Traditional construction materials in mines are officially old-school. Florida-based company Vero Building Systems said there is an alternative: customizable, shotcrete-coated polystyrene,
or Styrofoam.
By Donna Schmidt
Saving money and upping the score in a mine’s eco-friendliness are always welcome changes. How about a technology that can be used at surface or underground, is modular and easy to transport, and can withstand hurricanes, fires, earthquakes and more?
Styrofoam is now at the core of constructing secure tunnels and rooms underground. Vero Building Systems has brought a groundbreaking building method that utilizes expanded polystyrene as an alternative to traditional construction materials to the United States at scale for the first time.
The fully customizable expanded polystyrene panels are modular and enclosed by double-galvanized steel mesh that is then coated in Shotcrete on both sides. The result is a structure that can survive earthquakes up to a 10 on the Richter scale. The panels are blast tested to withstand an explosion of 3 tons per square foot. And the panels can be on fire for 150 minutes and the walls and roof will remain intact, with no structural damage. Plumbing and wiring inside the panels is also protected from the heat and flames.
In late 2023, building solutions group Vero Building Systems unveiled what it called a groundbreaking building method using the expanded polystyrene as an alternative to traditional construction materials to the United States at scale for the first time. The panels, modular and enclosed by double-galvanized steel mesh, can in addition to mining be used in residential homes, schools, hospitals, bridges, restaurants, office buildings, industrial sheds and more.
“There are many benefits of utilizing expanded polystyrene panels in construction instead of wood or any other traditional building method,” according to Vero, which noted that the panels can reduce construction costs by up to 30% and timelines by up to 40%.
Additionally, the panels can be more environmentally friendly than traditional materials. During a build, 40% less CO2 emissions are created when using Vero Building Systems panels, and 65% less CO2 is created over the lifetime of the structure.
“No waste is created in the manufacturing of the … panels, every scrap is recycled and reused,” the company said. “Manufacturing the panels requires no harmful chemicals, and no harmful emissions are generated.”
Putting it to the test
Vero co-founder Annette Rubin pointed out that, as the frequency of extreme weather events and natural disasters increase, the need for new building methods that are more durable becomes more urgent – and the use of it in the harsh condition of a mining application rises in parallel.
In fact, the panels meet Category 5 hurricane outlines, can survive earthquakes up to a 10 on the Richter scale, winds up to 150 miles per hour, and windborne objects projected at 66 miles per hour with no damage.
When on fire, the panels are self-extinguishing, and the placement of infrastructure like plumbing and wiring inside the panels also protects them from heat and flame. They are both bulletproof and blast resistant, tested to withstand an explosion of three tons per square foot.
Taking on mining
Rubin said that, with the customizable expanded polystyrene panels now available in 13 unique product codes, mining is a natural extension for various applications above and below ground.
Its use in mining was first discovered when the company began working with Belt Tech, which had come to Vero for assistance with a mine overcast project.
“We are working with Belt Tech on a mine project in Alabama and are looking to several more projects with them in 2024,” Rubin added. The partnership has already seen many panels installed at a depth of about 2,000 feet.
The company is looking forward to making an impact with the panels well into the future for mining customers everywhere. As Rubin noted, one of the biggest benefits both above and below ground is an added layer of safety and durability due to the insulated factor of the EPS and the shotcrete applied to each side to create a nearly indestructible product.
“Along with the thermal insulation capabilities, they help with airflow within the mine itself. Our goal is to learn as much as possible during these projects and then continue to partner with the mining community across North America to bring these benefits to their operations,” she said.
“At the heart of Vero, our goal is to impact 7,700 lives per year positively with our panels, and we are grateful to have the opportunity to partner with the mining community to utilize our panels in a non-traditional way. We want to thank Belt Tech for introducing us to this industry, and are eager to expand these partnerships in 2024.”
The panels are available now for immediate use in mine shafts and overcasts.
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