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.