Euromac 2 floors work on the same principle as the wall system. They are steel reinforced EPS formwork designed to cast reinforced concrete floors where the EPS remains in situ after, acting as insulation.

How does it work?
The floor elements consist of two Z-shape steel re-enforcements (like that in the roof) running through the dense EPS. The reinforcements give the elements greater strength and provide fixing points for ceiling battens. The floor elements can be produced in any length and are manufactured to order minimising waste and excess materials on site. They are easily cut with a reciprocating saw if required.

The floor elements are symmetrical looking end on; this is because when placed side by side they form a repeating pattern of troughs and peaks. The troughs are referred to as beam channels and are what gives the floor its strength.

Typically the floor elements are orientated so that the spanning length is the shortest allowing for a thinner and more cost effective floor composition. The total floor thickness can vary from 260mm to 360mm depending on the clear floor span and the required load bearing capacity.

The floor elements are delivered to site cut to length and are lifted into position manually. Plastic nails are used to secure them to the inner leaf of the Euromac 2 walls and the joints between elements are taped. Steel reinforcement is inserted into the beam channels and held in position with chairs to ensure concrete cover all round, reinforcing mesh is laid over the panels on chairs to ensure good concrete cover. The elements are propped underneath with engineered beams and Acrow props.
L175/300 edge pieces are fitted to the perimeter of the floor to maintain the thermal envelope of the building and contain the concrete.

Concrete is pumped onto the floor and vibrated with a high frequency poker to ensure there are no voids and that the concrete is as dense as possible. The concrete can be finished by means of a hand tamp, roller striker or power float.

As an added benefit under floor heating can be installed directly to the Euromac 2 elements prior to the concrete pour. This offers a considerable saving reducing labour costs and negating additional insulation and screed. The floor thickness is also kept down allowing for additional ceiling heights.

The concrete must be allowed to cure for a minimum of four days before construction of the next level may commence, the props supporting the floor must remain in situ for a minimum of 28 days.

The Euromac 2 floor elements boast considerable advantages over block and bean or hollow core floors;

Suitable for domestic and commercial buildings, new or old.
Suitable for ground floors, intermediate floors and flat roofs
U Values from 0.33 to 0.24 W/sq.mK
Great heat retention within the thermal mass of the concrete
Total suppression of cold bridges
Improved air tightness
Excellent impact and ambient sound proofing properties
Flexibility in design
Proven technology long lasting and low maintenance
Can be erected in all weathers
EPS is water repellent and rot-proof.
Can be laid on ICF walls, cavity walls or solid block/brick
The elements are cut to length, no trimming on site
Can span eight meters plus
Under floor heating can be laid straight onto the Euromac 2 elements
Service ducts are already formed for easy plumbing and wiring.
12-14 sq.m of floor elements and steel are installed on average per hour
Is lightweight, can be laid without a need for cranes for heavy lifting machinery

Openings and features:

Stair wells:
Stair wells are easily formed by forming trimmer beams of reinforced concrete. Timber shuttering is used to form the opening and removed once the concrete has cured.

Balconies:
Euromac 2 floor elements are ideal for forming balcony’s. The dense concrete offers a robust and long-lasting structure while the EPS provides insulation. Euromac 2 can be used to form cantilevered balcony’s which appear to float unsupported projecting out of the building. Euromac 2 balcony’s can easily be waterproofed with cement slurry’s or epoxy resins.

Conduits/Pipes:
It may be necessary to insert conduits or pipes through the Euromac 2 floors. For best results this is done prior to the concrete pour.

Conduits and pipes should be fitted through the peak of the Euromac 2 elements at the thinnest point taking care not to obstruct or dissect the beam channel. Holes may be cored our retrospectively taking care to avoid the beam channels once more.

Floor finishings:
Depending on how the concrete was finished many floor finishing’s are suitable.

If a tamped finish was used the Euromac 2 can be levelled with self levelling compounds or screeds, cement or calcium sulphate screeds are suitable. An intermediate layer of insulation between screeds may be required if under floor heating was not incorporated into the Euromac 2 floor.
                                               
If a power float finish was achieved or the floor is suitably level timber flooring or carpet may be laid directly over. Tiles can be fixed directly to the concrete substrate; specialist flexible adhesives are recommended if under floor heating was installed. Some adhesives may require the substrate to be primed to aid adhesion.

Ceilings:
Typically battens are mechanically fixed to the underside of the Euromac 2 elements using self tapping screws. The battens run across the Euromac 2 elements at 90 degrees to the element span. The battens are fixed at 400 or 600 centres to take a layer of plasterboard. The joints can be taped and filled or the boards skimmed. It is also practical to mechanically fix plasterboard directly to the Euromac 2 with self tapping screws.