Expanded Polystyrene for Building Insulation: Effect of Graphite and Moisture on Thermophysical Properties

Improving the energy efficiency of the building envelope is critical for global decarbonization, yet a gap remains in the comprehensive thermophysical characterization of carbon-enhanced Expanded Polystyrene (EPS). This study evaluates the impact of expansion ratios and moisture content on the thermal behavior of two commercial EPS grades, EPS-A (12.7 ± 0.5 kg/m3) and EPS-B (16.0 ± 1.1 kg/m3), investigating the counterintuitive role of graphite (1.4–1.8 wt.%) in enhancing the thermal insulation properties. Thermal conductivity and diffusivity were independently determined via Transient Plane Source (TPS) and Heat Flow Meter (HFM) methods across a 10–50 °C range, while specific heat capacity (cp) was analyzed using HFM and Differential Scanning Calorimetry (DSC) through the sapphire comparison method and Temperature-Modulated DSC (TOPEM®). Methodologically, it was found that standard HFM protocols are unsuitable for cp determination in low-density foams, yielding an average relative error of ±29%; conversely, the sapphire comparison method provided the most reliable results in agreement with theoretical expectations. Results indicate that the efficacy of graphite as a radiative shield is closely coupled with cellular morphology, proving significantly more effective in the higher expansion grade (EPS-A, 70 wt.% open porosity) than in the denser EPS-B. Furthermore, 30-day water immersion tests revealed that the higher open porosity of EPS-A facilitates increased water uptake of 144 ± 17 wt.% (compared to 97 ± 7 wt.% for EPS-B), causing the geometric densities of the two grades to converge and fundamentally altering thermal transport mechanisms. The study concludes that accurate thermal modeling of carbon-enhanced insulation requires careful selection of testing parameters, particularly when accounting for moisture-induced degradation in high-porosity systems.