EPS Foam Used as Insulation in Precast Concrete Wall Panels

Precast Concrete Wall Panel Install

The use of precast concrete wall panels is nothing new. In fact, precast concrete wall panels including insulation is not that new either. However, since the inclusion of EPS foam insulation sheathing has been used in the sandwich design, insulation values are now capable of exceeding R-30.

As found in the ANSI/ASHRAE/IES Standard 90.1-2016 Energy Standard Except for Low-Rise Residential Buildings:

“insulation that is continuous across all structural members without thermal bridges other than fasteners and service openings. It is installed  on the interior or exterior or is integral to any opaque surface of the building envelope.”

The process of factory fabricated panels is constructing interior and exterior wythes (a vertical section of masonry that is considered one unit thick) with insulation (in our case Geofoam) sandwiched between. These make for convenient, uniform construction panels that can be assembled in the field with the use of bolts and fasteners. Doing so with carbon-cast fiber composite connectors will provide an efficient and fully composite thermal design. These wythes can also be connected via wythe connectors, thereby maintaining the integrity of the thermal efficiency without bridging gaps.


XPS, or extruded polystyrene, is often used in sandwich wall panel construction but has been proven to be inferior to EPS, or expanded polystyrene. EPS can withstand moisture better. That is EPS can handle wet and dry alternatives routinely as opposed to XPS, whose performance deteriorates over time comparatively. EPS costs less per R-value point of XPS, and the uncoated rough surface of EPS actually helps with shear value and boosts the structural performance of composite panels. EPS thicknesses can be as thick as 4 inches.

Factory Fabrication

By forming concrete in the form of 2 wythes (as described below) with a layer of Geofoam between them (see example image).

Sandwich Barrier Panels

The image herein reflects aggregate concrete being used, but it is not necessary.


This unified component is used as a single unit, and is easily transportable, Lengths can be as large as 24 feet tall by as many as 10-foot widths, 3.5 to 10 inches in thickness, as stated by OpenLab.

Engineer’s Specifications for Bowing Deflection

Concrete, like any other substance, will shrink and swell based on weather fluctuations. Each dimension of the wythes will have a particular thermal transfer, as well as cost, and cost of installation. However, to meet the end user’s standards, bowing of the structure must be taken into consideration. Bowing is a common phenomenon. All sandwich wall systems will exhibit a level of bending despite which connector method is used, the thickness and/or height and width.

The act of bowing can be created by things beyond weather as well. The level of pre-stressing during, axial load, deflection by shrinkage or swelling, thermal gradients because of panel thickness, or other such variables. Bowing may even result from improper storage of panels before connecting/installation. The only recommendation by consulting engineers in the standardization of sandwich panel construction (concrete or wood/composite) is to understand and minimize the bowing effect through proper handling, transfer, and type of connector devices used.

Why Use Sandwich Panels?

The image below is a graphic display of the consistency of temperature variance consistency that insulated concrete wall panels can provide.

precast thermal efficiency

Image Credit: precast.org


Project engineers, architects, business owners and city planners should not settle for building systems that do not minimize adverse effects that traditional construction methods now employ. Insulated precast concrete wall panels are environmentally friendly, offer little maintenance for decades to come, are easier to construct, and cost-effective concurrently.

It would be wise to consider this method of construction in all future construction projects.

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