With the increasing awareness in the region of the benefits offered by insulation, Dammam-based Al Sharq Polystyrene Factory (StayroMax) says it has witnessed a surge in business.

Established in 1995, Al Sharq has already grown to become one of the largest factories specialised in the production of polystyrene products within the kingdom. At its 68,000 sq m facility in Dammam, the company annually rolls out 7,200 tonnes of high-quality StayroMax range of products, which include roof and wall panels to thermally insulate buildings, block inserts, all kinds of decoration shapes for masonry works, hordi blocks for ceilings, industrial packing and pipe insulation, says a spokesman.
The company has already established a sizeable market in Saudi Arabia and made inroads into the Bahrain, Qatar and Kuwait markets and is now hoping to successfully penetrate the UAE market.
Elaborating on the importance of polystyrene, the spokesman continues: 'Soaring energy costs and energy availability problems have emphasised the need to conserve energy. An effective way of saving energy is to improve the thermal insulation of the buildings, particularly important in hot climates where the energy demand for cooling by air-conditioning is very high. In addition to the need for energy saving, high insulation standards also offer improved comfort levels and increased building life.
'Polystyrene products play a major role in energy conservation. Polystyrene has the following characteristics:

• Saves 50 per cent in electrical consumption;
• Is a good shock absorbent;
• Is soundproof, light weight and can be cut in all sizes and volumes;
• Is free from chemicals and side effects;
• Does not absorb water and humidity;
• Is not harmful to human health and properties and does not emit poisonous gases in the event of a fire; and
• Conforms to Saudi and international specifications and standards measurements.

'Polystyrene is available in two types based on their manufacturing process: expanded (moulded) polystyrene (EPS); and extruded polystyrene (XPS).

Expanded polystyrene
'EPS - a moulded, closed cell/cellular plastic made from petrochemicals derived from crude oil - is a unique material, having excellent insulating qualities. Being lightweight, strong and resilient, non-corrosive, dimensionally stable material, it can be moulded into blocks and is available in many different densities and thicknesses.
'EPS foam used as thermal insulation reduces harmful air emissions by saving resources and energy, which would be consumed due to greater heating and air -conditioning requirements.
'It is an efficient, effective and environmentally safe thermal insulation material, which does not use CFCs (chlorofluorocar-bons) or HCFCs (hydrochlorofluorocarbons) in its manufacture; and is hence non-toxic and inert,' he says.
Al Sharq offers insulating block manufactured from the expanded polystyrene, in two thicknesses (6 cm and 7.5 cm). These are inserted inside concrete hollow blocks, thereby reducing block weight and increasing heat insulation capacity.

Extruded polystyrene
XPS is manufactured by a continuous extrusion process that imparts a characteristic closed cell structure, which gives the product its unique physical properties, says the spokesman. XPS rigid foam has a high resistance to water absorption and good mechanical properties. The manufacturing process, combined with the inherent qualities of the inert component thermoplastic material gives XPS predictable long-term performance and high insulating value.
Al Sharq produces insulating sheets with different densities ranging between 16 kg/cu m to 35 kg/cu m and can be cut into various sizes and thickness as per client requirements. Using computerised machines, the company can manufacture decorative shapes and forms such as arches, stoops, partitions, and domes. The material can be used in insulating walls, roofs, and grounds as well as in protecting fragile materials such as glass, mirrors and electrical instruments during transportation.
'Much of the company's success stems from its ability to offer high-quality products. Al Sharq Polystyrene Factory has a well-equipped quality control department with modern measuring and analytical instruments as well as qualified, trained and experienced staff. Every required raw material and finished product is systematically sampled and analysed in our laboratory to confirm that they meet specified quality standards. Continuous chemical and physical analysis are conducted during production to ensure specifications are met and certificate of analysis issued to accompany shipments to customers,' he concludes.