Thermopore Blocks
for Construction,
Cold Storage & More.
Large thermopore blocks in multiple densities — for cold storage panels, sandwich panel cores, EIFS systems, custom cutting, industrial molds, and stage props. Factory-direct pricing with custom cut service from IK Thermopore. Nationwide delivery across Pakistan.
Product Specifications
EPS Thermopore Blocks — IK Thermopore
Thermopore Blocks — What Are They and Why Are They Different from Sheets?
Thermopore blocks — also called EPS blocks, thermocol blocks, or polystyrene foam blocks in Pakistan — are large, thick forms of Expanded Polystyrene material manufactured by IK Thermopore. Think of them as the raw mass from which everything else is cut. A standard thermopore block measures approximately 1000mm × 500mm × 500mm, though we produce them in various dimensions on demand. The block format gives complete dimensional freedom that pre-cut sheets simply cannot offer.
If you need a standard 1-inch or 2-inch insulation panel in a 4×8 ft size, you buy thermopore sheets. But if you need a 75mm, 100mm, or 150mm thick section for a cold storage room wall, or a custom-shaped piece for a packaging mold, or a large single piece for stage decoration — you need thermopore blocks. Blocks solve the problem of non-standard requirements. They are purchased by businesses and professionals who need something that does not fit the standard sheet dimensions available in the market.
In Pakistan, the main buyers of EPS blocks fall into distinct groups. Cold storage construction companies build entire rooms using thick EPS block panels for walls, ceilings, and floors. Sandwich panel manufacturers use thermopore blocks as the insulating core between two metal sheets. Packaging businesses use blocks as the raw material from which custom product-specific foam molds are cut. Event and stage production companies sculpt large blocks into three-dimensional props and decorations. And construction projects increasingly use thermocol blocks for insulation in applications that require greater thickness than standard sheets provide.
Key advantage: IK Thermopore's factory cutting service means you do not need to buy full thermopore blocks and cut them yourself. Share your required dimensions and we cut to specification before delivery — saving you labor, material waste, and on-site time.
Thermopore Blocks vs Thermopore Sheets — When to Use Which?
This is the most common question from first-time thermopore block buyers. The difference is straightforward once you understand it:
| Feature | Thermopore Blocks | Thermopore Sheets |
|---|---|---|
| Form | Large thick mass (1m+ dimensions) | Flat pre-cut panels |
| Standard Thickness | Any thickness — you specify it | 1 inch, 2 inch (25mm, 50mm) |
| Custom Shapes | Yes — cut to any shape, angle, cavity | Flat sheets only |
| Cold Storage Panels (75–150mm) | Yes — standard application | Not available in these thicknesses |
| Sandwich Panel Cores | Yes — primary supply for manufacturers | Too thin for most panel specifications |
| Standard Roof/Wall Insulation | Yes — but sheets are more convenient | Yes — most convenient option |
| Packaging Mold Making | Yes — cut cavities to product shape | Cannot achieve required depth |
| Stage Props & Decoration | Yes — sculpt any 3D shape | Too thin for 3D forms |
| Price Unit | Per cubic meter | Per sheet |
| Lead Time | 1–3 days (+ cutting if custom) | 1–2 days (stock items) |
Simple rule: Standard thicknesses (1" or 2") for roof or wall → order thermopore sheets. Non-standard thickness, custom shape, or large volume for industrial use → order thermopore blocks. Not sure? Call us with your project details and we'll tell you exactly which format makes more sense for your budget and timeline.
Thermopore Blocks Density Guide — Choosing the Right EPS Grade for Your Project
Density (measured in kg/m³) is the most important specification when ordering thermopore blocks. It determines compressive strength, thermal performance, and suitability for different load conditions. Higher density means more polystyrene per unit volume — stronger, more durable, slightly heavier, and more expensive. Here is a clear guide to each grade:
Basic insulation, decorative applications, stage props, and void fill. Lowest cost per cubic meter. Adequate for non-load-bearing insulation where physical strength is not a concern. Cuts and shapes very easily.
The most widely used grade for thermopore blocks in Pakistan. Balances thermal performance, compressive strength, and cost effectively. Suitable for most wall, roof, and floor insulation applications in commercial and residential construction.
For cold storage rooms operating at above-zero temperatures, exterior EIFS wall cladding, and applications with moderate physical loads. Better compressive strength than standard grade maintains panel integrity over time under sustained loads.
Standard for freezer rooms (-5°C to -20°C), pharmaceutical cold rooms, and under-slab insulation where concrete is poured directly on the EPS surface. Compressive strength at this density handles construction loads during concrete placement.
For blast freezers below -20°C, structural EPS formwork in concrete construction, and extreme-load applications. Maximum density for demanding environments where long-term dimensional stability under sustained compression is critical.
Not sure which density your thermopore blocks need? Call +92 328 8304 655 with your application and required performance — we recommend the most cost-effective grade that meets your actual requirements. Over-specifying density wastes money unnecessarily.
Seven Ways Thermopore Blocks Are Used Across Pakistan
EPS thermopore blocks serve a broader range of professional buyers than almost any other insulation product. Here is a complete picture of who uses them and exactly how.
1. Cold Storage Room Construction
This is the largest industrial use for thermopore blocks in Pakistan. Cold storage rooms for food, pharmaceuticals, and dairy products require thick EPS insulation on all six sides — four walls, ceiling, and floor. The thickness required (75mm to 200mm depending on operating temperature) cannot be achieved with standard pre-cut sheets, so EPS blocks are the essential material for this application.
Construction companies building cold rooms lay the thermocol blocks in multiple layers bonded together to achieve the required panel thickness. Alternatively, they use sandwich panels with an EPS block core — where the block is cut to panel thickness and bonded between two galvanized steel sheets. Either way, thermopore blocks from IK Thermopore are the insulation core. See our cold storage thickness guide below for specific recommendations by temperature.
2. Sandwich Panel Core Supply
Sandwich panels — two metal face sheets bonded to an insulating core — are everywhere in Pakistan's industrial and commercial construction sector. Factories, warehouses, cold storage facilities, container offices, and prefab buildings all use them for roofs and walls. The insulating core in EPS sandwich panels is cut directly from thermopore blocks.
Panel manufacturers buy blocks at the required density grade, cut them to panel thickness (typically 40mm, 50mm, 75mm, 100mm, or 150mm), and bond them between the pre-painted steel sheets using structural adhesive under pressure. IK Thermopore supplies consistent-density EPS blocks to sandwich panel manufacturers who need uniform thermal performance across every panel in a production batch.
3. EIFS Exterior Wall Insulation
EIFS (Exterior Insulation Finish System) is a method of wrapping an entire building's exterior in EPS insulation before applying a decorative render or protective coating. It eliminates thermal bridging through the wall structure completely — a significant energy performance improvement over interior insulation that leaves structural elements exposed to outside temperature.
EIFS uses high-density thermopore blocks (typically 20–25 kg/m³) cut to the required thickness and mechanically fixed to the building's exterior. Mesh is embedded in a base coat, followed by the final textured render. In Pakistan, EIFS is growing in use on commercial buildings and high-rise residential developments where architects specify it for both energy performance and facade aesthetics.
4. Custom Packaging Mold Base
Businesses that manufacture custom EPS packing for specific product shapes start with large thermopore blocks and cut the required cavity shape into them. A pharmaceutical company needs a custom tray for 500ml medicine bottles — the designer defines the cavity dimensions, and the block is cut to create the precise fit. An electronics company needs a mold for a new appliance — the same process applies.
Blocks used for packaging molds require tight dimensional tolerance in the cut and a consistent density throughout so the finished packing provides predictable protection. IK Thermopore's cutting service produces mold pieces to specification, and our consistent density EPS blocks ensure the same protection level across every production unit.
5. EPS Formwork in Concrete Construction
High-density thermocol blocks (25–30 kg/m³) are used as permanent formwork (shuttering) in concrete construction. Unlike traditional timber or metal shuttering that is stripped out after the concrete sets, EPS formwork stays in place permanently and continues insulating the structure for its entire life. The concrete bonds to the EPS surface, and the EPS remains as the insulation layer.
This technique is used for insulated raft foundations, below-grade walls in basements, and under-slab insulation layers. For construction projects in Pakistan that specify thermal insulation as part of the structural design, thermopore block formwork delivers both functions — structural support during concrete placement and permanent insulation — in a single operation.
6. Stage Props & Event Decoration
Large thermopore blocks are the go-to material for stage set designers, event production companies, and wedding decorators across Pakistan who need three-dimensional structures that are large, lightweight, and quick to produce. A large EPS block can be sculpted using a hot wire cutter into almost any three-dimensional shape — columns, arches, decorative walls, logos, signage, themed elements, and structural stage components that appear solid and realistic but weigh almost nothing.
The ease of cutting and the light weight mean these props can be constructed quickly and moved easily on the day. After painting and surface treatment, EPS props are visually indistinguishable from plaster, timber, or stone — at a fraction of the cost, weight, and production time.
7. Non-Standard Thickness Insulation
Not every insulation project fits standard 1-inch or 2-inch sheet dimensions. Industrial projects often specify 75mm, 100mm, or even 150mm thick insulation in a single continuous layer — without the joint that two stacked standard sheets would create. Poultry shed projects in Punjab's extreme heat zones often specify 3-inch or 4-inch continuous insulation. Pharmaceutical warehouses with strict temperature requirements specify unusual thicknesses for specific R-value targets.
All of these are thermopore block applications. IK Thermopore cuts blocks to the exact specified thickness so the project receives a continuous, unjointed insulation layer — which always performs better thermally than stacked sheets of the same total thickness because it eliminates the interface between layers.
Thermopore Blocks for Cold Storage — Insulation Thickness Guide for Pakistan
Pakistan's summer temperatures create unusually high insulation demands for cold storage facilities. An ambient temperature of 45–50°C in Multan or Sukkur means the temperature differential across a freezer room wall can reach 60–75°C — significantly higher than what European insulation standards are typically designed for. Use this thermopore block thickness table as a baseline guide and consult your refrigeration engineer for final specifications:
| Cold Room Type | Operating Temp | Min EPS Thickness | Recommended Density | Application |
|---|---|---|---|---|
| Chiller / Fruit Room | +2°C to +10°C | 75mm (3") | 20 kg/m³ | Vegetable storage, flower cold rooms, dairy |
| Meat Cold Room | 0°C to +2°C | 100mm (4") | 20–25 kg/m³ | Butcher shops, meat processing, restaurants |
| Standard Freezer Room | -5°C to -18°C | 125mm (5") | 25 kg/m³ | Food processing, poultry freezers, ice cream |
| Deep Freeze Storage | -18°C to -25°C | 150mm (6") | 25–30 kg/m³ | Frozen food warehouses, fish storage |
| Blast Freezer | -25°C to -40°C | 200mm+ (8"+) | 30 kg/m³ | Rapid freezing facilities, ice factories |
| Pharmaceutical Cold Room | +2°C to +8°C | 100mm (4") | 25 kg/m³ | Vaccine storage, medicine distribution |
Important: These are minimum baseline recommendations for Pakistan's climate. Your refrigeration engineer should verify final thermopore block insulation specifications based on the actual ambient temperatures at your site, room volume, door frequency, and cooling equipment capacity. We recommend always adding 25mm to the minimum for critical applications.
Thermopore Blocks Custom Cutting — Your Dimensions, Our Factory
You should not have to cut thermopore blocks yourself on site. It is time-consuming, creates waste, and the results are rarely as dimensionally precise as factory cutting. Our custom cutting service delivers EPS blocks pre-cut to your exact specifications — ready to install or use immediately on arrival.
Share Your Specifications
Tell us the required thickness, width, length, and any special cuts — beveled edges, channel cuts for pipe accommodation, chamfers for joint design, or cavity cuts for packaging molds. Technical drawings are helpful but a clear description or a photo of your requirement is usually sufficient to begin.
We Recommend Density Grade
Based on your application — cold storage panel, exterior wall, packaging mold, stage prop — we recommend the appropriate density grade for your thermopore blocks. Getting this right the first time saves you money and ensures the material performs as expected. We will flag if a specification seems under-specified for its intended use.
Quote & Confirm
We send a price and lead time the same business day. Custom cuts are priced by volume of material plus a small cutting charge. For recurring orders in the same specification, we set up a standard order profile so subsequent orders process faster with one call.
Cut, Check & Dispatch
Blocks are cut using precision equipment calibrated to your specified dimensions. Each cut piece is checked against the specification before packaging. Dimensional accuracy means less adjustment on site and no wasted pieces from mis-cut material. Completed order is dispatched to your location across Pakistan.
Typical cut lead time: Simple flat cuts (any thickness) — 1 business day. Complex shapes with angles and channels — 2–3 business days. For large construction projects, plan thermopore block orders 5–7 days ahead to ensure delivery matches your installation schedule.
Request a Custom Cut Quote
Share your dimensions, density requirement, and quantity. We price and confirm the same working day.
📞 +92 328 8304 655 info@ikthermopore.comSix Reasons Businesses Choose IK Thermopore Blocks in Pakistan
EPS thermopore blocks from different suppliers vary more than most buyers realize. Here is what distinguishes ours — and why quality-conscious buyers specify IK Thermopore.
Consistent Density Across Every Block
Inconsistent density is the most common quality failure in EPS blocks — the surface reads the right density but the interior is softer. In cold storage panels, this creates hot spots. In packaging molds, it creates inconsistent protection. We test density from block core samples across every production run, not just surface measurements.
Complete Dimensional Freedom
Thermopore blocks can be cut to any thickness, width, and length — including non-standard dimensions that no pre-cut sheet product covers. Complex shapes with multiple angles, channel cuts for pipe accommodation, and internal cavities for packaging molds are all within our cutting capability.
Moisture-Resistant for Life
Thermocol blocks do not absorb water even in wet construction environments, cold storage humidity, or underground applications. A cold room's insulation maintains its full thermal performance for decades without moisture degradation — unlike mineral wool which can absorb water and lose up to 50% of its insulation value when wet.
Most Economical Per Unit of Insulation
Thermopore blocks provide the lowest cost per unit of thermal resistance (R-value) among rigid insulation materials available in Pakistan. For large-scale cold storage or commercial insulation projects where volume is significant, the cost difference versus polyurethane or XPS insulation is substantial on the total project budget.
Lightweight — Even at High Density
A 25 kg/m³ EPS block measuring 1m × 0.5m × 0.5m weighs just 6.25 kg. For construction sites where materials must be lifted manually or moved through congested spaces, this weight advantage is operationally significant. Large cold room panels can be installed by two workers without mechanical lifting equipment.
Factory-Direct With Same-Day Quotes
We manufacture our own thermopore blocks — no middleman adds their margin between our factory and your project. Quotes are provided the same business day. For large recurring orders from panel manufacturers and construction companies, we maintain dedicated supply arrangements with priority production scheduling.
Who Buys Thermopore Blocks from IK Thermopore?
From cold storage builders to stage designers — our EPS thermopore blocks serve professional buyers across Pakistan's most demanding sectors.
Thermopore Blocks Price in Pakistan — Nationwide Supply
Thermopore blocks are priced per cubic meter. Density grade is the primary price factor — higher density contains more raw material and costs proportionally more. Custom cutting adds a modest processing charge. Large volume orders receive factory-direct rates.
EPS block pricing is quoted per cubic meter based on density and volume. 16 kg/m³ standard thermopore blocks are the most economical. 25–30 kg/m³ industrial blocks cost more due to higher raw material content. Bulk project orders — construction, cold storage, panel manufacturing — receive the best rates. Call with your density, approximate volume, and delivery location for a same-day written quote.
Frequently Asked Questions About Thermopore Blocks in Pakistan
Questions construction companies, cold storage builders, and packaging manufacturers ask us most often before placing their first thermopore block order.
Have a Project-Specific Question?
Call our team directly — we advise on density, thickness, cutting specifications, and pricing for any thermopore block order.
📞 +92 328 8304 655 info@ikthermopore.comMore EPS Products from IK Thermopore — Pair with Thermopore Blocks
Ready to Order Thermopore Blocks?
Share your required density, dimensions, approximate volume, and delivery location. We send factory-direct pricing with lead time confirmation the same business day. Custom cutting available with every thermopore block order.