BAHRAIN-based Thermo Foam Blocks Factory aims to build cheaper and greener houses with its novel thermo blocks that are claimed to have the ability to cut down energy bills by 60 per cent.

The company’s thermo foam blocks (TFBs), manufactured from polystyrene with double thermal insulation, come with important features like double the sound insulation and waterproofing and walls that exhibit three times the strength of those constructed using conventional units, in addition to energy savings of up to 60 per cent.

General director Volodymyr Shpychak says that by using these thermo blocks, a house or building can be constructed four times faster than when utilising traditional technology used in Bahrain. “It’s one monolith construction without columns,” he says.

The system comprises thermo blocks that are filled with concrete and steel reinforcement, and can insulate against noise as loud as 53 dB. Thermal walls combine a solid concrete and expanded polystyrene (EPS) to provide a quiet and cozy atmosphere inside the house “even if it’s near a highway”, says Shpychak. In terms of insulation, he says the advantages are substantial. A wall thickness of 25 inches provides the same insulation as a concrete wall that is 4 m thick, he claims.

He adds that electrical fittings and plumbing can also be easily incorporated in
these blocks.

Shpychak says Thermo Foam Blocks Factory has the ability to manufacture blocks for an entire two-storey villa covering a land area of 250 sq m in a day, cutting down on the construction time from six months to two, and provide customers a turnkey project, that is, right from the foundation to the fit-outs.

The company, however, does not offer the blocks on the market, choosing to offer a supply-and-apply service. “Not everyone can layout these blocks, so if they are not installed properly that will get our company a bad reputation. So currently we are using the blocks ourselves in our own projects,” he says.

In addition to thermo blocks, the company also manufactures interlock tiles, boundary walls and exterior façade tiles in various designs.

Elaborating on the features of Thermo Foam Blocks Factory’s thermo façade system, Shpychak says it is five times cheaper than façade bricks and more reliable and stronger than standard bricks. The system also does not require long-term ‘wet’ cycle façade works nor highly skilled installers and can be installed under any weather conditions.

The TFB technology comprises a double-layer façade finishing panel measuring 50 by 50 cm and weighing 4.5 kg. The protective and decorative layer, which has a thickness of 12 to 15 mm, is made of high quality white cement with polymeric and other additives, providing strength and durability.

The insulating layer, depending on the performance requirement, may be 2 cm to 20 cm thick and consists of polystyrene (Grade M35) or basalt slabs.

The special technology used to create these blocks provides a wall structure with increased strength. Each panel is glued to the wall and further strengthened by four anchors, each capable of withstanding a load of 130 kg. As such, a properly reinforced TFB panel can withstand more than half a tonne of weight, Shpychak says.

Moreover, the installation of these panels doesn’t require special knowledge or skills.

The company has also developed decorative concrete that Shpychak describes as a breakthrough in facade technology, which offers facades in colours and textures that cannot be distinguished from natural stone, wood and old bricks.

Thermo Foam Blocks Factory also offers decorative boundary walls, consisting of precast concrete panels and supporting pillars, which are the parts of the connecting panels.

The firm’s interlock tiles comprise quality paving stones for pavements, streets and walkways to buildings. The tiles are easy to install and maintain, can withstand extremes of temperature and do not emit harmful gases.

Thermo Foam Blocks Factory has already undertaken a number of projects in Bahrain including housing jobs in Hamad Town, an apartment building in Seef, a first floor villa extension at Abu Saiba, and another villa extension over 250 sq m at Dar Kulaib. It also has an upcoming 25-villa compound project in Hidd.

About the business scene in Bahrain, Shpychak says it is improving and provides bright prospects. The company too is growing, he says, adding that the material it offers is among the most cost competitive in the market.

Thermo Foam Blocks Factory is located at Bahrain Investment Wharf (BIW) in Hidd. The company also has plans to open up a branch in Saudi Arabia in the near future.