Modular Building Blocks

Modular Building Blocks

polyurethane foam building block
Polyurethane foam building block

This picture shows a polyurethane foam building block that measures 8-feet-by-4-inches-by-4-inches. The Zipblock building system is based on cubes. The block in this picture is based on 4-inch-cubes. If you look closely you will see lines on the side of this block every 4-inches. The lines serve two main purposes. The lines allow to you determine the length of a block and they indicate where you can safely cut blocks into smaller lengths. When you cut a Zipblock into two sections there is no waste, you are only cutting a longer block into two smaller blocks(that are various lengths of 4-inch-cubes).

Because our system is based on cubes, it is extremely easy to create a manifest of supplies that are required for a project. Say for example that you wanted to build a 20-foot-long-by-10-foot-tall wall. Here is how easy it is to determine how many 8-foot long blocks you will need:

  • 10 feet x 20 feet = 200 square feet
  • 200 square-feet x 9 zipblock-cubes-per-square-foot = 1800 4-inch-cubes
  • 1800 4-inch-cubes / 24 cubes-per-8-foot-long-building-block = 75 8-feet-by-4-inches-by-4-inch-polyurethane-blocks

So, to build a 20-foot-long-by-10-foot-tall wall you would need 75 8-foot-long-building-blocks. But why waste your time using a bunch of blocks when you can use 8-feet-by-4-feet-by-4-inch-building-panels in place of some of the blocks? Here is how easy to figure out what you will need if you go this route:

  • You can build out the first 8-foot-high-by-20-foot-long section using 5 8-feet-by-4-feet-by-4-inch-polyurethane-building-panels
  • The remaining 2-foot-high-by-20-foot-long section covers 20-foot x 2-foot = 40 square-feet
  • 40 square-feet x 9 zipblock-cubes-per-square-foot = 360 4-inch-cubes
  • 360x 4-inch-cubes / 24 cubes-per-8-foot-long-building-block = 15 8-feet-by-4-inches-by-4-inch-polyurethane-blocks

So, as opposed to using 75 blocks to build a 8-foot-high-by-20-foot-long wall, you could just use 5 panels and 15 blocks!

More pictures, movies, and information about our blocks.

polyurethane foam building block
Polyurethane foam building block

This picture shows as small 16-inch-by-4-inch-by 4-inch Zipblock.

Larger blocks that measure up to 8-feet in length are available.

polyurethane foam building block
Polyurethane foam building block

This picture shows a 4-inch-by-4-inch-by-8-foot polyurethane building block.

To the left of the block is a six-foot measuring stick. This was placed in the picture to provide a sense of scale.

Shorter blocks can be created from long blocks like this. To create shorter blocks you simply cut the block at one of the lines that exists at four-inch intervals along the side of the block. A simple hand-saw or sharp knife is all that is required to cut these blocks.

When you cut a larger block into smaller blocks there is no waste, you are simply creating two complete smaller length blocks.

polyurethane foam block wall
Polyurethane foam block wall

This picture shows a corner section of a wall that was that was built using Zipblock interlocking polyurethane foam blocks. The simplicity of the Zipblocks system makes building walls an easy process.

Note: These blocks can easily be used to build single story structures. Three-pound foam is rated at around 50-lbs-per-square-inch. Five-pound foam is rated at around 100-lbs-per-square-inch. The blocks illustrated here were created using our second generation of molds (we have since moved on to a third generation of molds that produce higher quality parts) and their foam density is about five-pounds-per-cubic-foot. Once a desired wall height is reached, a steel plate is placed along the length of the topmost blocks (the lugs get cutoff before placing the steel plate), the plate is compressed downward with threaded rod that gets anchored into a cement foundation, and then you can drop roof trusses on top of the steel plate.