There will be strict parameters in place when working on a construction project, so you’ll need the correct materials to build your project to standard. Foam was once a niche material, but now it is part of almost all construction tasks across commercial, industrial, and residential spaces.

An insulator, sound blocker and structural supporter that is resistant against fire, there are dozens of reasons for builders, architects and homeowners to use foam. This blog will be your best explainer as to why!

So, how do foam sheets transform modern construction, and what supplies are best for your needs?

What Are Foam Sheets?

What are foam sheets, and why are they so essential to construction projects? You may have heard of foam board, a material used for workspaces, home decorations, and educational institutions, but they have a lot more applications. 

Foam is a flat, thin piece of material manufactured in the form of sheets and can be made from polyethylene, polyurethane, and expanded polystyrene (EPS). They can be purchased in a number of thicknesses, sizes, and densities for construction projects.

As for the cellular structure of foam, it comprises soft, resilient, tiny air-filled bubbles or pockets. Cells can be opened or closed; however, this depends on their intended usage and manufacturing process. Open-cell foam has interconnected air pockets that allow air and moisture to pass through, and closed-cell foam acts as a sealer, preventing air and water from getting through. 

Flexible, comfortable, cushy, and lightweight foam sheetings are used for insulation, padding, packaging, crafting, and more. A good example of this is polyethylene foam, which is moisture-resistant and can package fragile items.

Overall, foam sheets are unique and versatile, and can be used for insulation, as acoustic panels for noise reduction, for structural support, and even in fire-resistance for safety. It is indispensable for building structures in today’s day and age.

Let’s take a look at EVA230 foam in construction!

• EVA230 Foam (2300mm x 590mm) is a premium lightweight closed-cell thermoplastic

• Foam, waterproof, odourless, mould impervious, with good UV and chemical resistance

• Excellent thermal insulation properties, and is also recommended for applications where repeated compression and recovery are required

• Easily be cut from sheets and moulded to shape, making it ideal for a wide range of applications

• May be found in all types of appliances, automotive, building, marine, electronics, healthcare, packaging, sports, leisure, and recreation

EVA is competitively used in place of rubber and vinyl products in many electrical applications.

How Do Foam Sheets Assist Construction Projects?

What are the benefits of foam sheets in more detail? They’re more than just spongy, bouncy materials!

Acoustic Control

Traffic and other external noises can disrupt indoor environments, and foam is a trusted material for sound absorption. Here’s why:

• Acoustic foam panels trap and reduce sound waves, including echoes and reverberations

• Blocks external noise, creating a barrier to make indoor spaces quieter

• Improves privacy in offices, apartments, and other multi-unit buildings

• Foam is used underneath floorings to cut noise from footsteps and vibrations

• Can be applied to homes, commercial spaces, or public venues such as restaurants, theatres and auditoriums 

Structural Support

How can foam sheets work for structures? 

• Foam sheeting reduces the load on buildings, especially for the roofing system (such as flat or sloped roofs)

• Shaped or moulded easily to fit structural requirements

• Expanding foam fills voids and stabilises uneven concrete surfaces

• Fills gaps in foundations and stops cracking

• Foam is resistant to wear and tear

Fire Resistant

Foam is built for construction as it is treated with flame retardant to improve safety in construction. Let’s explore how exactly foam sheets can help.

• Foam sheeting slows flame spread

• Adds a layer of protection to walls, floors and ceilings

• Is compliant with Australian building codes for safety (AS1530.3)

• Foam retains its form and function even under extreme temperatures

• Can be used in high-risk environments such as factories or warehouses 

Eco-Friendly

When you invest in any material, you want it to be sustainable. Foam sheeting aligns with green building initiatives:

• Recyclable materials that cut back construction waste

• It is energy-efficient, as you don’t need to rely on heating and cooling as much

• It is durable, so it doesn’t need to be replaced frequently 

To learn more, read our blog on how to safely pack and ship electronics with anti-static foam!

Types of Foam Sheets at MSTOR

No matter the scope of your project, MSTOR has a variety of options to choose from that are extremely high quality.

EVA30 Foam Sheet

• Condensation protection

• Long-term reliability

• Helps maintain a seal in high-movement joints

• Non-conductive

• Excellent thermal insulation properties

• Very lightweight and non-abrasive

• Good UV resistance

• Easy to fabricate and non-dusting

• Excellent buoyancy

• CFC-free, odourless

• Impervious to mildew, mould, rot, and bacteria

• Resistant to water, chemicals, solvents and grease

• Excellent shock absorption and vibration dampening

• Conforms well to a variety of irregular surfaces

• Plasticiser FREE

Anti-Static Fire-Retardant PE Foam Sheet

Specially designed fire-resistant, anti-static foam with a closed-cell, cross-linked polyethylene structure and excellent resistance, toughness and flexibility. The foam has good tear strength, low water absorption, chemical resistance, and great UV properties. 

The foam is also free of heavy metals, plasticisers and CFCs, so it’s perfect for stringent packaging applications. It is also dust-free when cut and is simple to fabricate.

• Density = 45kg/m3

• Sheet size = 2100mm x 1100mm

PE45 Foam Sheet

• Excellent thermal insulation properties

• Very lightweight and non-abrasive

• Good UV resistance

• Easy to fabricate and non-dusting

• Excellent buoyancy and non-abrasive

• CFC-free, odourless

• Impervious to mildew, mould, rot, and bacteria

• Resistant to water, chemicals, solvents and grease

• Excellent shock absorption and vibration damping

• Non-conductive

This foam material is widely used in many applications, including isolation joint applications in the construction industry, sports equipment, carpet underlays, safety packaging and gasket applications in the automotive industry.

Neoprene Closed-Cell Foam Sheet

• Long-lasting closed-cell sponge

• Excellent weathering and ageing, and long-term reliability

• Condensation protection

• Prevents heat loss and noise between substrates

• Excellent gasketing material

• High load capability

• Conforms well to a variety of irregular surfaces

It has an excellent recovery rate and is self-extinguishing with excellent resistance to aging, alkalis, acids, oil, solvents, and many other chemicals. With a highly consistent cell structure and thickness with no voids or inclusions, the foam is suited to stringent automotive tolerances.

Blue IXPE Foam Sheet

• Conforms well to a variety of irregular surfaces

• Lightweight

• Easy to fabricate

• Extremely low odour

• Non-toxic

• High shock absorption

• Flexibility

• Good UV properties

• Die-cuts and slits easily for custom sizing

It is suited to automotive and construction tolerances and many demanding applications in different environments, as well as premium packaging inserts.

Read: Top Benefits of Using Thin Foam Sheets for Protecting Fragile Electronics.

Anti-Static PE Foam Sheet

• Anti-Static Foam (2100mm x 1100mm) is specially designed with a closed-cell cross-linked polyethylene structure with excellent resilience, toughness and flexibility. 

• It has great tear strength, low water absorption, excellent chemical resistance, and great UV properties. The foam is free of heavy metals, plasticisers and CFCs.

• The Anti-Static Foam is specially designed for stringent packaging applications where Anti-Static properties are required.

• The foam is dust-free when cut and is easy to fabricate. Applications are endless.

CUSTOM SIZES AND THICKNESSES AVAILABLE UPON REQUEST

Black IXPE Foam Sheet

• Conforms well to a variety of irregular surfaces

• Lightweight

• Easy to fabricate

• Extremely low odour

• Non-toxic

• High shock absorption

• Flexibility

• Good UV properties

• Die-cuts and slits easily for custom sizing

Whether you’re on the hunt for foam suppliers in Melbourne, Sydney, Brisbane, Perth, or Adelaide, MSTOR has foam, tapes, and plastic to get your construction project underway. 

MSTOR: Your Reliable Foam Suppliers in Australia

MSTOR is a trusted Australian supplier for foam products, from EVA Foam to IXPE Foam, Anti-Static Foam or EPDM Foam. With a dedication to excellence, precision, and customer satisfaction, MSTOR has been supplying and servicing automotive, insulation, building, construction, packaging, medical, and many other industries.

Products are available Australia-wide, all are customisable, and we also have wholesale pricing as an option for you. Do you require tape slitting, foam cutting, laminating, or foam cut to size? 

Contact us today for nationwide delivery, reliable quality, expertise, and custom solutions. Shop online or contact us for custom orders at sales@mstor.com.au. Bulk buy and save! FREE shipping on purchases over $150.

Please allow 2-5 business days for orders to be fulfilled.

Note: If the MSTOR product is deemed to be defective, damaged, or the incorrect item within MSTOR's control and responsibility, then the sole solution will be to replace the product, or in certain circumstances, refund the purchase price.