Abstract
As demand for energy-efficient buildings grows, the use of expanded polystyrene (EPS) insulation is expected to increase, intensifying the need for material-efficient strategies such as recycling and reuse. This study investigates the technical feasibility, chemical safety, and climate implications of reusing EPS insulation recovered from building and infrastructure applications. EPS boards with service lives exceeding 20 years were collected from demolition sites and characterised for density, compressive strength, thermal conductivity, and hazardous substance content. Measured material properties were compared with historical test reports from 1976 to 2009 to assess long-term performance. The thermal conductivity and compressive strength of the used EPS samples fell within or close to the 95% prediction intervals for the corresponding products at the time of production, indicating limited long-term degradation. No brominated flame retardants or other substances of concern were detected above the detection limits. Life cycle assessment (LCA) results showed that reuse provides greater greenhouse gas (GHG) emission reduction potential than improved recycling alone, primarily through avoided virgin EPS production and reduced processing needs. An important insight from this study is that key material properties of used EPS can be reliably estimated from simple measurements of density, dimensions, and weight, and that direct reuse is feasible for less demanding applications. Additionally, further work is needed to test additional samples from diverse demolition sites across various applications and climates to establish a consistent basis for reuse.