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Place your order by phone: (855) EPS-FOAM
Place your order by phone: (855) EPS-FOAM

EPS Sheets and Blocks

Build smarter, not harder with EPS sheets & blocks

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Lightweight strength for every project

Lightweight strength for every project

EPS sheets and blocks make construction faster, cleaner, and more efficient. Lightweight yet durable, they’re perfect for insulation, architectural details, and custom builds. Easy to cut, shape, and install, they save time without compromising quality. Transform your designs with versatile foam solutions that perform under any conditions.

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Choosing the right one

Choosing the right one

  • EPS foam sheets
    The workhorse. Lightweight, rigid, and quick to shape. EPS sheets and foam boards sit behind façades or beneath slabs. A single panel weighs less than a jacket — installers often carry several at once. Some crews even bring EPS or foam boards for temporary protection layers while they install them.
  • Styrofoam insulation sheets
    Same thing, different name. People ask for Styrofoam insulation, foam board panels, or polystyrene sheets as if they’re different products — they’re not. We’ve installed EPS and foam core board panels for insulation in green roofs where moisture destroys most materials. EPS and foam boards just stays stable — unlike other foams that start to swell in wet conditions. On site we often protect them with temporary foam poster boards until install.
  • Polystyrene blocks
    Large polystyrene foam blocks, foam board prototypes, and high-density foam core boards become signage, sculptural forms, even structural cores. Site staff use EPS or foam core blocks for construction as void fill or insulation under foundations. Entire walls? That’s what foam boards (ICF) are built from. Designers also use foam board posters and EPS prototypes to coordinate profiles before the real EPS gets cut.

Who Is This Solution For?

Home Associations

Enhance the character and value of your properties with timeless, custom-crafted architectural elements.

Architects

Bring your creative visions to life with exquisite details that elevate every design.

Builders

Deliver exceptional quality and distinctive style that sets your projects apart.

Homeowners

Transform your space with elegant, personalized accents that make a lasting impression.

How to Order From Royal Foam

Step 1. Ready design
We adapt it for production and installation, preserving every detail.

Step 2. Define your vision
Capture a clear picture of the client’s ideas before moving to design and rendering.

Step 3. Plan specifications
Outline measurements, production methods, and finalize materials, components, and finishes.

Step 4. Installation
Our team ensures precise setup, perfectly aligning your custom surround with the space.

Quote Request

Step 1
The aim of this step is to capture a precise picture of the client’s vision before proceeding to technical design and visual rendering.

Step 2
During this phase, we define the specifications, production methods, and measurements, while finalizing the look by selecting materials, elements, and finishes.

Step 3
Once fabrication is complete, our installation team will handle every aspect of the setup, ensuring your custom surround is fitted with accuracy and seamlessly integrated into your space.

Quote Request

Companies We Serve

Testimonials

I highly recommend the services of Royal Foam because they are always consistent with their quality of 3D letterings and other products.

Samuel Ridge

Thank You Royal Foam for providing me with the gorgeously designed monument sign I had ordered for my newly opened company.

Danial Bryan

After installing an arch from Royal Foam not only the look has improved but also my home has become a lot more spacious. I suggest and thank Royal Foam. I will contact again to Royal foam for my new arch work at my home. Designs are very good and finishing is also good.

Amy Corey

I had ordered plastic letters to put up in front of my Company and I’m thanks to the quality, come rain or sun, they shine like new always. Thank you for such good products Royal Foam.

Origin Teak

Frequently Asked Questions

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We can say with confidence that the materials we use have already proven themselves under Florida’s wind, humidity and sun. They perform exceptionally well in these conditions. With densities of 1.5–2.0 lb/ft³ and reinforced acrylic coatings between 2 and 4 mm thick, EPS demonstrates long-term durability — and we support that with our 20-year warranty.
We once completed a project in Jacksonville for a retail center. Our elements have been installed there for 12 years, and they are still in place today. There have been no visible changes — no cracks, no warping, nothing that would affect the visual or functional performance of the architectural components. Annual façade washing is all that’s needed, and EPS handles it perfectly.
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Our tolerance is only ±1 mm. We do everything possible to ensure that elements arrive fully ready for installation with no adjustments required on site. We once produced a decorative frieze that was 42 feet long, and not a single module required a length correction. The superintendent later told us it was the first time in many years that elements arrived so perfectly prepared that nothing had to be modified on site.
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Absolutely. We routinely produce panels from 3 to 12 inches thick with densities from 1.0 to 2.5 lb/ft³ depending on load requirements.
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Yes. For a hotel near Orlando, we built 10x10 ft ceiling modules weighing only 55 lb each. Coatings provided impact and abrasion resistance, and maintenance staff can clean and repair them easily.
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Price depends on density, block volume and CNC processing level. In one Savannah retaining wall project, using mid-density blocks reduced overall system cost by 14 percent while maintaining required strength.
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Both. One manufacturing partner in Georgia receives over 70 types of fully cut and pre-assembled inserts from us each quarter, packed by installation sequence—saving them two full days per equipment cycle.
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No. All louvers we produce are 100 percent decorative—non-opening and not part of HVAC systems.

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Eps sheets blocks

Design and architecture are never about solving just a single task — each decision addresses a whole set of challenges. And the more needs a particular architectural element can meet, the more valuable it becomes for the client. Today, it’s essential that an element fulfills practical requirements as well: it must fit the budget, stay within acceptable weight limits, maintain precision, and allow for fast, predictable installation. And of course, it must visually express the idea intended by the designer.

For example, a heavy material may look impressive on a drawing, but in practice the labor and time required for its installation can significantly reduce its overall value. It often demands expensive equipment, more labor hours, and more human resources — which turns an attractive concept into a complicated, costly operation.

That is why so many design teams switch to engineered lightweight solutions like eps foam blocks, eps sheets, eps styrofoam sheets, eps insulation sheets, 2 inch styrofoam sheets, 4x8 styrofoam sheets, large styrofoam sheets, and structural polystyrene foam blocks. These materials deliver precision, consistency and speed without the structural penalties typical of concrete, plaster or metal.

At Royal Foam US, for more than 25 years, we’ve been manufacturing eps foam blocks 4x8, monolithic expanded polystyrene blocks, high-density polystyrene building blocks, and custom CNC-cut architectural elements. All our products are manufactured in the state of Florida, USA, and this gives us full control over every stage of production and over the quality of each architectural element we create. We supervise the assembly process, and every component is delivered fully assembled, pre-painted, coated with protective finishes and backed by our 20-year warranty along with an extensive package of technical documentation.

Our clients include architects, developers, contractors, designers, exhibition builders and event-production teams. They choose our solutions when the visual impact must go hand in hand with precise geometry, predictable timelines, optimized budgets, lightweight installation and reduced labor requirements. In such projects, every detail matters.

We provide not just architectural elements — we provide custom-engineered solutions and the confidence that the project will be executed at 100 percent.

What EPS is and why the market depends on it

EPS (expanded polystyrene) is a closed-cell rigid foam consisting of 96–98 percent air and 2–4 percent polystyrene structure. That composition creates an unusual combination of properties:

  • extremely low weight
  • surprisingly high compressive strength
  • long-term dimensional stability

Key performance indicators:

  • Weight of a standard 4x8, 2 inch styrofoam sheet: typically 6–10 lb
  • Compressive strength: 10–60 psi (depending on density)
  • R-value: 3.6–4.5 per inch
  • Water absorption: typically under 4 percent by volume
  • Flexural strength: 30–90 psi
  • Service temperature: –200 to +165°F

From a design standpoint, EPS is a “freedom multiplier”: it lets you create large, expressive shapes without increasing structural loads or construction timelines. It replaces slow, heavy, site-dependent operations with factory-finished precision.

Materials, engineering and manufacturing depth

At our US facility we manufacture:

  • eps foam blocks 4x8 (thickness 1–16 inches)
  • eps polystyrene sheets cut to custom dimensions
  • styrofoam insulation sheets for thermal and decorative systems
  • expanded polystyrene foam blocks up to 4 x 4 x 16 feet
  • high-density polystyrene building blocks for industrial use

We operate with multiple density classes (0.9–4.0 lb/ft³), depending on structural loads, spanning, impact resistance and required finish.

Engineering work begins long before production starts, because we approach every project individually and with full personalization. This process goes far beyond selecting color, texture, finish or geometry. It includes evaluating wind loads and humidity levels, since we always clarify where our architectural elements will be installed and take local conditions into account during production. We also design joint layouts and consider how colors will behave under UV exposure. At the pre-production stage, we calculate thickness transitions, fixing points, compensating expansion gaps and the appropriate coating system. All of these parameters are determined based on your drawings, your specifications and the core idea of the project.

Parameter Typical eps foam blocks 4x8 Expanded polystyrene blocks Our design range Notes & engineering nuances
Density (lb/ft³) 1.0 – 2.0 1.5 – 4.0 0.9 – 4.0 Controls strength, screw pull-out, impact resistance
Compressive strength (psi) 10 – 25 15 – 60 10 – 60 Used to size façade projections, cornices and industrial inserts
Flexural strength (psi) 30 – 60 40 – 90 30 – 90 Critical for long, thin elements
R-value per inch 3.8 – 4.2 3.6 – 4.2 3.6 – 4.5 For dual-purpose decorative/insulation applications
Thermal conductivity k 0.24 – 0.26 0.24 – 0.27 0.23 – 0.27 Lower k = better insulation
Sheet weight (4x8x2") 6 – 10 lb n/a 5 – 12 lb Ultra-low weight = fast installation
Water absorption (%) < 4 < 4 1 – 4 Closed-cell structure + coatings
Typical block size n/a 48 x 48 x 192 in Up to 4 x 4 x 16 ft Ideal for CNC sculpting and industrial parts
Thickness range 1 – 16 in 8 – 48 in 1 – 48 in Large shapes built by lamination
Service temperature –200 to +165°F –200 to +165°F –40 to +150°F Coatings selected per climate zone
Dimensional tolerance ±1/16 in ±1/16 in ±1 mm (CNC) Supports high-precision architectural interfaces
Lead time 5–20 days 7–20 days 5–20 days Depends on complexity & coatings

We provide a full set of technical documentation for every project. This includes shop drawings, detailed marking of all connection and fixing points, tables showing the density of the materials used, technical data sheets for protective and finishing coatings, as well as recommendations and installation guidelines for the finished elements.

How EPS (expanded polystyrene) compares to traditional materials

EPS outperforms concrete, plaster and wood in:

  • Weight reduction by 70–90 percent
  • Installation speed improved by 30–60 percent
  • Structural load nearly negligible (6–15 lb per large decorative module)
  • Schedule reliability due to zero on-site shaping
  • Cost predictability thanks to all work done in factory conditions

Traditional materials certainly work in many situations and project types, but the real question is how rational and relevant their use is today. They often require additional equipment and machinery—cranes, specialized lifts—along with extra processes and extended time for curing or strengthening. On-site adjustments during installation are almost always necessary, and long-term maintenance of natural materials demands considerable labor, time and resources.

Where is EPS (expanded polystyrene) used?
1. Exterior architecture and facades

What we deliver:

Cornices, decorative louvers, window and door trims, pilasters, soffits, wall panels and decorative profiles that replicate stone or natural wood — all of these elements are delivered fully pre-assembled, pre-painted, coated with a protective layer and completely ready for installation and use.

Why does EPS work so effectively in this category?

Because it offers an exceptional and highly competitive weight — typically under 45 pounds per module. Another important advantage is CNC-cut precision: EPS modules provide exact geometry, meaning all components align perfectly during installation and joints remain virtually invisible.

A protective coating of 2 to 4 mm shields the elements from UV exposure, moisture and strong coastal winds — which is especially crucial in shoreline regions. EPS also allows the creation of deep projections and visually massive decorative forms without any significant structural reinforcement.

There are projects where we work specifically with EPS blocks or sheets for renovation, reconstruction, or visual updates of buildings that were originally finished with heavy plaster materials. One such example was a modernization project for a hotel in Tampa. The 1980s hotel building required a complete visual refresh and interior update. It had existing concrete belt courses, each weighing about 600 pounds.

During the project, we replaced them with EPS architectural elements assembled into 16-foot modules. And the key advantage of this solution was that each module weighed under 50 pounds. No cranes, no heavy equipment were needed for installation.

The façade crew completed the installation in just about 10 days compared to the originally planned 20 days. As a result, the project saved around 20% of the installation budget.

2. Interior architecture and retail environments

What we deliver:

3D wall panels, sculptural ceilings, faux beams, geometric surfaces, acoustic-friendly lightweight cladding.

Why EPS works here:

  • Low load on existing studs and ceilings
  • Easy to mount after hours without shutting down businesses
  • Oversized panels can be cut into interlocking modules
  • Fully painted at the factory—no odor or dust on site

One of the most interesting projects where we worked with EPS (expanded polystyrene) panels was a furniture showroom in Orlando. The client came to us with a clear goal: they wanted to replace the heavy gypsum decorative structures on the walls with something lighter, more modern, stylish and geometric.

For this project, we produced EPS sheet panels in a 4×8 format, 3 inches thick, and created around 20 unique designs. All panels were pre-painted in a warm matte white.

From an engineering perspective, the biggest advantage was that the total wall weight was reduced by approximately 2,000 pounds compared to the original gypsum construction. The installation was completed in just three working days, which was another significant benefit for the client.

3. Branding, events and experiential spaces

What we deliver:

Large letters, product sculptures, exhibition environments, podiums, immersive shapes carved from large styrofoam sheets or expanded polystyrene blocks.

Why EPS (expanded polystyrene) works here:

  • Fast turnaround for last-minute event deadlines
  • Massive shapes built in lightweight modules
  • Exact color matching with brand guidelines
  • Easy to store, repaint and reuse

Case: 24-ft illuminated brand sign in Atlanta

An energy brand launched a new product line and needed a 12-ft x 24-ft sculptural sign with ribbed geometry.

We built it from polystyrene flexible foam blocks (2 lb/ft³), divided into eight modules, each ~80 lb. On-site assembly took 5 hours. The same sign was repurposed later in another city after we recoated it with a new color.

4. Industrial and construction solutions

We supply concrete form inserts, lightweight void fillers, industrial packaging, composite-forming plugs, stairwell fillers, landscaping shapes and underground fillers.

Why does EPS work so effectively for these applications?

Because it provides predictable compressive strength and allows you to reduce the load on structural elements.

  • Lower concrete volume in many structural zones
  • Easy to shape industrial inserts with CNC
  • Excellent shock absorption for heavy-duty packaging

Case: Savannah retaining wall

A contractor needed to reduce soil pressure on a retaining wall. We engineered polystyrene building blocks at 1.35 lb/ft³, compressive strength 18 psi. This design reduced concrete volume by 27 percent, lowered backfill weight dramatically and accelerated the job by 6 days.

5. Hospitality, malls and public interiors

What we deliver:

Oversized ceiling coffers, false beams, giant light housings, thematic decorative walls.

Why EPS works here:

  • Panels up to 10x10 ft weigh only 50–60 lb
  • Ceiling systems experience much lower dead loads
  • Painted surfaces resist cleaning chemicals
  • Elements can be removed or replaced with minimal disruption
Installation, logistics and maintenance

We do not provide on-site installation, but we make installation extremely simple through:

  • CNC-cut modules that fit exactly per drawings
  • Factory pre-glued joints for maximum panel size per shipping limits
  • Pre-painted surfaces—no priming, no sealing, no field texturing
  • Full shop drawings with fixing points and anchor spacing
  • Coordination of freight (including oversized loads)
  • Free storage until your site is ready

Maintenance requirements are minimal:

  • Cleaning when necessary
  • Checking sealant every few years
  • Occasional touch-ups for high-traffic areas

We’ve monitored our elements in Florida and Georgia for decades—EPS panels with proper coatings remain stable in intense UV, humidity and temperature swings.

Why working with Royal Foam US is strategically profitable
  • Made in USA at our own production facility
  • Custom manufacturing for unique one-off items
  • Pre-assembled and pre-painted components
  • Personal manager for every project
  • Engineering flexibility in density, geometry, coating
  • Budget flexibility across multiple density/finish options
  • Fast estimating—often within minutes
  • Free warehouse storage
  • Samples and 3D mockups available
  • 20-year warranty
  • Environmental responsibility
  • Full technical documentation
  • Transparency from brief to delivery

For many partners, our products became not just a material line but a strategic tool for winning projects, reducing TCO and increasing the margin on their end.

Summary

EPS is not the “foam of the past.” It is the engineering material of the present—lightweight, precise, customizable and incredibly predictable. Whether you need eps sheets, large styrofoam sheets, 4x8 styrofoam sheets, eps insulation sheets, or monolithic polystyrene foam blocks, our solutions accelerate your schedule, stabilize your budget and remove risk from your workflow.

Send us your drawings. We will calculate the optimal configuration and deliver a fully engineered, fully documented, ready-to-install solution with a 20-year warranty.