								
										P: 07 3390 8955
									
						
						
				
				
				
				
							
			
		
						
				
				
		
				
				
					TAS (Polyfoam)				
				
		
				
				
					Bridgewater				
				
				
				
							
							
										113 Cove Hill Rd, Bridgewater, TAS 7030
									
								
										P: 03 6263 6900

#### Credit Application
Apply for Credit with Foamex				
				
				
				
							
			
						
		
						
				
					
				
		
					
		
		
				
				
							
			
						
		
						
				
				
				
					Credit Application				
				
				
				
				
									Thank you for expressing your interest in setting up a 30-day account with Foamex.IMPORTANT: For customers located in Victoria & South Australia, please click here to be taken to our online credit application form.For customers in all other states, please complete the form, and your local Foamex sales office will be in touch with you shortly to finalise your application.

#### FAQs
FAQs				
				
		
					
				
				
					Your Questions, Answered: Foamex Products, Recycling & Sustainable Building				
				
					
				
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
					General				
				
				
		
				
				
							
						
				
					 What is Expanded Polystyrene (EPS) and how is it used? 
							
			
			
		

						
				
				
				
									EPS is a lightweight, closed-cell plastic foam made up of thousands of air-filled beads. It’s widely used in construction, packaging, and insulation due to its thermal efficiency, strength, and versatility. At Foamex, our premium EPS is used in applications ranging from waffle pods and under-slab insulation to protective packaging and signage.								
				
				
					
						
				
					 Does Foamex sell directly to the public? 
							
			
			
		

						
				
				
				
									Yes. While our core business serves wholesalers and commercial clients, we also supply EPS products directly to individuals. Please note that minimum order quantities may apply depending on the product type and service requirements.								
				
				
					
						
				
					 Can EPS be custom-cut? 
							
			
			
		

						
				
				
				
									Absolutely. We offer custom cutting based on your drawings or dimensions. Our advanced cutting technology ensures precision, whether you’re after architectural profiles, 3D signage, or complex formwork shapes.								
				
				
					
						
				
					 Is EPS waterproof? 
							
			
			
		

						
				
				
				
									EPS is highly moisture-resistant due to its closed-cell structure. While it doesn’t absorb water like sponge-based foams, prolonged submersion may allow minimal water to fill surface channels—without affecting performance.								
				
				
					
					
						
				
				
					
				
		
					
		
				
				
					Ordering, Delivery & Support				
				
				
		
				
				
							
						
				
					 How do I get pricing for Foamex products? 
							
			
			
		

						
				
				
				
									Contact your nearest Foamex branch with details about your project or product needs on 1300 283 626. We’ll provide a tailored quote, including advice on quantities, turnaround time, and delivery options.								
				
				
					
						
				
					 Can I get help estimating quantities? 
							
			
			
		

						
				
				
				
									Yes—our team offers free scheduling and estimating services. Just provide your engineer’s drawings or specs, and we’ll calculate your materials and quantities.								
				
				
					
						
				
					 Does Foamex offer delivery? 
							
			
			
		

						
				
				
				
									Yes. We operate our own national fleet to ensure timely and reliable delivery across metro and regional locations.								
				
				
					
						
				
					 Can I get technical or product support? 
							
			
			
		

						
				
				
				
									Of course. Our team can assist with specs, installation guides, compliance, and sustainability requirements—making sure your project runs smoothly from start to finish.								
				
				
					
					
						
				
				
					
				
		
					
		
				
				
					Extruded Polystyrene (XPS)				
				
				
		
				
				
							
						
				
					 What is the difference between XPS and EPS? 
							
			
			
		

						
				
				
				
									While both are rigid polystyrene foam insulation products, EPS (Expanded Polystyrene) is made by expanding beads of polystyrene, while XPS (Extruded Polystyrene) is formed through a continuous extrusion process. XPS has a more uniform, closed-cell structure, which gives it higher compressive strength and moisture resistance—making it ideal for below-grade and high-load applications.								
				
				
					
						
				
					 What are the main applications of XPS insulation? 
							
			
			
		

						
				
				
				
									XPS is commonly used in under-slab insulation, rooftop gardens, perimeter slab edge insulation, basement walls, and inverted roofs. Its moisture resistance and thermal performance make it ideal for wet environments or where consistent insulation is critical. Foamex’s XPS products, including our Styroboard® XPS, are engineered for durability and performance in commercial and residential construction.								
				
				
					
						
				
					 What are the key benefits of XPS insulation? 
							
			
			
		

						
				
				
				
									XPS offers high compressive strength, excellent thermal insulation (with an R-value of around 1.13 per 50mm), and low water absorption. It’s also easy to handle, cut, and install—reducing labour time on site. Its durability and consistent performance over time make it a premium choice for demanding insulation applications.								
				
				
					
						
				
					  Can XPS be recycled? 
							
			
			
		

						
				
				
				
									Yes, XPS is fully recyclable. But we only recycle our own XPS, because we know our brand does not contain nasty materials. We are unable to accept XPS for recycler from imported, inferior quality boards. Our Styroboard® XPS with up to 90% recycled content,showcases our commitment to innovation and circularity—reusing reclaimed EPS to produce high-quality XPS insulation for sustainable builds.								
				
				
					
						
				
					  Is XPS suitable for energy-efficient and green building projects? 
							
			
			
		

						
				
				
				
									Absolutely. XPS provides long-term thermal efficiency that supports 7-star energy ratings, Green Star certifications, and compliance with the National Construction Code (NCC). Its insulating properties significantly reduce heating and cooling loads over the life of the building.								
				
				
					
					
						
				
				
					
				
		
					
		
				
				
					EPS in Construction				
				
				
		
				
				
							
						
				
					 What are the benefits of using EPS in construction? 
							
			
			
		

						
				
				
				
									EPS provides thermal insulation, strength, and formability at a fraction of the weight of other materials. It’s easy to handle, recyclable, cost-effective, and compliant with Australian standards—making it a preferred choice for modern slab construction, insulation, and void forming.								
				
				
					
						
				
					 What are EPS waffle pods and how do they work? 
							
			
			
		

						
				
				
				
									EPS waffle pods are used to create voids in concrete slabs, reducing concrete usage and enhancing thermal performance. The pods are laid out in a grid, reinforced with steel, and then encased in concrete—forming a strong, insulated slab system.								
				
				
					
						
				
					 Can waffle pods be used on all soil types? 
							
			
			
		

						
				
				
				
									Yes. EPS waffle pod systems are suitable for stable, moderately reactive, and highly reactive soil types when designed according to AS2870. They offer an adaptable solution for diverse site conditions.								
				
				
					
						
				
					 How do waffle pods improve energy efficiency? 
							
			
			
		

						
				
				
				
									EPS pods contribute up to R1.0 in thermal resistance within slab systems. This reduces heat loss and supports compliance with Australia’s 7-star energy rating requirement—lowering long-term energy costs in residential and commercial builds.								
				
				
					
						
				
					 What is the EPSA Pod Code of Practice, and does Foamex follow it? 
							
			
			
		

						
				
				
				
									Yes—Foamex fully adheres to the EPSA Pod Code. This includes best practices for pod storage, transportation, recycling, and site management. We also work with builders to ensure safe, compliant, and environmentally responsible installation.								
				
				
					
					
						
				
				
					
				
		
					
		
				
				
					EPS Packaging				
				
				
		
				
				
							
						
				
					 Why is EPS used for packaging? 
							
			
			
		

						
				
				
				
									EPS combines strength, shock absorption, and thermal insulation, making it ideal for protecting fragile items like electronics, pharmaceuticals, and perishable food during transit. It’s lightweight, which also reduces shipping costs.								
				
				
					
						
				
					 Can EPS packaging be recycled? 
							
			
			
		

						
				
				
				
									Yes—EPS is fully recyclable. Clean EPS packaging can be returned through Foamex’s commercial agreements or via public drop-off points through StyroCycle. Recycled material is remanufactured into insulation and other building products.								
				
				
					
						
				
					 Can EPS withstand water exposure? 
							
			
			
		

						
				
				
				
									Yes. EPS doesn’t absorb water in the way sponge or open-cell foams do. It retains its insulation and structural performance even in damp or cold-chain environments.								
				
				
					
						
				
					 Is EPS packaging banned in Australia? 
							
			
			
		

						
				
				
				
									No. EPS is only restricted in specific single-use contexts (like takeaway containers). It remains fully permitted—and essential—for construction, cold-chain transport, and industrial packaging under the National Plastics Plan.								
				
				
					
					
						
				
				
					
				
		
					
		
				
				
					Recycling Services				
				
				
		
				
				
							
						
				
					 What’s the difference between Foamex recycling and StyroCycle? 
							
			
			
		

						
				
				
				
									EPS combines strength, shock absorption, and thermal insulation, making it ideal for protecting fragile items like electronics, pharmaceuticals, and perishable food during transit. It’s lightweight, which also reduces shipping costs.								
				
				
					
						
				
					 Can I recycle EPS from my construction site with Foamex? 
							
			
			
		

						
				
				
				
									Yes. We offer scrap bags, tie-downs, and scheduled pick-up services for site waste. We recycle all EPS material—offcuts, unused pods, and fine dust—through our closed-loop manufacturing system.								
				
				
					
						
				
					 Do you offer commercial EPS collection services? 
							
			
			
		

						
				
				
				
									Absolutely. We partner with businesses of all sizes to provide bulk EPS collection. These are paid services tailored to location, volume, and frequency—supporting long-term waste reduction goals.								
				
				
					
						
				
					 What kind of EPS does Foamex accept? 
							
			
			
		

						
				
				
				
									We accept clean, white EPS—such as packaging blocks or construction offcuts. Material must be free of contaminants like sticky tape, food, paint, or plastic wrap to be processed.								
				
				
					
						
				
					 Where are your public drop-off locations? 
							
			
			
		

						
				
				
				
									Drop-off points are available at Foamex sites in VIC, NSW, and SA. Visit our Recycling page for up-to-date locations, hours, and rules on what can and can’t be accepted.								
				
				
					
					
						
				
				
					
				
		
					
				
				
									
				
					
				
		
				
				
							
					
				
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
									
				
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### Foamex Christmas Closure Dates
Christmas Closure & Delivery Deadlines 				
				
		
					
					
				
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
					Foamex | Victoria 				
				
				
		
				
				
									Last Day of Operations:Foamex Victoria will close at Midday, Friday 19 December 2025. Final Deliveries for 2025:Last delivery day: Thursday 18 December 2025Final Day for Recycling: Friday 19th December 2025 Orders for Early January 2026:Pods for delivery on 5–6 January: Orders due Wednesday 17 December 2025Sheets/Profiles for delivery on 12 January: Orders due Monday 15 December 2025 Reopening Dates:Pods (Bayswater only): Monday 5 January 2026All other products and VIC sites: Monday 12 January 2026Recycling Re-Opens: Monday 12 January 2026  								
				
				
					
				
		
					
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
					Foamex | New South Wales 				
				
				
		
				
				
									Last Day of Operations:NSW offices will close from Friday 19 December 2025. Final Deliveries for 2025:Last delivery day: 10am, 19th December 2025 Orders for Early January 2026:For delivery in the first week back, orders  must be received by:4:00pm – Tuesday 16 December 2025 Reopening Date:Operations resume on Thursday 8 January 2026. Recycling Re-Opens: Monday 12 January 2026  								
				
				
					
				
		
					
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
					Foamex | South Australia				
				
				
		
				
				
									Last Day of Operations:Foamex SA will close at Midday, Thursday 18 December 2025. Final Deliveries for 2025Last delivery/collection day: Wednesday 17 December 2025Limited delivery availability: Thursday 18 December 2025Reopening DatesOffice reopens: Wednesday 7 January 2026Factory reopens: Monday 12 January 2026Recycling Re-Opens: Monday 12 January 2026 								
				
				
					
				
		
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### Home
PREMIUM EPS & XPS INSULATION				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
				
				
					Australian-Made Sustainable PolystyreneSolutions for				
				
		
				
				
					Home Builders				
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
								
											
							
					
				
				
					PREMIUM EPS & XPS INSULATION				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
				
				
					Australian-Made Sustainable Polystyrene Solutions for				
				
		
				
				
					Concreters				
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
								
											
							
					
				
				
					PREMIUM EPS & XPS INSULATION				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
		
				
				
					Architects				
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
								
											
							
					
				
				
					PREMIUM EPS & XPS INSULATION				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
				
				
					Australian-Made  Sustainable Polystyrene  Solutions for				
				
		
				
				
					Civil Engineers				
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
								
											
							
					
				
				
					PREMIUM EPS & XPS INSULATION				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
				
				
					Australian-Made  Sustainable Polystyrene  Solutions for				
				
		
				
				
					Landscapers				
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
								
											
							
					
				
				
					PREMIUM EPS & XPS INSULATION				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
		
				
				
					Home Renovators				
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
								
											
							
					
				
				
					PREMIUM EPS & XPS INSULATION				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
				
				
					Australian-Made  Sustainable Polystyrene Solutions for				
				
		
				
				
					Creatives				
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
								
								
		
						
				
				
		
					
		
				
				
					Our Services				
				
				
				
				
							
				
		
				
				
					Custom Manufacturing				
				
		
				
				
									With eight manufacturing facilities across Australia, Foamex delivers custom EPS and XPS solutions tailored for the construction industry. From residential and commercial builds to large-scale infrastructure projects, we supply precision-cut polystyrene insulation, void fill, and lightweight structural solutions that also enhance thermal efficiency. 								
				
				
				
									
					
						
						
							
									Contact Us
					
					
				
								
				
				
				
				
				
				
				
		
				
				
					Specialised Toll Manufacturing				
				
		
				
				
									Foamex offers toll manufacturing services for the packaging industry, utilising state-of-the-art wire cutting, CNC shaping, and custom EPS moulding machinery. Our advanced capabilities ensure precision, efficiency, and cost-effective production for custom packaging solutions.								
				
				
				
									
					
						
						
							
									Contact Us
					
					
				
								
				
				
				
				
				
				
				
		
				
				
					End to End Contract Manufacturing				
				
		
				
				
									Foamex partners with businesses requiring private-label EPS and XPS products, managing the entire process from product development and prototyping to manufacturing, quality control, custom branding, and warehousing. Whether for construction, packaging, or industrial applications, we ensure seamless contract manufacturing solutions.								
				
				
				
									
					
						
						
							
									Contact Us
					
					
				
								
				
				
				
				
				
				
				
		
				
				
					Custom Architectural Services				
				
		
				
				
									Foamex delivers specialised EPS profiles and mouldings for architectural and engineering applications. Our custom polystyrene fabrication capabilities provide lightweight yet durable solutions for decorative facades, building insulation, and energy-efficient construction designs.								
				
				
				
									
					
						
						
							
									Contact Us
					
					
				
								
				
				
				
				
				
				
				
		
				
				
					EPS Recycling Solutions				
				
		
				
				
									As a leader in polystyrene recycling, Foamex is committed to reducing waste and promoting circular economy initiatives. We provide EPS recycling solutions for businesses with construction offcuts, packaging waste, and bulk polystyrene disposal needs helping customers meet environmental compliance and waste management goals.
								
				
				
				
									
					
						
						
							
									Contact Us
					
					
				
								
				
				
				
				
				
						
				
					
				
		
					
		
				
				
					Foamex 
Australian-made EPS and XPS Products				
				
				
		
				
				
									Foamex is one of Australia’s largest manufacturers of high quality building and insulation products, supplying a range of expanded polystyrene, extruded polystyrene, and specialty foam products for various residential and commercial building applications, civil engineering applications, packaging applications, as well as for retail and creative purposes.A nationally recognised leader in sustainable building & insulation solutions, Foamex is proudly Australian owned and operated, with branches across Australia. All of our polystyrene products are all manufactured in-house to strict Australian quality control standards.								
				
				
		
				
				
									As a long serving member of Expanded Polystyrene Australia (EPSA), we take our corporate responsibility seriously, and work with key industry partners to develop new and innovative ways to not only use, but re-use and recycle our polystyrene products.								
				
				
				
									
					
						
						
							
									Learn more
					
					
				
								
				
				
					
				
		
					
		
		
				
				
					Australia’s leading manufacturer of alternate building and insulation products for residential, commercial and retail applications.				
				
				
				
					
				
		
					
		
				
				
					Featured Products				
				
				
				
				
							
				
					
		
				
				
																														
				
		
				
				
					StyroRoof®: Green Roofs				
				
				
				
									XPS Insulation for Green Roofs and Rooftop Applications								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroPod®: EPS Waffle Pods				
				
				
				
									The Smart Choice for Stronger, Energy-Efficient Waffle Pod Slabs								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					QPOD™ 300 Pods (VIC & SA)				
				
				
				
									100% Recycled Earth-Friendly Foundations								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroSheet: EPS Sheets				
				
				
				
									High-performance expanded polystyrene sheets for lightweight, & energy-efficient insulation solutions.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroTherm®: XPS Sheets				
				
				
				
									High-Performance XPS Insulation for Foundations and Green Roofs								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					GeoFoamX®: Geofoam				
				
				
				
									High-performance, extremely strong, lightweight EPS blocks for structural fill								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroBloc®: EPS Blocks				
				
				
				
									High-Quality EPS Foam Blocks for Custom Profiling								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					Expol Underfloor R1.4				
				
				
				
									Underfloor Insulation for New & Existing Floors								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroLink®: XPS Roof Spacers 				
				
				
				
									High-Strength XPS Purlin Roof Spacer for Metal Roofing.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroPak®: EPS Boxes				
				
				
				
									Recyclable foam packaging designed for thermal & protective transport.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
						
				
					
				
		
					
		
				
				
					Why choose a Foamex  product for your next project?				
				
				
		
		
				
				
							

						
				
								
			
			
						

									
						
							Cost effective						
					
				
				
			
			
		
						
				
				
				
							

						
				
								
			
			
						

									
						
							Moisture resistancy						
					
				
				
			
			
		
						
				
				
				
							

						
				
								
			
			
						

									
						
							Light weight						
					
				
				
			
			
		
						
				
				
				
							

						
				
								
			
			
						

									
						
							Durability						
					
				
				
			
			
		
						
				
				
		
				
				
							

						
				
								
			
			
						

									
						
							Energy Efficient						
					
				
				
			
			
		
						
				
				
				
							

						
				
								
			
			
						

									
						
							Shock Absorbency						
					
				
				
			
			
		
						
				
				
				
							

						
				
								
			
			
						

									
						
							Acoustic Absorbency						
					
				
				
			
			
		
						
				
				
				
							

						
				
								
			
			
						

									
						
							Thermally efficient						
					
				
				
			
			
		
						
				
				
				
					
				
		
					
		
				
				
							
			
						
		
						
				
				
				
					Our Brands				
				
				
		
				
				
							
			
											
							
									
						
				
				
					
				
		
					
		
		
				
				
					Latest News				
				
				
				
				
									
					
						
									Read all news
					
					
				
								
				
				
		
				
				
							
				
					
		
				
				
					Featured Article				
				
				
		
				
				
					EPS foam blocks				
				
				
				
					/				
				
				
				
									24.07.2026								
				
				
				
				
					StyroBloc EPS foam blocks: cut-to-size and custom profiling				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
						
				
				
				
							
				
					
		
				
		
				
				
					EPS Panels				
				
				
				
					/				
				
				
				
									29.06.2026								
				
				
				
				
					EPS panels in Australia: the types, and the EPS core behind them				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS and XPS Foam				
				
				
				
					/				
				
				
				
									24.06.2026								
				
				
				
				
					How Do Custom EPS and XPS Foam Solutions Support Sustainable Construction in Australia?				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS Geofoam Blocks				
				
				
				
					/				
				
				
				
									15.06.2026								
				
				
				
				
					EPS Geofoam Blocks for Road Embankments and Civil Fill in Australia				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Under Slab Insulation				
				
				
				
					/				
				
				
				
									01.06.2026								
				
				
				
				
					Under Slab Insulation Australia: What Builders Need to Know Before the Pour				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					XPS Sheets				
				
				
				
					/				
				
				
				
									29.05.2026								
				
				
				
				
					XPS sheets in Australia: how to specify the right thickness, R-value and grade				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
						
				
				
					
				
		
				
				
							
					
				
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
									
				
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### Materials
EPS, XPS, GEPS & Recycled Polypropylene Materials 
				
				
				
				
					High-performance materials engineered for insulation, durability, and sustainability.				
				
				
				
							
			
						
		
						
				
					
				
		
					
		
		
				
				
					Materials				
				
				
				
								
				Expanded Polystyrene (EPS)
Extruded Polystyrene (XPS)
Graphite Expanded Polystyrene (GEPS)
100% Recycled Polypropylene (PP)
			
						
				Expanded Polystyrene (EPS)
Extruded Polystyrene (XPS)
Graphite Expanded Polystyrene (GEPS)
100% Recycled Polypropylene (PP)
			
						
				
				
				
		
		
		
				
				
							
			
						
		
						
				
				
				
					Introducing Styroboard® EPS				
				
				
				
				
					High-performance, lightweight, and cost-effective				
				
				
				
									Styroboard® EPS is Foamex’s Australian-made expanded polystyrene solution, manufactured to strict quality standards in compliance with AS 1366.3:1992. With a closed-cell structure made from 98% air and just 2% polystyrene, this ultra-lightweight yet rigid foam delivers reliable performance across construction, packaging, and insulation applications.Used for over 30 years in residential, commercial, and industrial projects, Styroboard® EPS is a versatile material ideal for insulation and protective packaging applications. Fully recyclable and lightweight, it offers an excellent balance of thermal efficiency, durability, and cost-effectiveness—making it a future-ready choice for sustainable construction.								
				
		
				
				
					Styroboard® EPS Products				
				
				
				
				
							
				
					
		
				
				
																														
				
		
				
				
					StyroPod®: EPS Waffle Pods				
				
				
				
									The Smart Choice for Stronger, Energy-Efficient Waffle Pod Slabs								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroSheet: EPS Sheets				
				
				
				
									High-performance expanded polystyrene sheets for lightweight, & energy-efficient insulation solutions.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					GeoFoamX®: Geofoam				
				
				
				
									High-performance, extremely strong, lightweight EPS blocks for structural fill								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroBloc®: EPS Blocks				
				
				
				
									High-Quality EPS Foam Blocks for Custom Profiling								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					Expol Underfloor R1.4				
				
				
				
									Underfloor Insulation for New & Existing Floors								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroPak®: EPS Boxes				
				
				
				
									Recyclable foam packaging designed for thermal & protective transport.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					Insulclad (NSW Only)				
				
				
				
									High-Performance, Lightweight Cladding Solution								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
						
				
				
				
							
			
						
		
						
				
				
		
		
				
				
							
			
						
		
						
				
				
				
					Styroboard® XPS				
				
				
				
				
					Robust, moisture-resistant, and thermally efficient				
				
				
				
									Styroboard® XPS is the only extruded polystyrene solution made in Australia. Foamex’s XPS products are engineered for demanding applications where moisture resistance and high compressive strength are critical. Manufactured to comply with AS 1366.4, this rigid, closed-cell foam delivers exceptional thermal performance and long-term durability across construction and civil engineering projects.Lightweight yet structurally resilient, Styroboard® XPS is ideal for use in floors under load, inverted roofs, green roofs, car parks, and commercial insulation applications. It is dimensionally stable, water-resistant, and made from up to 90% recycled EPS collected from imported packaging —supporting green building outcomes whilst meeting the thermal and structural demands of Australia’s built environment.								
				
		
				
				
					Styroboard® XPS Products				
				
				
				
				
							
				
					
		
				
				
																														
				
		
				
				
					StyroRoof®: Green Roofs				
				
				
				
									XPS Insulation for Green Roofs and Rooftop Applications								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroTherm®: XPS Sheets				
				
				
				
									High-Performance XPS Insulation for Foundations and Green Roofs								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
				
				
					
		
				
				
																														
				
		
				
				
					StyroLink®: XPS Roof Spacers 				
				
				
				
									High-Strength XPS Purlin Roof Spacer for Metal Roofing.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
						
				
				
				
							
			
						
		
						
				
				
		
		
				
				
							
			
						
		
						
				
				
				
					Graphite-Enhanced EPS				
				
				
				
				
					Advanced insulation with improved thermal efficiency				
				
				
				
									Graphite Expanded Polystyrene (GEPS) is an enhanced version of traditional EPS, infused with high-purity graphite particles to significantly boost thermal performance. Manufactured in compliance with AS 1366.3:1992, GEPS offers superior R-Values compared to standard EPS—making it an ideal choice for energy-efficient construction where space is limited.Lightweight, durable, and recyclable, GEPS combines the proven benefits of EPS with increased thermal resistance, helping reduce heating and cooling demands. Its grey appearance and enhanced performance make it suitable for wall, floor, and roof insulation in residential and commercial buildings focused on sustainable outcomes.								
				
		
				
				
					Graphite EPS Products				
				
				
				
				
							
				
					
		
				
				
																														
				
		
				
				
					Expol Underfloor R1.8				
				
				
				
									Graphite-infused underfloor insulation that’s 30% more energy efficient.								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
						
				
				
				
							
			
						
		
						
				
				
		
		
				
				
							
			
						
		
						
				
				
				
					100% Recycled Plastic 				
				
				
				
				
					Circular, durable, and versatile for concrete slab construction				
				
				
				
									Made entirely from post-consumer and post-industrial plastic waste, 100% recycled polypropylene (PP) supports circular manufacturing practices without compromising strength or function. This robust, chemically resistant material is ideal for high-demand applications such as construction accessories and void fill.100% recycled plastic pods are reshaping the way raft foundations are built. Designed for strength, stability, and improved concrete flow, these pods provide a reliable and sustainable alternative to traditional materials. Their interlocking structure supports uniform slab performance while contributing to waste reduction and circular construction goals. Without replacing proven solutions like EPS, recycled plastic pods offer another viable pathway toward more responsible, future-focused slab design.								
				
		
				
				
					100% Recycled Plastic Products				
				
				
				
				
							
				
					
		
				
				
																														
				
		
				
				
					QPOD™ 300 Pods (VIC & SA)				
				
				
				
									100% Recycled Earth-Friendly Foundations								
				
				
				
				
				
									
					
						
						
							
									Explore
					
					
				
								
				
					
				
				
						
				
				
				
					
				
		
				
				
							
			
						
		
						
				
				
		
					
		
				
				
					Frequently Asked Questions 				
				
				
				
									
					
						
						
							
									Get in touch today
					
					
				
								
				
				
		
				
				
							
						
				
					 What is the difference between EPS, XPS, and GEPS? 
							
			
			
		

						
				
				
				
									EPS (Expanded Polystyrene) is a lightweight, rigid foam used in insulation and packaging. XPS (Extruded Polystyrene) offers higher compressive strength and moisture resistance, ideal for structural applications. GEPS (Graphite EPS) includes graphite particles for improved thermal performance compared to standard EPS.								
				
				
					
						
				
					 Are Foamex polystyrene products recyclable? 
							
			
			
		

						
				
				
				
									Yes. Foamex’s EPS and XPS products are 100% recyclable. We actively support closed-loop recycling, using recovered materials in the manufacture of new products—minimising waste and supporting sustainable construction practices.								
				
				
					
						
				
					 Which Foamex material should I use for my project? 
							
			
			
		

						
				
				
				
									It depends on your application. EPS is ideal for walls, under slab insulation, and packaging. XPS suits high-load or moisture-prone areas like floors, inverted roofs, and car parks. GEPS offers enhanced thermal performance for tight spaces, and recycled PP is great for industrial or structural accessories. Not sure which to choose? Try our handy [Product Selector Tool] to find the right solution for your project.								
				
				
					
						
				
					 Do your materials meet Australian building standards? 
							
			
			
		

						
				
				
				
									Yes. All Foamex products are manufactured in Australia and comply with relevant Australian Standards, including AS 1366.3 (EPS) and AS 1366.4 (XPS), ensuring performance, quality, and safety across all construction and industrial applications.								
				
				
					
					
						
				
				
					
				
		
				
				
							
					
				
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
									
				
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### My account
My Account				
				
				
				
					Login

		Login

		

			
			
				Username or email address *Required
							
			
				Password *Required
				
			

			
			
				
					 Remember me
				
								Log in
			
			
				Lost your password?

#### Newsroom
News from Foamex				
				
				
				
					Keep up to date with the latest news from Foamex.				
				
				
				
							
			
						
		
						
				
					
				
		
					
				
				
					Keep in touch with the latest news from Foamex regarding our products and the  latest happenings in the polystyrene manufacturing industry in Australia.				
				
					
				
		
					
				
				
					Filter				
				
				
				
					News Filter
		
		
		
						All Blogs
					
	

		
		
		
						7-Star Energy Ratings
					
	

		
		
		
						Building & Construction
					
	

		
		
		
						Building Sustainable
					
	

		
		
		
						Circular Economy
					
	

		
		
		
						Civil Engineering
					
	

		
		
		
						Creative Signage
					
	

		
		
		
						Custom Foam Manufacturer
					
	

		
		
		
						EPS and XPS Foam
					
	

		
		
		
						EPS Blocks
					
	

		
		
		
						EPS foam blocks
					
	

		
		
		
						EPS Geofoam Blocks
					
	

		
		
		
						EPS Insulation
					
	

		
		
		
						EPS Packaging
					
	

		
		
		
						EPS Panels
					
	

		
		
		
						EPS Sheets
					
	

		
		
		
						EPS vs XPS for Slabs
					
	

		
		
		
						Expanded Polystyrene (EPS)
					
	

		
		
		
						Extruded Polystyrene (XPS)
					
	

		
		
		
						Geofoam
					
	

		
		
		
						Graphite EPS
					
	

		
		
		
						NCC Compliance
					
	

		
		
		
						Polystyrene Sheets
					
	

		
		
		
						Polystyrene Wall Cladding
					
	

		
		
		
						Recycling & Sustainability
					
	

		
		
		
						Set Design & Props
					
	

		
		
		
						Slab Edge Insulation
					
	

		
		
		
						Thermal Insulation
					
	

		
		
		
						Uncategorized
					
	

		
		
		
						Under Slab Insulation
					
	

		
		
		
						Underfloor Insulation
					
	

		
		
		
						Void Fill
					
	

		
		
		
						Waffle Pod Size
					
	

		
		
		
						Waffle Pod Slab System
					
	

		
		
		
						Waffle Pods
					
	

		
		
		
						XPS Foam Board
					
	

		
		
		
						XPS Insulation
					
	

		
		
		
						XPS Sheets
					
	

				
				
				
				
							
				
					
		
				
				
					Featured Article				
				
				
		
				
				
					EPS foam blocks				
				
				
				
					/				
				
				
				
									24.07.2026								
				
				
				
				
					StyroBloc EPS foam blocks: cut-to-size and custom profiling				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS Panels				
				
				
				
					/				
				
				
				
									29.06.2026								
				
				
				
				
					EPS panels in Australia: the types, and the EPS core behind them				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS and XPS Foam				
				
				
				
					/				
				
				
				
									24.06.2026								
				
				
				
				
					How Do Custom EPS and XPS Foam Solutions Support Sustainable Construction in Australia?				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS Geofoam Blocks				
				
				
				
					/				
				
				
				
									15.06.2026								
				
				
				
				
					EPS Geofoam Blocks for Road Embankments and Civil Fill in Australia				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Under Slab Insulation				
				
				
				
					/				
				
				
				
									01.06.2026								
				
				
				
				
					Under Slab Insulation Australia: What Builders Need to Know Before the Pour				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					XPS Sheets				
				
				
				
					/				
				
				
				
									29.05.2026								
				
				
				
				
					XPS sheets in Australia: how to specify the right thickness, R-value and grade				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS Insulation				
				
				
				
					/				
				
				
				
									29.05.2026								
				
				
				
				
					Lightweight Expanded Polystyrene Insulation Panels with High R-Value				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Polystyrene Sheets				
				
				
				
					/				
				
				
				
									25.05.2026								
				
				
				
				
					Extruded polystyrene foam sheets: performance, specification and application				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Polystyrene Sheets				
				
				
				
					/				
				
				
				
									13.05.2026								
				
				
				
				
					Buy polystyrene sheets: how to specify the right grade, thickness and format				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					XPS Foam Board				
				
				
				
					/				
				
				
				
									29.04.2026								
				
				
				
				
					XPS Foam Board: 5 Critical Applications That Improve Building Performance				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Waffle Pod Size				
				
				
				
					/				
				
				
				
									27.04.2026								
				
				
				
				
					Choosing the Right EPS Waffle Pod Size for Strong, Efficient Australian Slabs				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Waffle Pod Slab System				
				
				
				
					/				
				
				
				
									25.04.2026								
				
				
				
				
					Waffle Pod Slab vs Traditional Concrete Slab: Which Foundation Suits Your Australian Build?				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS Insulation				
				
				
				
					/				
				
				
				
									22.04.2026								
				
				
				
				
					What Are the Best EPS Insulation Boards for Exterior Walls?				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Waffle Pods				
				
				
				
					/				
				
				
				
									30.03.2026								
				
				
				
				
					How Waffle Pod Suppliers Are Adapting to Australia’s Extreme Weather Conditions				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Custom Foam Manufacturer				
				
				
				
					/				
				
				
				
									25.03.2026								
				
				
				
				
					How to Choose the Right Custom Foam Manufacturer for Your Project in Australia				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					Building Sustainable				
				
				
				
					/				
				
				
				
									23.03.2026								
				
				
				
				
					Under Slab Insulation in Australia: Building Sustainable, Low-Carbon Floors				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS Panels				
				
				
				
					/				
				
				
				
									16.03.2026								
				
				
				
				
					How EPS Panels Can Simplify Prefabricated Home Construction				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS vs XPS for Slabs				
				
				
				
					/				
				
				
				
									27.02.2026								
				
				
				
				
					EPS vs XPS for Slabs: Choosing the Right Polystyrene Sheets				
				
				
				
									
					
						
									Read More
					
					
				
								
				
					
				
				
				
				
					
		
				
		
				
				
					EPS Panels				
				
				
				
					/				
				
				
				
									27.02.2026								
				
				
				
				
					Sustainability Benefits of EPS Panels in Energy-Efficient Buildings				
				
				
				
									
					
						
									Read More

#### Privacy Policy
Privacy Policy				
				
				
				
									How Foamex collects, holds, uses and discloses your personal information in accordance with Australian privacy law.								
				
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
					Contents				
				
				
				
							
			
						
		
						
				
				
				
							
							
											

											About this Policy
											
									
								
											

											Our Commitment
											
									
								
											

											Information We Collect
											
									
								
											

											How We Collect
											
									
								
											

											Why We Collect & Use
											
									
								
											

											Product Websites
											
									
								
											

											Salesforce CRM & Pardot
											
									
								
											

											Direct Marketing
											
									
								
											

											Cookies & Tracking
											
									
								
											

											Types of Cookies
											
									
								
											

											Third-Party Pixels
											
									
								
											

											Advertising Platforms
											
									
								
											

											Managing Cookies
											
									
								
											

											Disclosure of Information
											
									
								
											

											Overseas Disclosure
											
									
								
											

											Security
											
									
								
											

											Retention
											
									
								
											

											Accuracy
											
									
								
											

											Access & Correction
											
									
								
											

											Unsubscribing
											
									
								
											

											Complaints
											
									
								
											

											Data Breaches
											
									
								
											

											Third-Party Links
											
									
								
											

											Social Media
											
									
								
											

											Children
											
									
								
											

											Automated Decisions
											
									
								
											

											Changes to Policy
											
									
								
											

											Contact Us
											
									
						
						
				
				
		
		
				
				
					EntityFoamex Group Pty Ltd				
				
				
				
					ABN80 109 683 909				
				
				
				
					ACN109 683 909				
				
				
				
					Last Updated30 April 2026				
				
				
				
				
							
						
				
		
		
				
				
					1.				
				
				
				
					About this Privacy Policy				
				
				
				
				
									This Privacy Policy explains how Foamex Group Pty Ltd, together with its related bodies corporate, brands, divisions, websites and authorised representatives, collects, holds, uses and discloses personal information in the course of its business activities.In this Privacy Policy, the terms “Foamex”, “we”, “us” and “our” refer to Foamex Group Pty Ltd and, where the context permits, its related bodies corporate, business units, brands, employees, contractors, agents and authorised service providers.This Privacy Policy applies to personal information collected through all Foamex business activities, including:Foamex websites, product websites, microsites and landing pages;download forms, contact forms, product enquiry forms, sample requests, quote requests and technical documentation requests;sales and customer service enquiries, including by phone, email and in-person communications;trade shows, events and industry presentations;digital advertising campaigns and social media pages;customer relationship management (CRM) and marketing automation systems;supplier, distributor and contractor relationships; andrecruitment and employment enquiries.This Privacy Policy also applies to Foamex product, campaign and brand websites that link to this policy, including product information pages and microsites for individual Foamex solutions.Where a separate privacy notice or collection statement is provided to you at the time information is collected, that notice should be read together with this Privacy Policy.								
				
				
				
				
							
						
				
		
		
				
				
					2.				
				
				
				
					Our Commitment to Your Privacy				
				
				
				
				
									Foamex respects your privacy and is committed to handling personal information responsibly, transparently and in accordance with the Privacy Act 1988 (Cth) and the Australian Privacy Principles (APPs).We aim to collect only the personal information reasonably necessary for our business operations, including supplying products, responding to enquiries, managing customer relationships, providing technical information, improving our websites, supporting digital marketing activities, and communicating with customers, builders, architects, designers, engineers, specifiers, concreters, contractors, distributors, suppliers and other industry contacts.								
				
				
				
				
							
						
				
		
		
				
				
					3.				
				
				
				
					What Personal Information We Collect				
				
				
				
				
									The personal information we collect depends on how you interact with us and the nature of your enquiry or relationship with Foamex. We may collect the following kinds of information.								
				
				
				
					3.1 Contact Information				
				
				
				
									
 	name, business name and job title;
 	email address, phone number and mobile number;
 	postal address, delivery address, state or territory, postcode and country;
 	preferred contact method.
								
				
				
				
					3.2 Business and Project Information				
				
				
				
									
 	company name, industry or business type, role or profession;
 	product interest, project type, project location and project timing;
 	building or construction requirements, technical enquiry details and specification requirements;
 	sample requests, quote requests, order history and customer service records;
 	communications with our team.
								
				
				
				
					3.3 Website and Digital Information				
				
				
				
									When you use our websites, landing pages or digital content, we may collect:IP address, browser type, device type and operating system;approximate location, pages viewed, time spent on pages and links clicked;forms started or submitted, files downloaded, referring website and advertising campaign source;UTM parameters, cookie identifiers and pixel identifiers;interaction with advertisements and email engagement activity (where applicable).								
				
				
				
					3.4 Form Submission Information				
				
				
				
									When you complete a website form, we may collect the information you provide, such as:name, email address, phone number, company, state and postcode;product interest, message or enquiry details, and marketing consent preferences;the resource or download requested, the landing page URL, the campaign source, and the date and time of submission.This includes forms used to request product packs, brochures, whitepapers, technical data sheets, samples, quotes, sales contact, newsletters or other Foamex resources.								
				
				
				
					3.5 Marketing and Communication Preferences				
				
				
				
									
 	email subscription preferences and marketing consent records;
 	unsubscribe records and cookie consent preferences;
 	advertising consent preferences and records of communications sent to you;
 	records of whether you opened or clicked marketing emails (where this is enabled);
 	records of your interactions with Foamex digital campaigns.
								
				
				
				
					3.6 Customer, Supplier and Transaction Information				
				
				
				
									If you are a customer, supplier, distributor, contractor or other business contact, we may collect:quote, order, invoice and delivery information;account information, payment-related records and credit account application information;supplier or contractor records and product supply records;warranty and technical support information;complaint or dispute records.								
				
				
				
					3.7 Recruitment Information				
				
				
				
									If you apply for employment, work experience, a contractor role or another opportunity with Foamex, we may collect:your resume, cover letter, employment history, education and qualifications;references, right-to-work information, licences and certifications;interview notes;background check information where relevant and lawful.								
				
				
				
					3.8 Sensitive Information				
				
				
				
									We do not generally seek to collect sensitive information through our websites or product enquiry forms.Sensitive information includes information about your health, racial or ethnic origin, political opinions, religious beliefs, union membership, criminal record or biometric information.Please do not provide sensitive information to us unless we have specifically requested it and it is necessary for the relevant purpose. If you voluntarily provide sensitive information, you consent to us collecting and handling that information for the purpose for which it was provided, unless the law requires or permits otherwise.								
				
				
				
				
							
						
				
		
		
				
				
					4.				
				
				
				
					How We Collect Personal Information				
				
				
				
				
									Where reasonable and practicable, we collect personal information directly from you. This may occur when you:visit a Foamex website or submit a website form;request a product pack, downloadable resource, quote or sample;make a product, technical, sales or project enquiry;subscribe to emails or marketing updates;contact us by phone, email, social media or in person;place an order or apply for a trade or credit account;attend a trade show, event, presentation or demonstration;interact with our digital advertising or social media pages;apply for employment or contractor opportunities with Foamex.In some circumstances, we may also collect personal information from third parties, including:builders, architects, engineers, specifiers, contractors and project partners;distributors, stockists, suppliers and referral partners;sales representatives and agents;publicly available business directories and professional sources;industry event organisers, advertising platforms and analytics providers;CRM and marketing automation platforms, and social media platforms;recruitment providers; andcredit reporting bodies or account assessment providers, where relevant and lawful.								
				
				
				
				
							
						
				
		
		
				
				
					5.				
				
				
				
					Why We Collect, Hold, Use and Disclose Personal Information				
				
				
				
				
									We collect, hold, use and disclose personal information for purposes connected with Foamex business activities, including to:respond to enquiries and send requested product information, brochures, samples, whitepapers and technical resources;provide quotes, sales support and technical advice or product guidance;assess product or project requirements;manage customer, supplier, contractor and distributor relationships;process orders, deliveries, invoices and account administration;provide customer service, warranty support and after-sales assistance;maintain business records and manage our CRM systems, including Salesforce;manage Salesforce Marketing Cloud Account Engagement (formerly Pardot) activity;manage marketing subscriptions and preferences, and send marketing communications where permitted;measure website and advertising performance, and record advertising conversions;understand which products, content and resources are of interest;improve our websites, landing pages, forms, products and services;conduct analytics, reporting, forecasting and business planning;manage events, trade shows and industry contact lists;protect website and system security, and detect, prevent and respond to fraud, misuse and security incidents;comply with our legal, accounting, tax, insurance and regulatory obligations;manage complaints, disputes and legal claims; andassess employment and contractor applications.								
				
				
				
				
							
						
				
		
		
				
				
					6.				
				
				
				
					Product Websites, Microsites and Landing Pages				
				
				
				
				
									Foamex may operate or use product-specific websites, microsites and landing pages, including pages dedicated to specific products, campaigns or downloadable resources.Where a product website or campaign page links to this Privacy Policy, the personal information collected through that website or page will be handled in accordance with this Privacy Policy.For example, if you submit a product pack request, technical resource request or product enquiry form, Foamex may use your details to send the requested information, respond to your enquiry, record the enquiry in our CRM, attribute the enquiry to the relevant advertising campaign, and follow up with you regarding related product or project needs.								
				
				
				
				
							
						
				
		
		
				
				
					7.				
				
				
				
					Salesforce CRM and Marketing Cloud Account Engagement (Pardot)				
				
				
				
				
									Foamex uses Salesforce CRM and Salesforce Marketing Cloud Account Engagement (formerly known as Pardot) to manage enquiries, leads, customer relationships, sales activity, campaigns, marketing communications, website engagement and product resource requests.When you submit a website form, your information may be transmitted to Salesforce so that Foamex can:respond to your enquiry and send the materials you have requested;manage follow-up communications;record your product interests;manage sales and technical communications;attribute enquiries to marketing campaigns; andmanage marketing consent and unsubscribe preferences.Where Salesforce Account Engagement tracking is used, it may help Foamex understand engagement with our websites, landing pages, emails and campaigns. Salesforce tracking technologies may use cookies or similar technologies, which will generally be treated as analytics or marketing technologies and managed through our cookie consent settings where appropriate.								
				
				
				
				
							
						
				
		
		
				
				
					8.				
				
				
				
					Direct Marketing Communications				
				
				
				
				
									Foamex may use your personal information to send marketing communications about Foamex products, services, technical resources, sustainability information, case studies, industry updates, events, offers and related business information.We may send marketing communications to you where:you have provided your consent;you have subscribed to receive communications from us;you have requested information from us;you have an existing relationship with Foamex and would reasonably expect to receive relevant communications; orwe are otherwise permitted by law to do so.Marketing communications may be sent by email, telephone, SMS, social media, digital advertising platforms or other channels. Every commercial electronic marketing message we send will identify Foamex as the sender and provide a means to unsubscribe or opt out, as required by the Spam Act 2003 (Cth).You may unsubscribe from marketing communications at any time by:clicking the unsubscribe link in any marketing email;contacting us using the details set out in this Privacy Policy; orupdating your preferences where a preference centre is available.Please note that unsubscribing from marketing communications will not stop operational or transactional communications, such as responses to enquiries, order updates, delivery notifications, account communications, safety information, legal notices or customer service messages.								
				
				
				
				
							
						
				
		
		
				
				
					9.				
				
				
				
					Cookies and Similar Technologies				
				
				
				
				
									Foamex websites use cookies, pixels, tags, scripts, local storage, device identifiers and similar technologies (collectively, cookies).These technologies help us to:ensure our websites function properly and remain secure;remember your cookie preferences;measure website performance and understand how visitors use our websites;improve content and user experience;measure advertising campaign performance and record conversions;support remarketing and the delivery of relevant advertising; andunderstand engagement with product information and technical resources.Cookies may be set by Foamex directly, or by third-party providers we engage.								
				
				
				
				
							
						
				
		
		
				
				
					10.				
				
				
				
					Types of Cookies We Use				
				
				
				
				
					10.1 Essential Cookies				
				
				
				
									Essential cookies are required for our websites to operate correctly. They support functions such as page loading, website security, form submission, cookie preference management, spam protection, session management and core website functionality.Essential cookies generally cannot be switched off through our cookie preference centre, as parts of our websites may not work correctly without them.								
				
				
				
					10.2 Functional Cookies				
				
				
				
									Functional cookies provide enhanced website features. They may support embedded videos, maps, chat tools, saved preferences, third-party content and other improvements to website functionality. If functional cookies are disabled, some website features may not work as intended.								
				
				
				
					10.3 Analytics Cookies				
				
				
				
									Analytics cookies help us understand how visitors use our websites. They may collect information such as pages viewed, time on page, device type, browser type, referring website, approximate location, campaign source, form interactions and download activity.We use analytics information to improve website performance, content, product information, campaigns and customer experience.								
				
				
				
					10.4 Marketing and Advertising Cookies				
				
				
				
									Marketing and advertising cookies help us measure and improve our advertising activity. These may be used in connection with:LinkedIn advertising, Meta advertising and Google Ads;search advertising and remarketing;conversion tracking;Salesforce Account Engagement (Pardot) tracking;campaign attribution, audience measurement and ad performance reporting.Marketing cookies may help us deliver relevant Foamex advertising to people who have visited our websites or engaged with Foamex content.								
				
				
				
				
							
						
				
		
		
				
				
					11.				
				
				
				
					Third-Party Tracking Pixels				
				
				
				
				
									Foamex may use third-party tracking pixels or tags from platforms such as LinkedIn, Meta, Google, Salesforce and other marketing or analytics providers.Tracking pixels may collect or transmit information such as IP address, device information, browser information, page URL, referring website, pages viewed, button clicks, form events, campaign identifiers, cookie IDs and advertising identifiers.We use these technologies to measure advertising performance, understand campaign effectiveness, record conversions and support relevant advertising. We do not intend to use tracking pixels to collect sensitive information.Where available, we provide cookie controls so that visitors can reject or manage non-essential tracking technologies.								
				
				
				
				
							
						
				
		
		
				
				
					12.				
				
				
				
					Google, LinkedIn, Meta and Search Advertising				
				
				
				
				
									We use Google Analytics and Google Ads to improve our website experience and deliver relevant advertising. By using this site, you acknowledge our use of these tools for performance and advertising purposes. Foamex also use advertising and analytics services provided by social platforms such as LinkedIn and Meta. These services may help Foamex to:

measure website traffic;
record form submissions and conversions;
understand advertising performance;
build advertising audiences;
show relevant advertising and limit irrelevant advertising; and
measure return on marketing activity.

These platforms may use cookies, pixels and similar technologies in accordance with their own privacy policies and user settings. You can manage some advertising preferences directly through those platforms, your browser settings, and our cookie preference tool where available.								
				
				
				
				
							
						
				
		
		
				
				
					13.				
				
				
				
					Managing Your Cookies				
				
				
				
				
									When you first visit our websites, you may be presented with a cookie banner or consent notice. Depending on the settings available, you may be able to:accept all cookies;reject non-essential cookies;manage cookies by category; andchange your preferences at a later time.You can also control cookies through your browser settings. Please be aware that blocking some cookies may affect website functionality, form submissions, embedded content or your overall browsing experience.								
				
				
				
				
							
						
				
		
		
				
				
					14.				
				
				
				
					Disclosure of Personal Information				
				
				
				
				
									Foamex may disclose personal information to:Foamex related bodies corporate, business units and staff;authorised sales representatives, distributors, stockists and project partners;IT, hosting, website and security service providers;CRM providers, including Salesforce;marketing automation providers and email service providers;analytics providers, advertising platforms and social media platforms;payment, finance, credit and account administration providers;freight, delivery and logistics providers;professional advisers, including lawyers, accountants, auditors and insurers;recruitment and human resources service providers;government authorities, regulators or law enforcement bodies, where required or permitted by law; andother parties where you have consented to the disclosure or where the disclosure is otherwise permitted by law.Foamex does not sell personal information to unrelated third parties.								
				
				
				
				
							
						
				
		
		
				
				
					15.				
				
				
				
					Overseas Disclosure				
				
				
				
				
									Some service providers, technology platforms, CRM systems, cloud hosting providers, analytics providers and advertising platforms used by Foamex may store, process or access personal information outside Australia.The countries in which overseas recipients are located may vary depending on the provider and its systems, and may include the United States and other countries in which our service providers or their sub-processors operate.Where personal information is disclosed overseas, Foamex will take reasonable steps required by Australian privacy law to ensure that the overseas recipient handles the information in accordance with the Australian Privacy Principles, unless an exception applies.								
				
				
				
				
							
						
				
		
		
				
				
					16.				
				
				
				
					Security of Personal Information				
				
				
				
				
									Foamex takes reasonable steps to protect personal information from misuse, interference and loss, and from unauthorised access, modification or disclosure. These steps may include:secure systems and reputable hosting providers;access controls and password and authentication controls;restricted CRM access;staff confidentiality obligations and training;security monitoring and system maintenance;data backup and recovery processes; andperiodic review of our service providers, where appropriate.While we aim to apply technical and organisational safeguards appropriate to the nature of the information we hold, no method of electronic transmission or storage is completely secure, and we cannot guarantee absolute security.								
				
				
				
				
							
						
				
		
		
				
				
					17.				
				
				
				
					Retention of Personal Information				
				
				
				
				
									Foamex retains personal information for as long as is reasonably necessary for the purpose for which it was collected, including to:respond to enquiries and manage customer relationships;supply products and services;maintain business records;comply with our legal, accounting, tax, insurance and regulatory obligations;manage marketing preferences and record consent and unsubscribe requests;resolve disputes; andmaintain CRM records and campaign history.When personal information is no longer required, we will take reasonable steps to destroy, delete, de-identify or securely archive it, subject to our legal and business record-keeping obligations.								
				
				
				
				
							
						
				
		
		
				
				
					18.				
				
				
				
					Accuracy of Personal Information				
				
				
				
				
									Foamex takes reasonable steps to ensure that the personal information we hold is accurate, complete and up to date.You can help us maintain accurate records by letting us know if your details change, or if you believe the information we hold about you is inaccurate.								
				
				
				
				
							
						
				
		
		
				
				
					19.				
				
				
				
					Accessing or Correcting Your Personal Information				
				
				
				
				
									You may request access to the personal information that Foamex holds about you. You may also ask us to correct your personal information if you believe it is inaccurate, out of date, incomplete, irrelevant or misleading.To request access to or correction of your personal information, please contact us using the details set out in Section 28 (Contact us). We may need to verify your identity before responding to your request, and we will respond within a reasonable period.In some circumstances, we may decline access or correction where permitted by law. If we decline a request, we will provide written reasons for our decision and inform you of the available complaint mechanisms, unless it would be unreasonable or unlawful to do so								
				
				
				
				
							
						
				
		
		
				
				
					20.				
				
				
				
					Unsubscribing and Opting Out				
				
				
				
				
									You may opt out of Foamex marketing communications at any time by:clicking the unsubscribe link in any marketing email;using a preference centre, where one is made available;contacting Foamex using the details below; orchanging your cookie preferences through the Cookie Preferences link, where available.If you opt out of marketing communications, Foamex may still send you non-marketing communications, such as order updates, delivery notices, account information, safety notices, customer service responses and legal communications.								
				
				
				
				
							
						
				
		
		
				
				
					21.				
				
				
				
					Privacy Complaints				
				
				
				
				
									If you have a concern or complaint about how Foamex has handled your personal information, please contact us using the details set out in Section 28 (Contact us). Please include sufficient information for us to understand and respond to your concern.We will aim to:acknowledge your complaint within a reasonable time;review the matter carefully;request further information from you if needed;provide a written response setting out the outcome of our review; andtake appropriate steps if we identify an issue.If you are not satisfied with our response, you may contact the Office of the Australian Information Commissioner (OAIC) at www.oaic.gov.au.								
				
				
				
				
							
						
				
		
		
				
				
					22.				
				
				
				
					Notifiable Data Breaches				
				
				
				
				
									If Foamex becomes aware of a data breach involving personal information, we will assess the incident and take steps to contain and respond to it.Where required under the Notifiable Data Breaches scheme set out in Part IIIC of the Privacy Act 1988 (Cth), we will notify affected individuals and the Office of the Australian Information Commissioner.								
				
				
				
				
							
						
				
		
		
				
				
					23.				
				
				
				
					Links to Third-Party Websites				
				
				
				
				
									Foamex websites may contain links to third-party websites, platforms, documents, videos, forms or services. Foamex is not responsible for the privacy practices, content or security of any third-party websites.You should review the privacy policies of those third parties before providing any personal information to them.								
				
				
				
				
							
						
				
		
		
				
				
					24.				
				
				
				
					Social Media				
				
				
				
				
									If you interact with Foamex through social media platforms, your personal information may also be collected and handled by those platforms. Social media platforms have their own privacy policies, settings and advertising controls, which we recommend you review.Foamex may collect information that you make available to us through social media interactions, such as comments, messages, enquiries, profile information, and engagement with our posts and advertisements.								
				
				
				
				
							
						
				
		
		
				
				
					25.				
				
				
				
					Children				
				
				
				
				
									Foamex websites, products and services are intended for business, construction, building, design, engineering, architectural, trade and adult consumer audiences.We do not knowingly collect personal information from children through our websites. If you believe that a child has provided personal information to us, please contact us so that we can review and, where appropriate, delete that information.								
				
				
				
				
							
						
				
		
		
				
				
					26.				
				
				
				
					Automated Decision-Making				
				
				
				
				
									Foamex may use technology systems to assist in managing enquiries, recording campaign engagement, segmenting marketing lists, prioritising follow-up activities and improving customer communications.We do not intend to use automated decision-making to make decisions that would have a legal or similarly significant effect on individuals without appropriate human involvement. If this position changes, we will update this Privacy Policy accordingly.								
				
				
				
				
							
						
				
		
		
				
				
					27.				
				
				
				
					Changes to This Privacy Policy				
				
				
				
				
									Foamex may update this Privacy Policy from time to time to reflect changes in our business, websites, products, technology, legal obligations or privacy practices.The updated version will be posted on our website with the revised “Last updated” date. We encourage you to review this Privacy Policy periodically.								
				
				
				
				
							
						
				
		
		
				
				
					28.				
				
				
				
					Contact Us				
				
				
				
				
									For privacy questions, requests to access or correct your personal information, unsubscribe requests, or complaints, please contact our Privacy Officer using the details below.								
				
		
		
				
				
					Privacy Officer, Foamex Group Pty LtdABN 80 109 683 909  |  ACN 109 683 909				
				
				
		
				
				
					Emailsales@foamex.com.au				
				
				
				
					Phone1300 AU FOAM (1300 283 626)				
				
				
				
					Postal Address31 - 33 Gatwick Road, Bayswater North 3153				
				
				
				
				
				
					
				
		
					
				
				
					Get in touch for more information				
				
				
				
							

						
				
								
			
			
						

									
						
							1300 AU FOAM (1300 283 626)

#### Recycling
EPS Recycling Services Across Australia				
				
				
				
					 Leading the way in closed-loop EPS recycling solutions				
				
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
																														
				
				
		
		
				
				
																														
				
				
				
				
									At Foamex, we believe expanded polystyrene (EPS) should never go to landfill. As one of Australia’s largest and most experienced EPS recyclers and manufacturers, we’re committed to driving a national circular economy.With more than four decades of industry leadership, we use recycled EPS to manufacture sustainable building products that support energy-efficient construction and reduce environmental impact. We operate a national fleet of trucks, manage in-house recycling infrastructure, and offer services for households, builders, businesses, councils, and third-party recyclers.Whether you’re dropping off packaging at a local site, booking a construction site pickup, or arranging a commercial collection, Foamex makes it easy to recycle EPS responsibly—and keep it in use.								
				
				
					
				
		
				
				
							
			
						
		
						
				
				
		
					
		
		
				
				
					Recycling 				
				
				
				
								
				Community Recycling
Business Recycling
Construction Recycling
			
						
				Community Recycling
Business Recycling
Construction Recycling
			
						
				
				
				
		
		
		
				
				
							
			
						
		
						
				
				
				
					Free EPS Packaging Recycling  For Households
				
				
				
				
				
					Drop-Off Locations & Hours
				
				
				
				
									Foamex proudly partners with StyroCycle to provide the public with a free and easy way to recycle household EPS packaging. You can drop off clean polystyrene foam—like the packaging used to protect electronics and appliances—at selected Foamex sites across Victoria, New South Wales, and South Australia.This program is designed to keep EPS out of landfill and repurpose it into new, sustainable products like under-slab insulation, void formers, and other thermally efficient building materials. EPS is 100% recyclable, and at Foamex, we ensure it’s processed into feedstock for use in manufacturing.IMPORTANT: Polystyrene Packaging Recycling is FREE for occasional users, up to a car boot, ute load, small/medium van, or small trailer load (max 8 ft × 5 ft). Fees apply for regular drop-offs or volumes in excess of these limits. Please find our rates in the Business Recycling section. 								
				
				
				
					Victoria				
				
		
		
				
				
					Bayswater North				
				
				
				
							
							
										31 - 33 Gatwick Road 
									
								
										Mon–Fri, 8:30am–5:00pm
									
						
						
				
				
		
				
				
					Coolaroo 				
				
				
				
							
							
										430 Barry Rd
									
								
										Mon–Fri, 8:30am–4:00pm
									
								
											
													
										Free Public Drop Off Now CLOSED due to illegal dumping by residents. Commercial Recycling ONLY accepted. Contact us for rates
									
						
						
				
				
		
				
				
				
				
					New South Wales				
				
		
		
				
				
					REVESBY				
				
				
				
							
							
										31 Mavis St
									
								
										 Mon–Fri, 9:00am–1:00pm
									
						
						
				
				
		
				
				
					ORANGE				
				
				
				
							
							
										6 Colliers Ave
									
								
										Mon - Fri, 9:00am - 1:00pm
									
						
						
				
				
		
				
				
		
		
				
				
					South Australia				
				
		
				
				
					Edinburgh North				
				
				
				
							
							
										15 Peachey Rd
									
								
										Mon–Fri, 8:00am–3:00pm
									
						
						
				
				
				
		
				
		
				
				
				
				
					 Drop-off locations are closed on weekends and public holidays				
				
				
				
									To be accepted, polystyrene must be:Clean and free of contaminants (no food, sticky tape, labels, or paint)Rigid EPS packaging only – no soft foam or foam rubber								
				
				
				
									See below Accepted EPS Types & Volumes								
				
				
				
									
					
						
						
							
									What Can Be Recycled
					
					
				
								
				
				
				
							
			
						
		
						
				
				
		
		
				
				
							
			
						
		
						
				
				
				
					Commercial EPS Packaging Recycling 				
				
				
		
		
				
				
									If your business generates large volumes of EPS (expanded polystyrene) packaging, Foamex offers flexible, cost-effective recycling solutions tailored to commercial needs. We work with distributors, retailers, local councils, and waste management companies to recover and recycle EPS used in packaging & logistics.Service availability by state:VIC & SA:  Collection and bulk drop-off options available (subject to volume and location).  NSW: Bulk drop-off with paid processing for commercial EPS packaging (collection not available).								
				
		
				
				
									
					
						
						
							
									recycling rates 
					
					
				
								
				
				
				
									
					
						
						
							
									Contact
					
					
				
								
				
				
				
		
				
				
																														
				
				
				
		
				
				
							
			
						
		
						
				
				
				
		
		
				
				
							
			
						
		
						
				
				
				
					EPS Waffle Pod Recycling				
				
				
				
				
									As proud members of Expanded Polystyrene Australia (EPSA) Foamex makes it simple for builders to recycle leftover EPS from waffle pods. We offer scrap collection, including the supply of scrap bags, tie-downs, and pick-up services. This helps reduce site waste, improve safety, and ensure polystyrene offcuts are reprocessed into new products instead of going to landfill.								
				
				
				
					Watch: How to Prepare EPS for Pickup by EPSA				
				
				
				
							
					
						
				
				
				
									Working with Foamex ensures:Clean, safe, and organised building sitesCompliance with green building practicesZero EPS waste to landfill								
				
				
				
					Want to book a pick-up or learn more? Contact our team to get started.				
				
				
				
									
					
						
						
							
									Contact
					
					
				
								
				
				
				
					
				
		
				
				
							
					
				
					
		
				
				
					Get in touch for more information				
				
				
				
							
							
											

												
													
										1300 AU FOAM  (1300 283 626)
											
									
						
						
				
				
		
				
				
									
				
				
				
							
			
			
			

							
			
			
								
												
								First Name							
														
											
								
												
								Last Name							
														
											
								
												
								Email							
														
											
								
												
								Company							
														
											
								
												
								State							
								
			
							
			
									State
							
		
						
								
												
								Phone							
								

						
								
												
								Postcode							
														
											
								
												
								Comment							
										
								
					
						
															
																										
																						submit

#### Resources
Polystyrene Technical Information & Resources				
				
				
				
					Technical resources for industry professionals.				
				
				
				
							
			
						
		
						
				
					
				
		
					
		
				
				
					Brochures				
				
				
		
				
				
							
				
					
		
				
				
					Styroboard EPS Products Brochure				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard XPS Products Brochure				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					StyroPak Brochure (SA & VIC Only)				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					StyroPak Box Catalogue (SA & VIC Only)				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Expol R1.4 Underfloor Insulation				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Expol R1.8 Underfloor Insulation				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					StyroPod Product Brochure				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					GeoFoamX Product Brochure				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
						
				
				
					
				
		
					
		
				
				
					Technical
Specifications				
				
				
		
				
				
							
				
					
		
				
				
					Styroboard XPS Technical Data				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard EPS Technical Data				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Expol Underfloor Technical Data				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard XPS – ODP				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard EPS – Thermal Resistance (R-Values)				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard EPS – ODP				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard EPS Dust
Specifications & Price				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
						
				
				
					
				
		
					
		
				
				
					Material Handling
/ Safety Data Sheets				
				
				
		
				
				
							
				
					
		
				
				
					Styroboard XPS – Material Safety Data				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard EPS – Material Safety Data				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard XPS Products – Material Handling				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					StyroPod – EPSA Code of Practice				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
						
				
				
					
				
		
					
		
				
				
					Whitepapers				
				
				
		
				
				
							
				
					
		
				
				
					Waffle Pods The Facts – Sustainability				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					QPODS: Green From the Ground Up				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard XPS – A framework for
energy-efficient building design				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
						
				
				
					
				
		
					
		
				
				
					Certifications				
				
				
		
				
				
							
				
					
		
				
				
					Australian Made Certification				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
						
				
				
					
				
		
					
		
				
				
					Warranties				
				
				
		
				
				
							
				
					
		
				
				
					Styroboard XPS Warranty				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Styroboard EPS Warranty				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Expol Underfloor Warranty				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
						
				
				
					
				
		
					
		
				
				
					Returns Policies				
				
				
		
				
				
							
				
					
		
				
				
					Foamex Returns Policy				
				
				
		
				
				
									
					
						
						
							
									Download
					
					
				
								
				
				
					
				
				
				
				
					
		
				
				
					Foamex Inclement
Weather Policy				
				
				
		
				
				
									
					
						
						
							
									Download

### Products

#### Expol Underfloor R1.4
Expol Underfloor Insulation by Foamex is a cost-effective way to improve your home’s comfort and energy efficiency by creating a thermal barrier that stops heat entering in summer and escaping in winter. Manufactured in Australia using high-quality expanded polystyrene (EPS) — and, where possible, incorporating recycled content — Expol contains flame retardant, is CFC-free, and designed to compress snugly between timber floor joists with concertina cuts allowing up to 20mm of flexibility.
Suitable for both new and existing homes, Expol is non-allergenic, safe, and easy to install. Any offcuts can be returned to Foamex for recycling, supporting a closed-loop process and reducing waste.
Available from leading hardware stores and directly from Foamex.

#### Expol Underfloor R1.8
Graphite-infused underfloor insulation that’s 30% more energy efficient.

#### GeoFoamX<sup>®</sup>: Geofoam
GeoFoamX® by Foamex is a high-performance expanded polystyrene (EPS) void fill solution engineered for civil engineering, landscaping, and structural applications. Lightweight yet remarkably strong, GeoFoamX® reduces ground pressure while supporting heavy structural loads, making it ideal for bridge abutments, road embankments, piling walls, elevation changes, and retaining structures. Manufactured in Australia to stringent standards, it offers consistent quality, cost-effective transport, and weatherproof installation.
Made using recycled content, GeoFoamX® supports circular construction practices by turning waste into space—transforming post-consumer and offcut EPS into dependable, high-strength fill. With a variety of densities and sizes available, GeoFoamX® is dimensionally stable, easy to shape, and a smarter alternative to traditional fill materials in complex ground engineering projects.

#### Insulclad (NSW Only)
The Insulclad Rendered Wall System is a high-performance, lightweight cladding solution engineered to deliver superior thermal insulation, long-term durability, and modern architectural appeal. Made from fire-retardant expanded polystyrene (EPS), Insulclad panels provide a continuous insulation envelope that significantly improves a building’s energy efficiency while also supporting compliance with energy rating requirements.
Designed and manufactured in Australia by Foamex NSW, Insulclad is a trusted alternative to traditional materials such as fibro, weatherboard, and brick veneer. It’s ideally suited for both residential and low-rise commercial construction, offering a sleek, rendered finish that enhances curb appeal and allows for a wide range of design flexibility. With its CodeMark certification, Insulclad is recognised by building authorities nationwide and provides peace of mind for specifiers, architects, and builders looking for a reliable, compliant system that performs in Australia&#8217;s diverse climate conditions.

#### QPOD™ 300 Pods (VIC &#038; SA)
Available in Victoria &amp; South Australia only. QPOD™ is a high-performance plastic pod flooring system designed for raft and continuous slab construction. Manufactured from 100% recycled plastic and fully recyclable, QPOD™ supports sustainable construction outcomes without compromising strength or structural integrity.
Ideal for flood-prone zones, engineered sites, and builders seeking smart, future-ready solutions, QPOD™ is lightweight, fast to install, and easy to transport. Its patented interlocking design and integrated 40mm barchairs simplify on-site setup, helping to reduce labour and streamline slab preparation.
QPOD™ integrates seamlessly with Foamex insulation products to meet the energy efficiency demands of modern homes. As a proud distributor of QPOD™ in Australia, Foamex offers builders the best of both worlds: proven insulation expertise and next-generation foundation systems.

#### StyroBloc<sup>®</sup>: EPS Blocks
StyroBloc® is a high-performance expanded polystyrene (EPS) foam block designed for wholesale supply and downstream customisation. Manufactured in Australia from our trusted Styroboard® EPS, StyroBloc® is lightweight, durable, and extremely versatile — ideal for wholesalers, fabricators, and manufacturers looking to cut, shape, laminate or mould EPS into their own range of products. From insulation panels and construction void fillers to creative retail signage, StyroBloc® offers consistent quality and adaptability at scale.
Foamex also offers the option to incorporate up to 75% recycled content, supporting sustainable supply chains and helping your business meet circular economy targets.

#### StyroLink<sup>®</sup>: XPS Roof Spacers 
Precision-engineered from Styroboard® XPS, StyroLink® roof spacers are a high-compression, thermally efficient solution for commercial metal deck roofs. Installed directly over roof purlins, StyroLink® creates a consistent gap for insulation recovery, allowing thermal blankets to retain their full nominal thickness and perform at peak R-Values. The closed-cell XPS structure ensures excellent water resistance, minimal thermal bridging, and long-term compressive strength. Lightweight and easy to handle, StyroLink® is custom-cut to your project’s needs and proudly made in Australia from recyclable materials.
StyroLink® is manufactured from Styroboard® XPS, which contains up to 90% recycled polystyrene. This recycled content is sourced through Foamex’s closed-loop recycling model, collecting clean waste from building site offcuts, factory floor surplus, and post-consumer packaging via dedicated drop-off points. By turning recovered polystyrene into high-performance insulation products, StyroLink® supports circular construction practices without compromising technical integrity.

#### StyroPak<sup>®</sup>: EPS Boxes
StyroPak® by Foamex offers a durable, economical, and food-safe packaging solution made from expanded polystyrene (EPS). Designed to safeguard temperature-sensitive and fragile items, these Australian-made boxes are ideal for transporting seafood, fresh produce, pharmaceuticals, and other perishables. Lightweight yet strong, StyroPak® EPS boxes help reduce freight costs, protect goods during transit, and support sustainable packaging practices through recyclability and reusability.
With high shock absorbency, thermal insulation, and resistance to moisture and bacteria, StyroPak® is trusted by wholesalers, food suppliers, and retailers who need a clean, reliable, and cost-effective packaging alternative to traditional materials like timber or cardboard.
Please note: StyroPak® EPS boxes are available exclusively through the Foamex SA office. For orders in VIC, NSW, QLD or TAS, please contact our manufacturing partner Polyfoam.

#### StyroPod<sup>®</sup>: EPS Waffle Pods
Foamex StyroPods® are high-performance polystyrene waffle pods engineered to enhance the strength, durability, and thermal efficiency of waffle pod slab construction. Designed for residential, commercial, and industrial applications, they provide a lightweight yet structurally robust foundation system that reduces concrete usage and overall construction costs.
Manufactured with recycled content, StyroPods® support sustainable building practices, with all offcuts being 100% recyclable. Through Foamex’s offcut collection service, excess material is repurposed into new building products, reinforcing a circular economy approach to construction waste.
With superior insulating properties, StyroPods® minimise heat loss, contributing to under-slab insulation performance and improving energy efficiency. Designed to meet Australian Standard AS 2870, they ensure compliance with national building codes while offering a proven, cost-effective solution for waffle pod slab construction.

#### StyroRoof<sup>®</sup>: Green Roofs
StyroRoof® by Foamex is a high-performance extruded polystyrene (XPS) insulation board engineered specifically for green roofs and rooftop applications. Manufactured in Australia from Styroboard XPS—the only locally made XPS—StyroRoof offers excellent compressive strength, long-term thermal performance, and superior moisture resistance, making it ideal for demanding rooftop environments.
Its closed-cell structure ensures dimensional stability and low water absorption, even when exposed to wet and fluctuating conditions over time. StyroRoof® supports energy-efficient building design by reducing heat transfer through the roof, contributing to better energy ratings and reduced HVAC loads. With up to 90% recycled content, a lightweight profile, and full recyclability, StyroRoof delivers both environmental and structural performance in green infrastructure and commercial roofing systems.

#### StyroSheet: EPS Sheets
StyroSheet Expanded Polystyrene (EPS) sheets are robust, lightweight insulation boards ideal for diverse commercial and residential construction applications. Manufactured locally from Foamex’s industry-leading Styroboard EPS, these polystyrene foam sheets deliver superior insulation properties, durability, and versatility. Known for outstanding thermal insulation, structural integrity, and acoustic performance, StyroSheet is the preferred choice for Exterior Insulation and Finish Systems (EIFS), wall and floor insulation, and garage door insulation.
Safe to handle, simple to install, and environmentally friendly, StyroSheet boards contain no harmful CFCs and are fully recyclable, offering builders and architects a high-performance insulation solution.

#### StyroTherm<sup>®</sup>: XPS Sheets
Made from our Styroboard® XPS, StyroTherm® by Foamex is a premium extruded polystyrene (XPS) sheet insulation solution, engineered for long-term performance in construction and architectural applications. With its high compressive strength and closed-cell structure, StyroTherm® offers outstanding thermal performance and water resistance—ideal for slab insulation, edge detailing, and below-ground protection. Manufactured in Australia from high-quality XPS using a process free from ozone-depleting gases, StyroTherm® delivers stable, high R-values across a range of building types.
Whether insulating a concrete slab or designing a sustainable green roof with StyroRoof® &#8211; our specialised XPS board for rooftop applications &#8211; Foamex provides high-performance insulation with proven durability, moisture resistance, and environmental integrity. As part of our circular production model, StyroTherm® also incorporates up to 90% recycled polystyrene, helping builders meet sustainability goals without compromising on performance.

### Product Accessories

#### Central Locking System
QPOD™ isn’t just about sustainable materials—it’s about smart system design. The Central Locking System connects four closed-sided QPODs to form a rigid 1100mm x 1100mm square pod, matching the volume of a traditional void former. This creates consistent rib spacing at 1100mm centres—delivering reliable slab performance across residential and commercial builds.
The locked-together pods form a stable grid that stays in place during setup, concrete pouring, and even windy conditions. The result? Faster installs, greater accuracy, and a clean, professional finish every time.

#### EXPOL Joist Saddles – New Floor Builds
Speed up your underfloor installation with Expol Joist Saddles. Designed for new builds, these durable saddles hold panels in place from above the joist, saving time and ensuring correct positioning before floorboards or sheeting are laid. Pack of 50.

#### EXPOL WireGuard Insulation Roll
Protect your electrical cables with WireGuard — a waxed adhesive paper strip that prevents contact between EPS panels and wiring. Simple to install and essential for safety when Expol insulation is used around electrical cables in floors and subfloors.

#### EXPOL Z Clips – New &#038; Existing Floors
Quick-fit Z Clips make installing underfloor insulation even easier. No nails needed — just push into place between the joist and panel. Use two clips per panel to secure Expol insulation snugly and safely. Suits both new and existing floors.

#### Polystyrene Recycling Bags
Foamex supports the EPSA Pod Code of Practice, ensuring the responsible use and disposal of EPS waffle pods on construction sites. Our EPS recycling bags facilitate the collection of offcuts, which are then recycled into new sustainable building products at our state-of-the-art recycling facilities.

#### StyroPod<sup>®</sup> 2 Way Spacer
Designed to fit 100mm or 110mm internal spacings, the StyroPod 2 Way Spacer provides internal bar support for waffle raft slabs, reinforcing steel placement between pods and in trenches to ensure a stable, structurally sound slab foundation.

#### StyroPod<sup>®</sup> 4 Way Interlock
The StyroPod 4 Way Interlock enhances waffle pod slab stability, securing pods in place during concrete pours for a uniform and consistent slab finish. Engineered for time efficiency, this accessory locks into the lugs at each pod’s corner, allowing for double stacking when required.
Available sizes: 100mm, 110mm.

#### StyroPod<sup>®</sup> 4 Way Spacer
Designed for precise reinforcement placement, the StyroPod 4 Way Spacer allows reinforcing bars to be positioned accurately within a waffle pod slab, ensuring uniform concrete flow and cost-efficient waffle slab construction that meets Australian building standards.
Available sizes: 100mm, 110mm.

#### StyroPod<sup>®</sup> Rails
Featuring stabilising spikes, StyroPod Rails secure waffle pods in place, even in high winds or inclement weather. The wide base design distributes the weight of the reinforcing mesh, improving concrete flow, slab safety, and overall structural integrity while increasing productivity and reducing labour time.
Available size: 600mm L x 75mm W x 40mm H.

#### StyroPod<sup>®</sup> Slab Edge Spacer (Only Available in SA)
Engineered for precise edge beam bar placement, the StyroPod Slab Edge Spacer ensures accurate reinforcement positioning along the outer edge of a waffle pod slab, enhancing slab strength and stability.
Available size: 110mm.

### Resources

#### Styroboard EPS &#8211; ODP
URL: https://www.foamex.com.au/resources/styroboard-eps-odp-updated-august-2021/

#### Styroboard EPS &#8211; Thermal Resistance (R-Values)
URL: https://www.foamex.com.au/resources/styroboard-eps-technical-data/

#### Styroboard EPS Dust
Specifications &#038; Price
URL: https://www.foamex.com.au/resources/styroboard-eps-dust-specifications-price/

#### Styroboard EPS Products Brochure
URL: https://www.foamex.com.au/resources/styroboard-eps-products-brochure/

#### Styroboard EPS Technical Data
URL: https://www.foamex.com.au/resources/styroboard-eps-thermal-resistance-r-values/

#### Styroboard EPS Warranty
URL: https://www.foamex.com.au/resources/styroboard-eps-2/

#### Styroboard XPS &#8211; A framework for
energy-efficient building design
URL: https://www.foamex.com.au/resources/styroboard-xps-a-framework-for-energy-efficient-building-design/

#### Styroboard XPS &#8211; Material Safety Data
URL: https://www.foamex.com.au/resources/styroboard-xps-material-handling-of-styrotherm-xps-sheets/

#### Styroboard XPS &#8211; ODP
URL: https://www.foamex.com.au/resources/styroboard-xps-odp-updated-march-2022/

#### Styroboard XPS Products Brochure
URL: https://www.foamex.com.au/resources/styroboard-xps-products-brochure/

#### Styroboard XPS Technical Data
URL: https://www.foamex.com.au/resources/styroboard-xps-technical-data/

#### Styroboard XPS Warranty
URL: https://www.foamex.com.au/resources/styroboard-xps-2/

#### StyroPak Box Catalogue (SA &#038; VIC Only)
URL: https://www.foamex.com.au/resources/styropak-box-catalogue-sa-only/

#### StyroPak Brochure (SA &#038; VIC Only)
URL: https://www.foamex.com.au/resources/styropak-brochure-sa-only/

#### StyroPod &#8211; EPSA Code of Practice
URL: https://www.foamex.com.au/resources/styropod-epsa-code-of-practice/

#### StyroPod Product Brochure
URL: https://www.foamex.com.au/resources/styropod/

### Services

#### Custom Architectural Services
URL: https://www.foamex.com.au/services/custom-architectural-services/

#### Custom Manufacturing
URL: https://www.foamex.com.au/services/custom-manufacturing/

#### End to End Contract Manufacturing
URL: https://www.foamex.com.au/services/end-to-end-contract-manufacturing/

#### EPS Recycling Solutions
URL: https://www.foamex.com.au/services/recycling-sustainability-solutions/

#### Specialised Toll Manufacturing
URL: https://www.foamex.com.au/services/toll-manufacturing/