Filcor - Structural Fill

Filcor (Expanded Polystyrene) is increasingly being specified for an ever-growing range of applications. The most common applications include use as a lightweight structural fill alternative to more traditional fill materials.


  • A range of compressive strengths available
  • Lightweight and easy to handle
  • Available as standard sheets or blocks
  • Can be profiled to customer requirements
  • Provides a high degree of insulation
  • Flame Retardant (FR) properties
  • Available as individual sheets or shapes wrapped in Puraflex VOC Membrane

The versatility of Filcor means that any shape, size or profile can be manufactured with relatively short lead times. In addition, a range of materials of increasing compressive strengths are available to meet the loading requirements of the application, whilst also providing the most cost effective solution. In applications where Filcor may be in contact with petroleum, hydrocarbons or solvents it should be protected through encapsulation in Puraflex VOC Membrane, this can be done on site or, sheets/shapes can be supplied pre-wrapped for a faster installation.


Filcor can be used for a range of applications including lightweight structural fill and insulation. The product can be manufactured in standard sheet sizes or alternatively profiled to the installer’s exact requirements.

Standard sheet/block 2400mm long x 1200mm wide x required depth.

Each Filcor sheet/block can be manufactured to the required depth, with a minimum depth of 25mm and a maximum depth of 1200mm.

Additionally Cordek can supply an individual Hot Wire Cutter for hire.

Application Reason
Hard Landscaping
  • Range of compressive strengths to match specific application, whether it be low loadings such as pedestrians or high loadings such as motor vehicles.
  • Lightweight
  • Quick and easy to install and can be cut to create falls, steps and other features.
  • Water resistant with a very long design life
  • Insulation
Soft Landscaping
  • Quick and easy to install
  • Can be profiled to create landscape features including complex shapes
  • Lightweight
  • Water resistant with a very long design life
Podium Slab
  • Lightweight
  • Range of compressive strengths to match specific application, whether it be low loadings such as pedestrians or high loadings such as motor vehicles.
  • Suitable under hard and soft landscaping
  • Insulation
Swimming Pools
  • Lightweight void former profiled to create the falls at the bottom of the pool with a high degree of accuracy
  • Simple and cost efficient solution for filling in pools that are no longer required
Steps, ramps and shapes
  • Off site construction method where Filcor can be cut and profiled prior to being delivered to site, including complex shapes.
  • Range of compressive strengths to match specific application, whether it be low loadings such as pedestrians or high loadings such as motor vehicles.
  • Simple and easy to install
  • Lightweight


Please consult the Filcor Technical Data Sheet for details of the physical properties of the product range.

Manufactured BS EN 13163:2012 Physical PropertiesFilcor 20Filcor 45Filcor 70Filcor 90Filcor 100Filcor 120Filcor 140Filcor 160Filcor 190
Compressive Strength at 1% strain (kPa)20457090100120140160190
Nominal Density (kg/m3)152025303540455055
Thermal Conductivity Value +W/mK0.0380.0360.0350.0340.0330.0330.0330.0330.033
Other Data         
Max Depth of Concrete (assumed 25k/N/m3) to not exceed
Compressive Strength at 1% strain (mm)

Filcor complies with both BS EN 13163:2012 and BS EN 14933:2007

Environmental facts about Filcor EPS

The manufacture of Filcor is a low pollution process. Steam is he key component and the water is re-used many times. There is no waste in the process as all cut offs or rejects are recycled.

Filcor is 98% air. This makes Filcor a uniquely resource-efficient material with small carbon footprint.

Filcor is HFC, CFC and HCFC free and Pentane is used as its blowing agent. Pentane has a low Global Warming Potential* (GWP) of less than five. (The EU does not register pentane as a substance hazardous to human health or environment.)

Styrene, used in the manufacture of Filcor, occurs naturally in many commonplace items including strawberries, beans, nuts, beer, wine, coffee beans and cinnamon

* Global warming potential (GWP) is a means of measuring the strength of different 'greenhouse' gases in the atmosphere and can be used to define the impact greenhouse gases have on global warming over specified periods of time. As an example CO has a GWP of 1 over 100 years. All other greenhouse gases HFC, CFC HCFC and methane are measured relative to CO2.
Filcor Recycling
Filcor is 100% recyclable. As a single polymer, Filcor is straightforward to recycle and is recyled into items such as replacement hardwood decking or garden furniture and coat hangers


Data Sheets

Product Issue Date Version Size Download
Filcor Data Sheet 01/2024 10 412.3 KB

MSDS Data Sheets

Product Issue Date Version Size Download
Expanded Polystyrene MSDS 06/2017 5 137.3 KB


Product Issue Date Version Size Download
Construction Solutions 01/2020 2 6.6 MB

Installation Guides

Product Issue Date Version Size Download
Filcor Installation Guide 112023 3 327.3 KB

NBS Clauses

Our NBS Clauses are hosted on the external website - view NBS Clauses

BIM Library

Please select the BIM file in the format you require.

Name IFC Size IFC Download Revit Size Revit Download
Filcor 10.7 KB 956.0 KB

Not sure which product meets your requirements?

Contact a Technical Advisor now

Case Study

The Kia Oval - Peter May Stand

Cordek was asked to provide a lightweight structural fill solution to raise the height of the newly constructed terraces, thus enabling additional rows of seating to be added.

Find your nearest Technical Advisor

For international enquiries please contact Peter Blanchard

For enquiries in the Manchester or Liverpool
areas please contact James Provan

Or contact Cordek Head Office