TECHNICAL DATA 
THERMOSETTING PHENOLIC COMPOSITE - TPC 
Delta Insulation Systems 
P: +61 07 3271 2170   E: info@deltainsulationsystems.com   W: www.deltainsulationsystems.com.au 
A: 49 Bernoulli Street, Darra Qld. 4076   ABN: 12 122 760 552 
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What is Thermosetting Phenolic Composite 
(TPC)  
The TPC product is produced by coating Expanded 
Polystyrene (EPS), a closed cell lightweight cellular 
plastics material with a phenolic composite coating to 
produce a core material with superior fire ratings. The 
EPS material has been modified by the addition of 
flame-retardant additives.  
  
The finished product produces a core material with all 
the known physical attributes of EPS with a vastly 
superior fire performance. 
  
The Manufacturing Process  
Pre-Expansion of the EPS 
The small expandable beads are subjected to steam, 
which causes the thermoplastic polystyrene to soften. 
Increasing vapour pressure caused by the blowing 
agent causes the beads to expand to up to 40 times 
their original volume. It is this prefoam stage which 
determines the final density of the expanded 
polystyrene block.  
  
Aging of the EPS bead 
After pre-expansion the pre-foam is transferred via to 
fluidized drying bed to large silos for aging. This 
process is designed to allow for the replacement of 
expanding agent by air in the cells of the bead. Aging 
also allows for stabilization and cooling of the pre-
foam.  
  
Blending the Pre-Mix 
The resin along with the addition of additional 
additives are thoroughly mixed under temperature 
control conditions as per strict SOP requirements 
 
 
 
 
Coating the EPS bead 
The aged EPS beads and the Pre-Mix are fed into the 
coating machine along with a catalyst. The flow rates 
are critical to ensure an even coating over the EPS 
beads. The coated beads travel along a fluidized bed 
allowing them to dry. 
 
Aging of the Coated Beads 
After clearing the coating machine, the treated beads 
are transferred to an aging silo. This allows for 
stabilization and cooling of the coated beads 
 
Moulding of the TPC Blocks 
Once conditioned by aging, the coated beads are 
transferred to specially designed Moulding machines to 
be formed through the introduction of steam into fused 
blocks. 
 
Drying of the TPC Blocks 
To provide dimensionally stable dry blocks it is 
necessary to pass them through a temperature-
controlled oven. This process also ensures that any 
residual blowing agent has been removed.   
 
Finished Product  
For most customers the manufacturing process is not 
complete until the EPS blocks have been cut into 
various shapes. This process is mainly carried out using 
a hot wire cutting machine that gives a fine finish to the 
product and enables very fine cutting tolerances to be 
achieved.   
  
Quality Control  
To ensure compliance with customer requirements we 
operate a fully accredited Integrated Managed System 
(IMS) to ISO9001. Additionally, we a have a Safety 
Management System accredited to ISO 45001:2018. 
  
 
Table 1 
Physical Properties of TPC, according to AS 1366, Part 3 – 1992 
Physical Property   
Unit 
 
Test Method  
Nominal Density (kg/m3)  
 
40 
N/a  
Compressive stress at 10% deformation (min)  
kPa 
165 
AS2498.3  
Cross-breaking strength (min)  
kPa 
320 
AS2498.4  
Rate of water vapour transmission (max) measured 
parallel to rise at 23°C  
μg/m2s 
400 
AS2498.5  
Dimensional stability of length, width, thickness (max) at 
70°C, dry condition 7 days  
% 
1.0 
AS2498.6  
Thermal resistance (min) at a mean temperature of 25°C 
(50mm sample)  
M2K/W 
1.70 
AS2464.5 or AS2464.6  

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