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Inspection of properties of Expanded Polystyrene (EPS), Compressive


behaviour, bond and analytical examination of Insulated Concrete Form (ICF)
blocks using different densities of...

Article  in  International Journal of Civil Engineering and Technology · February 2017

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International Journal of Civil Engineering and Technology (IJCIET)
Volume 8, Issue 1, January 2017, pp. 209–221, Article ID: IJCIET_08_01_022
Available online at http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=1
ISSN Print: 0976-6308 and ISSN Online: 0976-6316
© IAEME Publication

INSPECTION OF PROPERTIES OF EXPANDED


POLYSTYRENE (EPS), COMPRESSIVE BEHAVIOUR,
BOND AND ANALYTICAL EXAMINATION OF
INSULATED CONCRETE FORM (ICF) BLOCKS USING
DIFFERENT DENSITIES OF EPS
A. Arun Solomon
Assistant Professor, Department of Civil Engineering,
Karunya University, Coimbatore, Tamil Nadu, India

G. Hemalatha
Associate Professor, Department of Civil Engineering,
Karunya University, Coimbatore, Tamil Nadu, India

ABSTRACT
Insulated Concrete Form (ICF) is an emerging construction technology using the interlocking
of Expanded Polystyrene (EPS) sheet with poured in place concrete. Expanded Polystyrene has
many advantages like lighter in weight, good thermal insulation, moisture resistant, durable,
acoustic absorption, low thermal conductivity, etc., In this study, the properties of EPS were
determined by the standard procedure as per IS 4671:1984, compression behavior of ICF and
bondage between EPS and concrete were analyzed using ICF specimens casted using M25 grade
concrete. Two types of ICF specimens were casted with corrugated EPS and Plain EPS and using
different densities of 4,8,12 kg/m3and varying thickness of 50 mm and 100 mm EPS. The results
show that the compressive strength of ICF blocks casted with plain EPS was higher than the
samples casted with corrugated EPS as well as results show that good bondage exist between EPS
and concrete for plain and corrugated EPS without adding any bonding agent while casting and
when compared to plain concrete all the ICF blocks exhibit tremendous ductile nature of failure.
Key words: EPS sheet, Insulated Concrete Form, load-deflection curve, compressive strength.
Ductility ratio.
Cite this Article: A. Arun Solomon and G. Hemalatha. Inspection of Properties of Expanded
Polystyrene (EPS), Compressive Behaviour, Bond and Analytical Examination of Insulated
Concrete Form (ICF) Blocks Using Different Densities of EPS. International Journal of Civil
Engineering and Technology, 8(1), 2017, pp. 209–221.
http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=1

1. INTRODUCTION
The rapid growth of population in India has increased the demand for residential, commercial and
industrial structures. It is expected that the construction sector needs to build a structure with maximum

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A. Arun Solomon and G. Hemalatha

benefit like cost, time of construction, disaster resistant, flexible to construct, etc., ICF systems of
construction is an emerging technology that provides light weight, faster construction and many more
advantages. Common applications for this method of construction are low-rise buildings, with property
uses ranging from residential to commercial and to industrial. Insulated Concrete Form (ICF) is made by
interlocking of Expanded Polystyrene (EPS) sheets and the cavity filled with concrete that holds EPS
together during the curing operation and remains in place permanently afterwards to serve as thermal
insulators. Figure 1 shows the typical ICF model made with interlocked EPS blocks. ICF are becoming
widely used today for a full range of building designs including residential theaters, schools and hospitals
[1, 2].

Figure 1 Typical Interlocked EPS for ICF blocks

1.1. Literature Survey


M. A. Mousa and N. Uddin [3] studied buckling behavior of Composite Structural Insulated wall panel
(CSIP). Here, the author used low cost thermoplastic orthotropic glass/polypropylene (glass-PP) laminate
as a face sheet and expanded polypropylene foam as a core. Investigations on the behavior of CSIPs under
concentric and eccentric load were carried out. Global buckling was observed when experimental
investigations were carried out with sample size of 101.6 x 76.2 x 34.48 mm. Analytical expressions for
concentric and eccentric loading to validate the experimental results were developed and found both results
were in good agreement. Design graphs for global buckling that can be used for preliminary design of the
composite structural insulated panel under concentric and eccentric loading were also developed.
In 2012, M. A. Mousa and N. Nuddin [4] developed smaller scale experiments into large scale
experiments. The size of the specimen was 1220 x 2440 x 147 mm and Pull off strength test was carried
out to determine the bonding nature between cores and face sheet of CSIP panel made with different
bonding agents. By the experimental results of Pull off strength test, it was concluded that spray adhesive
is the best solution for manufacturing CSIP panels because of its high strength and low cost benefits when
compared to other adhesives. CSIP panels designed to satisfy the design and deflection limits of ACI-318.
The failure of the panel was by debonding between face sheet and the inner core.
C. A. Yahia and T. Majidzadeh [5] experimentally investigated the identification of honeycomb in
between the contact surface of EPS sheet. Ground penetrating radar was used to locate the honeycomb or
voids in the Insulated concrete form structure. It was concluded that GPR was an effective method to
detect voids in between EPS sheet and concrete, though smaller voids less than 18.75 mm were difficult to
detect.
W. A. Friess et al. [6] carried out research on the increase in energy demand of Dubai and the
development of new technology of construction using EPS to reduce the energy consumption in terms of
electricity usage in Dubai. The energy demand was studied using past 10 years record of electricity
consumption in Dubai as well as model building of two storey semi detached single family villa was
constructed that mostly resembles at Dubai’s traditional construction. The building wall was constructed
using standard mid plane insulated precast concrete blocks (200 mm) typically utilized in Dubai in that 60
mm Expanded Polystyrene (EPS) as used as a mid plane and 70 mm aerated concrete on both sides of EPS.
As built villa is simulated with energy modeling software Design Builder (version 2.3.6) which uses the
well tested Energy Plus (version 6.0) hourly simulation engine by one year of billed electricity

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Inspection of Properties of Expanded Polystyrene (EPS), Compressive Behaviour, Bond and Analytical
Examination of Insulated Concrete Form (ICF) Blocks Using Different Densities of EPS

consumption and infiltration data measured using a blower door tester. The extensive energy saving
analysis was carried out using simulated Energy Plus model and U value was determined for the wall and
RC frame with varying parameters and concluded that by Energy Utilization Index non-insulated block of
50 mm EPS can be preferred to decrease cost and increase thermal mass insulation over 30 % when
compared to other models and the yearly energy consumption saving up to 20000 kWh per villa as well as
reduction of CO2 emission up to 7.6 tons per household can be achieved.
L. Smakosz and J. Tejchman [7] examined experimentally the characteristics and behavior of
composite structural insulated panels (CSIP) developed by Glass Fibre Reinforced Magnesia Cement
Boards as face sheets and expanded polystyrene foam (EPS) as a core. The properties of used material in
terms of compression, tension, bending and shear were tabulated. Various properties were examined
through different test by using large and small scale specimens. It was found that CSIP panel has enormous
potential in terms of crushing debonding and load bearing, however, it was also mentioned that when
compared to traditional Structural Insulated Panel (SIP) CSIP panels were failed by brittle nature.
From the study, it is understood that EPS can be a prime material for construction and many research
are under progress with EPS, though ICF walls has limited research reports. ICF considered in this paper is
fabricated using M25 grade concrete with three different densities of EPS is 4, 8, 12 kg/m3 and two varying
thickness of 50 and 100 mm. The compression and flexure properties of different densities of EPS were
evaluated as per IS4671:1984 [10]. The compression behavior of ICF blocks made with different densities
and varying thickness of EPS was examined using computerized universal testing machine. Bonding nature
was analyzed using corrugated EPS and plain EPS. The results indicate that 12 kg density 100 mm thick
EPS exhibits good ductile nature when compared to other ICF blocks, but there was not much variation in
compression strength. EPS also displayed a high level of bonding with concrete without addition of any
admixture.

2. EXPERIMENTAL INVESTIGATION
Initially, to understand the compressive nature of ICF wall, ICF blocks were cast and tested for
compressive load. This paper examines the properties of EPS and investigates the compressive behavior of
ICF blocks with corrugated and plain EPS as well as to observe bonding nature between EPS and concrete

2.1. Description of the Materials


Expanded Polystyrene (EPS) is a rigid cellular plastic that is made from expandable polystyrene that
contains an expansion agent. Polystyrene is extracted from petroleum and gas industry. Styrene of 0.5 to
1.5 mm diameter called monomers expands 40 to 50 times its initial size through the process of
polymerization that is called as Expanded Polystyrene (EPS). The most common applications of EPS are
low thermal conductivity, ductility property, shock absorption, energy efficiency, etc., that makes the
material attain the demand for which it is used. EPS based construction provides reduction of scaffolding
and shuttering work and eliminates curing process and drastically decreases the construction time. The
densities of EPS taken for this study are 4, 8, 12 kg/m3 and thickness of 50 and 100 mm. Figure 2 shows
the typical 50 mm and 100 mm thick EPS sheets that would be cut by mechanical system to the required
size for compression and flexure test of EPS and to cast the ICF blocks. M25 grade concrete has been used
to prepare ICF blocks and the mix design was carried out using IS 10262:2009 [8] and IS 456:2000 [9] and
presented in Table 1.

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A. Arun Solomon and G. Hemalatha

Figure 1 Typical 50 mm and 100 mm thick EPS

Table 1 Mix ratio and quantities of M25 grade concrete

Materials Quantity Ratio


3
Cement 435.45 kg/m 1
3
Fine Aggregate 676 kg/m 1.55
Coarse Aggregate 1067.69kg/m3 2.45
Water 191.5 liters 0.44

2.2. Determination of Compressive Strength of EPS


The compressive strength of EPS was examined as per the standard procedure given in IS 4671: 1984 [10].
The sample size was taken as 200 x 200 mm and three different densities of EPS namely 4, 8 and 12 kg/m3
and two varying thickness of 50 and 100 mm was taken. As per the code, five samples have been prepared
(figure 3) for each category of EPS and compressive strength was determined by standard procedure using
a Universal Testing machine (Figure 4). Figure 4, shows the experimental setup for compression tests. It
was observed that, 100 mm thick EPS had the capacity to compress to its full length (figure 5) and regain
its one third of length after removal of load (figure 6), but the 50 mm thick EPS tend to buckle while
applying the compressive load (figure 7). Table 2 gives average of result of five specimen for maximum
load, compressive strength and maximum contraction of EPS. The compressive strength of EPS varies
between 0.15-0.21 MPa and 100 mm thick EPS shows more compression capacity (figure 9) when
compared to 50 mm thick EPS that fails by buckling during the compressive deformation of 33-41 mm
(figure 8).

Figure 3 Collected Samples for Figure 4 Typical testing arrangement for compression
Compression and Flexure test test of EPS

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Inspection of Properties of Expanded Polystyrene (EPS), Compressive Behaviour, Bond and Analytical
Examination of Insulated Concrete Form (ICF) Blocks Using Different Densities of EPS

Figure 5 Fully Compressed 100 thick EPS Figure 6 Tested samples compared with fresh
while testing samples

Figure 7 Buckled 50 thick EPS Figure 8 Tested samples compared with


while testing fresh samples

Table 2 Compressive Strength of EPS

Maximum Compressive Maximum


S.No EPS Specification Load Strength Contraction
(kN) (MPa) (mm)
1 4 kg Density 50 mm thick 1.5 0.15 36.9
2 4 kg Density 100 mm thick 3.6 0.18 123.7
3 8 kg Density 50 mm thick 1.5 0.15 33.4
4 8 kg Density 100 mm thick 4.1 0.205 128.9
5 12 kg Density 50 mm thick 2.1 0.21 40.9
6 12 kg Density 100 mm thick 3.7 0.185 132

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A. Arun Solomon and G. Hemalatha

0.25 140

Maximum Contraction
Compressive Strength Mpa
120
0.2
100
0.15 80

mm
0.1 60
40
0.05
20
0 0
1 2 3 4 5 6 1 2 3 4 5 6
Sample ID Sample ID

Figure 9 Compressive Strength and Maximum Contraction comparison chart of EPS

2.3. Determination of Flexural Strength of EPS


The flexural strength of EPS was determined as per the standards given in IS 4671:1984 [10]. The flexural
strength was determined with sample size of 300 x 200 mm for three different densities of EPS, 4, 8 and 12
kg/m3 and two varying thickness of 50 and 100 mm. As per the code, five samples were prepared for each
category of EPS and flexural strength was determined by standard procedure using a universal testing
machine (Figure 10). Figure 10 gives an experimental set up of EPS for flexural tests. The expression to
determine flexural strength is1.5 , where W is applied load in N, L is the length between the
supports, B is the width of the specimen and D is the thickness of the specimen in mm. It is observed that,
4 kg density 100 mm thick EPS exhibits its higher contraction and 12 kg density 100 mm thick EPS shows
higher flexural strength when compared to 50 mm thick EPS (Table 3 and Figure 11). Table 3 gives
average result five specimen for maximum load, maximum contraction and flexural strength of EPS, which
shows that the flexural strength of EPS varies between 0.10-0.45 MPa.

Figure 10 Typical experimental setup for flexure test of EPS

Figure 11 Typical failed samples of flexure test

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Inspection of Properties of Expanded Polystyrene (EPS), Compressive Behaviour, Bond and Analytical
Examination of Insulated Concrete Form (ICF) Blocks Using Different Densities of EPS

Table 3 Flexural Strength of EPS

Maximum Flexural Maximum


S.No EPS Specification Load Strength Contraction
(kN) (MPa) (mm)
1 4 kg Density 50 mm thick 0.9 0.41 28.2
2 4 kg Density 100 mm thick 0.9 0.10 47.9
3 8 kg Density 50 mm thick 0.6 0.27 16.5
4 8 kg Density 100 mm thick 1.4 0.16 21.6
5 12 kg Density 50 mm thick 1.0 0.45 12.4
6 12 kg Density 100 mm thick 1.5 0.17 20.0

0.5 60

Maximum Contraction
Flexural Strength MPa

0.4 50
40
0.3
mm
30
0.2 20
0.1 10
0
0
1 2 3 4 5 6
1 2 3 4 5 6
Sample ID Sample ID

Figure 11 Flexural Strength and Maximum Contraction Comparison Chart of EPS

2.4. ICF Block Compressive Strength


ICF blocks were cast with a width of 200 mm and height of 150 mm, 12 blocks were prepared using
corrugated EPS and 12 blocks were cast with plain EPS to analyze the bonding nature between EPS and
concrete. All the 12 samples were cast usingM25 grade concrete with three different densities 4, 8,12
kg/m3 and two varying thickness of 50 and 100 mm EPS. Two plain concrete blocks were also cast of size
200 x 150 x 60 mm without EPS to compare the test results of ICF blocks (figure12-15). Membrane curing
(figure 16) was adapted to cure the ICF specimens. 6mm diameter MS rods were used to interlock EPS
sheets. The 6 mm diameter MS rod was penetrated into the EPS sheets to hold the EPS sheets in position to
maintain 60 mm spacing and for uniformly pouring of concrete in between the sheets.

Figure 12 Typical Interlocked corrugated EPS by 6mm MS rod ready for concreting

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A. Arun Solomon and G. Hemalatha

Figure 13 Typical Casted ICF blocks with corrugated EPS Figure 14 Typical Casted ICF blocks with plain EPS

Figure 15 Plain concrete sample

Figure 16 Membrane curing

2.5. Experiments and Results


The compressive strength was found using 100 T capacity Computerized Universal Testing Machine.
Figure 17 shows the typical arrangement and position of test samples placed in UTM. The rate of loading
was controlled and monitored uniformly. Figure 18 shows the tested samples. It was observed that the
concrete failed by crushing, but no debonding or disintegration was observed in EPS sheet. Table 4 gives
test results of all samples. To understand the mode of failure and behavior of ICF blocks, load vs.
deflection graph was plotted. Figure 19 shows the load vs. deflection graph of ICF blocks with corrugated
EPS and Figure 20 shows load vs. deflection graph of ICF blocks with plain EPS. Figure 21 shows the
comparison of compressive strength between ICF blocks with corrugated EPS and plain EPS.

Figure 17 Typical Compressive testing arrangement of ICF in 100 T UTM

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Inspection of Properties of Expanded Polystyrene (EPS), Compressive Behaviour, Bond and Analytical
Examination of Insulated Concrete Form (ICF) Blocks Using Different Densities of EPS

Figure 18 Typical tested sample exhibits zero disintegration in EPS

Table 4 Test Results of all samples

With Corrugation With Plain EPS

Sample Specification (60 mm Def. Maxi Compr Def.


Sampl Comp.
thick concrete core with EPS Peak at mum essive Peak at Max.
e ID Strengt
of) load peak Defle Strengt load peak Def.
h
kN load ction h kN load mm
(MPa)
mm mm (MPa) mm
1 4 kg Density 50 mm thick 148.4 6.05 10.6 4.68 212.0 3.30 11.8 6.62
2 4 kg Density 100 mm thick 138.7 5.3 15.9 2.66 220.0 8.30 18.0 4.23
3 8 kg Density 50 mm thick 160.0 4.8 7.8 5.00 255.0 4.65 10.6 7.69
4 8 kg Density 100 mm thick 154.0 4.1 15.4 2.96 245.0 3.40 20.3 4.71
5 12 kg Density 50 mm thick 200.0 7.5 11.9 6.25 288.7 3.60 10.4 9.02
6 12 kg Density 100 mm thick 150.0 5.9 15.2 2.88 211.8 2.40 23.4 4.07
7 Plain Concrete 209.0 1.5 4.8 17.41

2.6. Analysis of Ductility Ratio


Ductility ratio or ductility factor is defined as the ratio of total deflection at ultimate load to the deflection
at elastic limit. It is a measure of ductile property of a material, the high ductility ratio indicates a higher
ductile property and vice versa. Ductile property is most desired property of a structure, especially for
seismic design. Table 5 and 6 give ductility ratio of ICF samples with corrugation and plain EPS and
Figure 21 shows the comparison of ductility ratio. It is understood from a table and chart that ICF
specimen of 12 kg density 100 mm thick plain EPS on both sides of the concrete has more ductility.

2.7. Discussion
The main objective of this paper was to find the basic properties of EPS as per code and to analyze
compression behavior of ICF specimens and to examine the bonding nature between EPS and concrete. It
is evaluated that, compressive strength of EPS varies from 0.15 to 0.21 MPa and flexural strength varies
from 0.1 to 0.41 MPa.

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A. Arun Solomon and G. Hemalatha

350
4 Kg-50 mm With
300 Corrugation
8-Kg-50 mm With
250 Corrugation
12 Kg-50 mm
Load kN
200 With Corrugation
4 kg-50 mm with
150
plain EPS
100 8 kg-50 mm with
plain EPS
50 12 kg-50 mm
With Plain EPS
0 Plain Concrete
0 5 Deflection mm10 15

Figure 19 Load Vs Deflection graph of ICF blocks with corrugation

300
4 Kg-100 mm
250 with
corrugation
8 kg-100 mm
200 with
Load kN

corrugation
150 12 Kg-100 mm
with
corrugation
100 4 kg 100 mm
with plain EPS
50
8 kg 100 mm
0 with plain EPS

0 5 10
Deflection mm15 20 25

Figure 20 Load Vs Deflection graph of ICF blocks with plain EPS

10
9
Compressive Strength MPa

8 With Corrugation
7
With plain EPS
6
5
4
3
2
1
0
1 2 3 4 5 6
Sample ID

Figure 21 Comparison chart of Compressive strength

Table 5 Ductility Ratio to the ICF samples with corrugation

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Inspection of Properties of Expanded Polystyrene (EPS), Compressive Behaviour, Bond and Analytical
Examination of Insulated Concrete Form (ICF) Blocks Using Different Densities of EPS

Peak Deflection Maximum Deflection


load Deflection Ductility
Sample ID Sample Specification at peak at Elastic
Ratio
(kN) load(mm) (mm) Limit(mm)
1 4 kg Density 50 mm thick 148.4 6.1 10.6 3.2 3.31
2 4 kg Density 100 mm thick 138.7 5.3 15.9 2.0 7.95
3 8 kg Density 50 mm thick 160.0 4.8 7.8 1.2 6.50
4 8 kgg Density 100 mm thick 154.0 4.1 15.4 1.2 12.8
5 12 kg Density 50 mm thick 200.0 7.5 11.9 1.2 9.90
6 12 kg Density 100 mm thick 150.0 5.9 15.2 1.1 13.8

Table 6 Ductility Ratio to the ICF samples with plain EPS


Deflection
Peak Deflection Maximum
at Elastic Ductility
Sample ID Sample Specifications load at peak Deflection
Limit Ratio
(kN) load(mm) (mm)
(mm)
1 4 kg Density 50 mm thick 151.6 3.3 11.8 1.0 11.80
2 4 kg Density 100 mm thick 220.0 8.3 18.0 1.5 12.00
3 8 kg Density 50 mm thick 255.0 4.6 10.6 1.2 8.830
4 8 kg Density 100 mm thick 245.0 3.4 20.3 1.2 16.92
5 12 kg Density 50 mm thick 288.7 3.6 10.4 0.8 13.00
6 12 kg Density 100 mm thick 211.8 2.4 23.4 0.8 29.25
7 Plain Concrete 209.0 1.5 4.8 1.1 4.363

35.00
Ductility Ratio

30.00
Without Corrugation
25.00
With Corrugation
20.00
15.00
10.00
5.00
0.00
1 2 3 4 5 6
Sample ID

Figure 22 Ductility Ratio Graph


To evaluate
aluate the compression behavior, 24 ICF specimen was cast. 12 samples were casted with
corrugated EPS and 12 samples were casted with plain EPS, each category consists of two specimens and
membrane curing was adopted to cure all the specimens. After 28 dayss of curing period, compressive test
was carried out using 100 T universal testing machine. It was observed that, ICF blocks exhibits ductile
failue rather than brittle failure nature of concrete
After attaining peak load plain concrete failed suddenly meanwhile
meanwhile all the ICF specimens reveals
extended load carrying capacity with larger deformation that could be understood from the consolidated

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A. Arun Solomon and G. Hemalatha

load vs. deflection graph (figure 18 & 19). And it was noticed that, ICF blocks with plain EPShas higher
compressive strength (figure 20) when compared to the ICF blocks with corrugated EPS. The compressive
strength of corrugated EPS might have reduced due to decreased concrete quantity because of corrugation.
Simultaneously, zero disintegration was observed in the joint between EPS and concrete, though without
the addition of admixtures. Hence it could be concluded that, provision of the corrugation is not needed to
increase bonding property between EPS and concrete. From the analyses for ductility ratio, it could be
concluded that, ICF specimen with 12 kg density 100 mm thick plain EPS on both sides of the concrete
provides increased ductility to the structure.

3. CONCLUSIONS
From the experimental investigation the following conclusions are drawn.
• It was observed that, the compressive strength of EPS varies from 0.15 to 0.21 MPa and the flexural strength
of EPS varies from 0.1 to 0.41 MPa. The compressive and flexural strength of EPS is not directly related to
the density of that specimen. It is observed that there is a decrease in compressive and flexural strength even
though an increase in density.
• When compared to ICF blocks with corrugated EPS, plain EPS ICF blocks exhibited better compressive
strength due to the reason that more concrete is present. No debonding was observed after failure without
adding any bonding agent to concrete. This indicates that, there was no need to go for corrugated EPS to
make ICF block to increase bonding property.
• A total of 24 ICF specimens and 2 plain concrete specimens were casted for compression tests. 12 ICF
specimens were casted using plain EPS and 12 ICF specimens were casted using corrugated EPS with three
different densities of 4, 8 and 12 kg/m3 and two varying thickness of 50 mm and 100 mm EPS. Membrane
curing was adopted to cure all the samples and after 28 days, compression test was carried out on 100 T
capacity computerized universal testing machine. Load vs. deflection curve was plotted for all the tested
specimens. Brittle failure was observed in the plain concrete specimen and ductile failures were observed in
the ICF specimens.
• ICF specimens with 100 mm EPS exhibited larger deformation after attaining peak load. Among the tested
specimens, 12 kg density 100 mm thick EPS had maximum deflection of 23.4 mm when compared to other
ICF specimens.
• The ductility ratio was plotted and observed that 12 kg density 100 mm thick EPS provides more ductility of
29.25 when compared to other specimens.
• No disintegration was observed in any of the EPS sheets during failure.

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Inspection of Properties of Expanded Polystyrene (EPS), Compressive Behaviour, Bond and Analytical
Examination of Insulated Concrete Form (ICF) Blocks Using Different Densities of EPS

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