DuraFill - Plymouth Foam

VERSATILE, LIGHTWEIGHT
CONSTRUCTION FILL
Durafill: Lightweight, Durable and Versatile
Easy to handle and put in place.
Fill weight reduced by up to 130 lbs. per cubic foot
when replacing standard dirt and gravel.
Unmatched compressive strength supports same
load burden as standard fill.
Cuts easily around plumbing and other structural elements.
Plymouth Foam’s Durafill™ Expanded Polystyrene
(EPS) geofoam is a lightweight cellular plastic foam
used in block or board form for a wide range of
geotechnical applications. Durafill is often used in
place of natural fill on building or road construction
projects where soft soil exists. Its weight-tostrength load bearing characteristics are uniquely
effective in reducing the weight burden on underlying soil without sacrificing compressive strength.
EPS has proven to be the most cost-effective, versatile and long-lasting of all the various cellular
foam varieties, and the use of EPS geofoam in engineered construction applications is growing rapidly.
Geofoam has performed extremely well in
projects where conventional earth fills such as foamed
concrete, wood chips, waste tires and cinders have
shown a history of poor performance and failure.
Durafill gives engineers and designers a unique
product that works in conjunction with more tradi-
Reduces lateral pressure when used around building
foundations.
tional materials to solve construction problems
such as soft or unstable ground, frost-heave and
lateral movement of approach fill at bridge abutments with unprecedented strength and flexibility.
Durafill Applications
Durafill is often used as lightweight fill for building and road construction on soft and
unstable soil, ground stabilization and pavement or sub-slab insulation.
Road Embankments
Durafill is up to 50 times less massive than traditional
lightweight fills (chipped bark, sawdust, cinders,
cellular concrete, etc.), providing:
䡲 Maximum available right-of-way
䡲 Faster construction schedule
䡲 Lower traffic impact
䡲 Cleaner construction
䡲 Reduced labor
䡲 Minimal future maintenance
Retaining Wall or Abutment Backfill
Durafill positioned behind retaining structures and
below-grade walls reduces lateral pressure, lowers
settlements, improves waterproofing and provides
better insulation. Durafill can also limit horizontal
forces against retaining structures during earthquakes.
Slope Stabilization
Durafill’s extremely low density makes it highly effective
in improving the stability and safety of slope construction by minimizing the potential of failure surfaces
between driving blocks and resisting blocks in a slope.
Pavement Insulation
Durafill is often used as highway, airport runway and
parking lot pavement subgrade insulation, reducing
subgrade stress and deformation and to protect
against frost heaving.
Other Uses Include:
䡲
䡲
䡲
䡲
䡲
Roadway Sound Barriers
Foundation Fill / Insulation
Plaza Decks
Levees / Dikes / Berms
Landscape Design
Types of Durafill Geofoam:
Durafill Advantage
䡲 Low Density/High Strength
The density of Durafill ranges from 1 to 2% of the density of
soil and rock, making it a superior, ultra lightweight fill material that significantly reduces the stress on underlying subgrades. The lighter load reduces settlements and increases
stability against bearing and slope failures.
䡲 Thermal Insulation
Durafill is 98-99% air by volume, making it a highly efficient
thermal insulator.
䡲 Variable Densities
Durafill geofoam can also be produced in a range of densities
to meet varying needs. Higher densities, for example, provide
higher R-values for greater insulation properties and lower
deformation.
䡲 No Leachates
Will not contaminate the surrounding environment
䡲 Durable
High compressive strength makes Durafill durable and
resistant to damage and shifting over time.
䡲 Low moisture absorption
Moisture absorption rates decrease as density increases, but
are still minimal.
䡲 Low interface friction
In direct shear tests the interface friction between sand and
Durafill is comparable to the internal friction of sand alone.
䡲 Inert
Experiences no physical breakdown during prolonged burial.
䡲 Design Flexibility
Typically is used in block form that can be cut into various
shapes and sizes as needed.
Durafill™ geofoam physical properties per
ASTM Specifications D 6817-02 and C 578-01
Property
ASTM D 6817-02 CLASSIFICATIONS
Units
ASTM Test
Compressive Resistance
at 1% Strain Deformation (2" cube)
at 1% Strain Deformation (12" cube)**
at 5% Strain Deformation (2" cube)
at 10% Strain Deformation (2" cube)
Flexural Strength
Oxygen Index
Density, minimum
Property
Min psi (kPa)
Min psi (kPa)
Min psi (kPa)
Min psi (kPa)
Min psi (kPa)
Min volume %
Min lb/ft3 (kg/m3)
C 303
ASTM C 578-01 CLASSIFICATIONS
Units
ASTM Test
Thermal Resistance (R-value)*
75 ± 2˚ F (24 ± 1˚ C
Compressive Resistance
at 10% Strain Deformation (2" cube)
Dimensional Stability
Change in dimensions
Moisture Resitance
Water Absorption by total immersion
Water Vapor Permeability of 1"
(25.4 mm) thickness max perm
Flexural Strength
Oxygen Index
Density, minimum
EPS 12
EPS 15
EPS 19
EPS 22
EPS 29
TBD
2.2 (15)
3.2 (22)
5.1 (35)
5.8 (40)
10.0 (69)
24.0
0.70 (11.2)
3.6 (25)
4.6 (32)
8.0 (55)
10.2 (70)
25.0 (172)
24.0
0.90 (14.4)
5.8 (40)
6.2 (43)
13.1 (90)
16.0 (110)
30.0 (207)
24.0
1.15 (18.4)
7.3 (50)
8.3 (57)
16.7 (115)
19.6 (135)
40.0 (276)
24.0
1.35 (21.6)
10.9 (75)
11.9 (82)
24.7 (170)
29.0 (200)
50.0 (345)
24.0
1.80 (28.8)
17.8 (123)
19.6 (135)
41.7 (287)
45.0 (310)
75.0 (517)
24.0
2.5 (40)
Type XI
Type I
Type VIII
Type II
Type IX
TBD
3.10 (0.55)
3.60 (0.63)
3.80 (0.67)
4.00 (0.70)
4.20 (0.74)
4.20 (0.74)
5.0 (35)
10.0 (69)
13.0 (90)
15.0 (104)
25.0 (173)
40.0 (276)
D 1621, C 165
Min R* for 1"
thickness
C 177, C 518
D 1621, C 165
Min psi (kPa)
Max %
D 2126
2.0
2.0
2.0
2.0
2.0
2.0
% by volume Max
Max perm/in
(ng/Pa*s*m2)
Min psi (kPa)
Min volume %
Min lb/ft3 (kg/m3)
C 272
E 96
4.0
5.0 (287)
4.0
5.0 (287)
3.0
3.5 (201)
3.0
3.5 (201)
2.0
2.0 (115)
2.0
2.0 (115)
C 303
10.0 (70)
24.0
0.70 (12)
25.0 (173)
24.0
0.90 (15)
30.0 (208)
24.0
1.15 (18)
35.0 (240)
24.0
1.35 (22)
50.0 (345)
24.0
1.80 (29)
75.0 (517)
24.0
2.5 (40)
*"R" means resistance to heat flow. The higher the R-value, the greater the insulating power.
**Independent Plymouth Foam, Inc. supporting test data available upon request.
***This type is currently under evaluation by ASTM for inclusion.
CONTACT PLYMOUTH FOAM
Please contact us for more technical and design assistance.
E-Mail:
Corporate Headquarters
Sales: sales@plymouthfoam.com
Plymouth Foam Incorporated
P.O. Box 407
Web Site
1800 Sunset Drive
www.plymouthfoam.com
Plymouth, WI 53073
Toll Free: 800-669-1176
Local: 920-893-0535
Fax: 920-892-4986
©2003 Plymouth Foam Inc (10/03)
All Rights Reserved
MANUFACTURING FACILITIES
Ohio
Wisconsin
126 New Pace Road
1800 Sunset Drive
Plymouth WI 53073
Newcomerstown, OH 43832
1-800-669-1176
1-800-446-2188
Minnesota
13900 Industry Ave.
Becker, MN 55308
1-800-759-3626
9323L00PFDF