• Euromac 2 - The Walls
  
  

  How does it work? Euromac 2 is an insulated concrete formwork (ICF). The basic principle behind all ICF’s is the same. A Euromac 2 block consists of two leaves of EPS (expanded polystyrene) connected by means of a fixed metal tie creating a cavity between. Moulded castellation on the top and bottom of the block allows each block to interlock firmly with the row above and below the bonds are staggered at each course at no less then 250mm. The blocks are marked at 50mm increments which simplifies cutting and speeds up the construction process. To stabilise the walls during construction metal frames called trestles are bolted to the slab or floor and temporarily fixed to the walls to ensure they remain straight and plumb.

  
  
  

  Once the walls are complete ready mixed concrete is poured into the walls by means of a concrete boom pump. The primary function of the Euromac 2 block is to act as a shuttering which will contain the concrete until it has cured. Once the concrete has cured its primary function has been for filed and EPS remains in situ as insulation for the building.
  
  
  
  Five thicknesses of block are available; always installing the thicker insulation leaf on the exterior of the building. Because the concrete load bearing core is sandwiched between two layers of insulation it acts as a thermal mass storing heat energy, insulating the building more efficiently then timber framed or cavity
  wall construction. 
  
  Typically only three component parts are needed to construct a simple
  building design:-
  
  1. Select the wall block that suits your requirements
  2. End stops (B16) to form the corners and close off window and door openings
  3. Lintel formers (FL16) to close off door and window heads.
  
  
  By reducing the number of component parts needed to build the walls, waste
  is drastically reduced and installation is quicker and easier.
  
  

  Sometimes variations on the standard wall blocks are required to overcome design problems or incorporate architectural features. Euromac 2 offer over 25 different components and block variations which can be assembled in an infinite number of ways. Euromac 2 have a block solution for every situation from super energy efficient blocks with a U-Value of 0.117 W/sq.mK to articulating blocks for curved walls of any radius and angles from 0-180 degrees.

  
  The steel ladder frame within the blocks makes them extremely strong allowing up to 4 meters of vertical wall to be poured in a single day. Typically the walls are completed and poured floor by floor but most single story building such as bungalows and garages and including first floor walls with gable ends can be poured in one day. The additional strength and pour height that Euromac 2 offers is a considerable benefit over other ICF systems.
  
  Most walls above ground need no additional steel reinforcement except in lintels over door and window openings where normally a single 20mm high yield bar is sufficient, larger openings over 2m may require more reinforcement.
  
  Because of the versatility of concrete it can be moulded to any shape or form and can easily be altered to cope with larger stresses or loads or reinforced with steels or used underground and over large openings or spans in place steel beams.

  
  The concrete used for the wall construction is standard unless site conditions require a stronger mix. C25 pump mix with 10mm aggregate at a slum of 80mm-120mm is the preferred specification. Depending on the slump and if the concrete is vibrated, once cured the concrete core will be around 21N in strength.

  
  The Euromac 2 walls combine a solid concrete core with dense EPS insulation giving it considerable advantages over other structures:
  
  Extremely strong, can be four times stronger then a cavity wall
  Thermal mass within the Euromac 2 blocks  
  U Values from 0.3 to 0.117 W/sq.mK
  Total suppression of cold bridges
  Rooms can be warmed up quickly, resulting in even lower heating costs.
  Sound Insulation
  Improved air tightness
  Flexibility in design
  Proven technology long lasting and low maintenance
  Can be erected in all weathers
  EPS is water repellent and rot-proof
  
  Energy efficiency & Air tightness
  The insulating characteristics of a Euromac 2 building are non-discriminatory allowing the building to be cool and remain cool in summer and warm in winter.

  The EPS formwork is a poor conductor of heat/cold energy. Heat energy is trapped within the concrete core of the building creating a thermal mass which retains heat and remains relatively constant fluctuating slightly with the change of seasons.

  Euromac 2 has developed a range of wall blocks achieving U-values from
  0.30 to 0.117 W/sq.mK. Owing to the governments commitment to lowering
  our energy consumption the minimum requirements for U-vales on new homes
  is set to increase. Euromac 2 can easily cope with this rise by just increasing
  the thickness of insulation at very little extra cost. It cost the same amount
  in labour and for concrete to install a 0.30W/sq.mK block as it does to install
  a 0.117W/sq.mK block.
  
  
  

  Depending on the choice of wall block the running costs of a Euromac 2 building can be 50-80% better than a conventional build.

  The energy efficiency of a building is now more relevant then ever; with the introduction of SAP ratings and HIPs packs when buying or selling a property.
  However what is frequently overlooked is the air tightness and pressure testing of buildings. Getting a building air tight is just as important as getting enough insulation in it. A building with vast quantities of insulation will not perform as well as it might on paper if it is built badly with cracks voids and gaps which allow heat to escape and cold air to penetrate.

  By ensuring a building is airtight you can significantly reduce:
  
  Draughts
  Heat loss
  External sound levels
  Energy consumption
  Running costs
  
  Euromac 2 is ideal when it comes to maintaining air tightness. Because Euromac 2 blocks fit tightly together and all the openings are securely closed off; when the concrete is poured into the walls a solid monolithic structure is created. As a result the number of joints between materials and air gaps is drastically reduced. The only possible leak joints on the walls are between the window and door frames and the junction of the roof, all of these areas which need sealing are easily visible and accessible allowing them to be sealed with ease.

  Building regulations require a pressure loss of no more then 10m3/hour, a Euromac 2 wall can easily achieve 2m3/hour or lower, a cavity wall or timber frame construction would struggle to achieve less then 6m3/hour. Where non ICF buildings are concerned the level of air tightness is directly linked to the quality of workmanship and quality of workmanship is largely dependent on time. If the building schedule and budget allows the air tightness of cavity wall or timber framed buildings may be improved but it is guaranteed with Euromac 2 without the additional costs.
  
  Minimum labour costs
  Labour is the largest percentage cost when constructing a building. Due to the lack of skilled tradespersons labour costs have risen considerably in the past decade, and are set to get higher.
  
  For self builders and developers keeping labour costs to a minimum is paramount. There are two options to cut labour costs, use more unskilled workers and do more work yourself or build  faster, Euromac 2 allows you to achieve both of these. The skill level required to construct in Euromac 2 is very low, this means workers can be trained quickly and there is less potential for error. Euromac 2 quick and easy to assemble, a team of three experienced installers can complete on average 4-5 m2/hour.

  With only a few days training a competent person could construct the shell of a building in a matter of days, without the need for any other skilled labour.  We provide full training and product support for all our products and can supply all the equipment and ancillaries need to complete the shell build.
  
  External Finishes:

  Render:
  There are many types of specialist renders on the market today with most manufactures having developed base coats specifically for use on EPS substrates. Most systems are through coloured and so are more robust resisting weathering and eliminating the need for decoration.

  Brick skin:
  If the L100K corbel module is used a brick or stone skin can be build abutting the Euromac 2 façade. Brick ties are inserted through the outer leaf of EPS prior to the concrete pour, once filled with concrete the ties are bonded solid providing a suitable anchor to tie in the external brick or stone wall

  Brick slips:
  If it is not practical to build a brick skin onto the façade of the Euromac 2 brick like tiles called slips can be used. They are adhered to the surface of the Euromac 2 with a specialist adhesive and the joints pointed in tater with mortar.

  Weatherboarding:
  Battens can be mechanically fixed onto the façade of the Euromac 2 walls to take hung slate or weatherboarding. Cement composite boards such as Marley Eternite are ideal as they are low maintenance and long lasting.

  
  Internal finishing:

  Plaster boarding:
  Plasterboard can be “dot & dabbed” directly to the Euromac 2 walls and the joints can be taped and filled or the boards skimmed. All other internal finishing are carried out as usual with the exception that longer fixings may be required to hang radiators or other heavy items.

  Tiled areas:
  Bathrooms can be “dot & dabbed” as with other walls or alternatively ply or tile backer board can be mechanically fixed to the Euromac 2 walls ready for tiling over. This may also be done in kitchens where wall mounted cupboards may be hung or tiling installed.

  Please note solvent based adhesives cannot be used as they adversely affect
  the EPS.

  
  
  

This document has more technical information regarding the Euromac 2 Wall system