The Manufacturing Process
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The Manufacturing Process

EPS is created in a two-stage process:

Raw beads are expanded using steam, creating pre puff beads, which are then cured in large bags before being conveyed to the mold. Once in the mold, the pre puff beads are again steamed to form a block that is anywhere from 37-1/2″ – 54″ x 49″ x 121-1/2″ – 220″. The blocks are then placed on the storage floor to age for the appropriate length of time before being cut into various shapes and sizes. Blocks are produced in several densities to meet specific project needs. Here at ICA we manufacture Low Density EPS foam blocks all the way up to 2.85 lb density.

Raw & Expanded Polystyrene Beads

EPS Size & Density

ICA’s new state-of-the-art Hirsch mold allows us to manufacture block sizes anywhere from 37-1/2″ – 54″ x 49″ x 121-1/2″ – 220″. Although ICA does not stock any cut foam, regularly cut sizes are: 48 inches by 96 inches and 24 inches by 96 inches. Almost any size is available as a custom order.

Thickness: 1/4″ to 54″
Lengths: Up to 216″ (18′)
Widths: Up to 48″
Densities: .75 lb to 2.85 lbs per cubic foot

Density is a measure of mass per volume. EPS is measured in pounds per cubic foot (lbs/pcf). ICA manufactures expanded polystyrene in the following minimum densities:

0.70 lbs/pcf
0.90 lbs/pcf
1.15 lbs/pcf
1.35 lbs/pcf
1.80 lbs/pcf
2.40 lbs/pcf
2.85 lbs/pcf

Additional densities available by custom order.

ICA-LITE Spec Sheet

Environmental Concerns

EPS is extremely “GREEN“. NEVER any CFC’s, NEVER any HCFC’s.

Expanded Polystyrene has always been CFC- and HCFC-free. ICA is an environmentally conscientious manufacturing plant. Our in-house EPS trim is recycled and we accept recyclable EPS from our customers and the public, significantly reducing the amount of EPS that would potentially end up in landfills. In 1994 ICA installed a pentane collection system for air quality control. The system captures the pentane that is released during production and reroutes it through our boiler. This reduces the amount of natural gas we use, saving natural resources while being environmentally responsible. We continued our efforts to be mindful of our environment by installing solar panels and replacing our lighting with energy efficient fixtures. All of these actions help to keep the air of our planet cleaner and lessen the impact of landfills on the population.

EPS Insulation is composed of organic elements – carbon, hydrogen and oxygen – and does not contain chlorofluorocarbons (CFCs) or hydrochlorofluorocarbons (HCFCs). For more information on EPS visit EPS Industry Alliance.

Due to our green efforts, in 2011 we were happy to announce our ICA-LITE® EPS panels and ICA-GEOFOAM were approved to add LEED® points to construction projects.

Safety Data Sheet RADCO Flame Spread & Smoke Developed Ratings Fire Resistance in Building & Construction Applications EPS & UV Exposure

Code Compliances

ICA-LITE® complies with the following codes and approvals:

• AIA (Section 702.9)
• Underwriters Laboratories
• Factory Mutual (Ceiling Tile)

ICA-LITE® can be manufactured to meet or exceed the following Federal and Military specifications along with others:

ASTM C578–11bε1 Types I, VIII, II & IX
Military Spec. MILP-19644C
Military Spec. MILP-40619A
Army Corps of Eng. CEGS 07220
Coast Guard CE256
Air Force AFM-88-15
HUD/FH Use of Material Bulletin #71
PA D.O.T. Bulletin 15 Section 1107.02(m)

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