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Introduction

At KARRU Built, we pride ourselves on building homes that are not only stronger and more sustainable, but also delivered faster and more affordably than traditional construction. The secret? Our EPS (Expanded Polystyrene) Cement Panel System—a modern solution that revolutionizes how buildings are designed, engineered, and constructed.

In this blog post, we take you through the entire journey of building with EPS panels—from the first sketch to the final handover—so you can understand exactly what goes into delivering the homes of the future, today.

Step 1: Architectural Design and Planning

Every project starts with a vision. Our architectural team works closely with clients to turn ideas into functional, aesthetically pleasing designs. We customize the layout, roof lines, elevation treatments, and energy-efficiency elements according to the client’s preferences and site conditions.

The design phase includes:

  • Site evaluation and environmental considerations
  • Floor plan development
  • Façade design and 3D rendering
  • Energy and thermal performance planning

EPS panels are incorporated into the design from the very beginning, allowing for optimal structural alignment and thermal efficiency.

Step 2: Structural Engineering

Next, our in-house structural engineers tailor a high-performance framing system that integrates seamlessly with the EPS panels. Unlike traditional bricks or timber framing, EPS cement panels require precise detailing to ensure strength and seismic compliance.

This step involves:

  • Load calculations and wind analysis
  • Steel framing integration (lightweight or structural steel)
  • Foundation design (typically a reinforced concrete slab)
  • Panel layout mapping and joint treatment details

All structural elements are designed to align with both Australian Standards and local building regulations.

Step 3: Prefabrication of Materials

While on-site preparation begins, our panel systems are manufactured and cut to size in a controlled factory environment. EPS panels are formed by sandwiching high-density polystyrene between two layers of reinforced cement board.

Advantages of prefabrication include:

  • Minimal on-site waste
  • High consistency and quality control
  • Faster assembly and delivery
  • Less dependence on unpredictable weather

Our panels come with embedded conduits for electrical and plumbing routing, reducing installation time further.

Step 4: Site Preparation and Foundation Work

While materials are being fabricated, the site is prepared for construction. This includes earthworks, grading, and laying the concrete slab foundation.

Key tasks include:

  • Surveying and pegging
  • Excavation and leveling
  • Footings and slab pour
  • Waterproofing and curing

Our team ensures a perfectly level base, which is essential for efficient EPS panel installation and structural stability.

Step 5: Panel Installation

Now the real transformation begins. The EPS panels are transported to the site and installed onto the steel framing system, forming the structural envelope of the home.

Installation includes:

  • Wall and roof panel erection
  • Joint sealing with construction-grade adhesives
  • Window and door openings pre-cut for easy placement
  • Integration of electrical and plumbing systems within the panels

Because of their light weight, panels are installed faster and more safely than bricks or blocks. An entire structure can be erected in a matter of days.

Step 6: Finishing and Cladding

Once the building envelope is complete, we move on to the finishes. EPS panel systems are versatile—they can be rendered, cladded, or finished in any architectural style, from ultra-modern to traditional.

Typical finishes include:

  • Cement render and paint
  • Timber, stone, or composite cladding
  • Roofing membrane or tile overlays
  • Internal plastering or direct paint on panel face

EPS panels offer outstanding thermal insulation and acoustic performance, improving comfort and reducing long-term energy costs.

Step 7: Final Inspections and Handover

With all systems installed and finishes completed, we conduct a thorough quality assurance process. This includes structural, electrical, and plumbing inspections, as well as final client walkthroughs.

Deliverables include:

  • Final occupancy permits
  • Energy rating certifications
  • Warranty documentation
  • Maintenance and care guide

Clients receive a completed home that is stronger, smarter, and greener—delivered on time and on budget.

Conclusion

EPS cement panel construction isn’t just a trend—it’s the future of sustainable, high-performance building. At KARRU Built, we’ve streamlined the entire process from design to build to make homebuilding faster, more efficient, and environmentally conscious.

Want to see what your future home could look like? Visit our website at www.karrubuilt.com to explore our gallery, watch real-time builds, and learn more about how EPS panels are redefining construction.