Processes for preparing foam composites

A process for preparing a polystyrene foam composite comprising the steps of:

• a) forming a mixture of expandable thermoplastic microspheres, reactive phenolic resole resin and expandable polystyrene particles in the presence of an acidic catalyst;
• b) conditioning the mixture to partially cure the reactive phenolic resole resin, wherein the conditioned mixture has a water content of less than 10% by weight based on the total weight of the conditioned mixture and water;
• and
• c) further curing the conditioned mixture by contacting with steam to form the composite.