Expanded Polystyrene Blocks for Large Scale Development Projects

Expanded polystyrene blocks are known for their fire retardant and insulating capacity, durability, and long-lasting application. These are the main features why expanded polystyrene blocks are ideal to use as a lightweight filler for building, road and geotechnical constructions.

As one of Australia's largest polystyrene innovators and manufacturers, Foamex developed M-grade expanded polystyrene blocks and sheets that comply with the Australian Building Standards. Foamex products are eco-efficient and have no trace of toxic substances like CFCs and HCFCs.

Foamex expanded polystyrene blocks were recently chosen for the Port of Melbourne Webb Dock Redevelopment. A project set for the port's return to its original role as an international container handling facility.

Port of Melbourne Webb Dock Redevelopment Project
The Port of Melbourne is considered to be the largest container and general cargo port in Australia. It is of great importance to the national and Victorian economy and trade industry. Economic forecasts indicated that the demand for container and general cargo throughput would substantially grow in the coming years. To accommodate the future needs, the Port of Melbourne Corporation (PoMC) has taken necessary measures to provide the additional capacity.

The $1.6 billion redevelopment project includes re-engineering of existing wharves at Webb Dock East, the new wharf at Webb Dock West, new road construction to Webb Dock Drive and Kooringa Way situated below the West Gate Bridge. With this project, the newly reconfigured port will be equipped with a state of the art automotive facility that is expected to handle 600, 000 vehicles and 1 million containers per annum.

Before the roads could be constructed, pipe works beneath the road need to be upgraded. Foamex expanded polystyrene blocks provided a lightweight fill solution that was layered to specific depths on top of the pipelines for protection against the volume and heavy traffic load. The EPS blocks were wrapped and sealed before the road surface began its construction over the expanded polystyrene blocks.

The use of expanded polystyrene blocks, in any application, comes with a significant reduction in its maintenance costs. Aside from its dimensional stability and low water absorption, Foamex expanded polystyrene blocks provided easy onsite handling and quick installation. Saving on valuable construction time and essential resources. Their strength and flexibility offer a cost-effective and conventional method of embankment construction where long-term ground support and improvement is required.

Foamex became involved in the project from February 2015 until its completion in May 2016. A total of over 1, 000 expanded polystyrene blocks were used to complete the project specifications. Foamex worked with BMD Construction, who were awarded the $80 million plus contract for the first stage of the project.

Foamex expanded polystyrene blocks, and other polystyrene products are the material of choice for major industry specifiers including architects, engineers, developers, builders, designers and property owners across Australia.

Foamex streamlined polystyrene products to fit any project requirements include the following: