www.crl.issres.net Vol. 4 (3) – Sept.

2013

Modification of EMMEDUE M2 Building System

Saeed A. Alsheikh1
1
Civil Department, Faculty of Engineering
Modern University, EGYPT
Received: 05/06/2013 – Revised 15/07/2013 – Accepted 20/08/2013

Abstract

Structural Insulated Panel Building Systems are one of the newest building systems
available in today’s building materials market. Despite of its limitation of having wide span
openings it is considered to be the easiest way to construct economic house units [1],[2].
The Emmedue M2 Building System consists of two types: floor panel and wall panel. The
use of EMMEDUE panels allows the construction of less energy-greedy buildings, ensuring
higher energy efficiency and thereby energy savings up to 80% throughout its life cycle [3].
This paper compares between three wall bearing systems and three slab systems showing
their fulfillment to mechanical requirements in the Egyptian Specifications [4][5].

Keywords: Emmedue M2; Panel; Polystyrene; Wall bearing.

1. Introduction
Panellized construction is a method of structured construction in which the building is subdivided
into basic planar elements that are typically constructed under some form of mass production and then
shipped directly to the construction site and assembled to form the finish structure[6]. The Emmedue is
a building system that combines in a single element all the functions needed to create a complete
architectural system ensuring maximum efficiency with all types of construction as: speed installation,
lightness, thermal insulation, earthquake resistance, fire resistance, and blast resistance [7]. The
Emmedue M2 Building System composed of polystyrene board imbedded in concrete composite with
prefabricated zinc coated steel wire mesh reinforcement; this system consists of two types, single
panel, and double panel. Both wall panel types have 2.5 mm diameter zinc coated steel wire mesh
reinforcement at 65mm centres on each face [8].The Emmedue M2 single panel is designed for use in
the construction of two to six storey buildings of all purpose groups [9],[10].

2. Literature review

For over 30 years Emmedue has been the market leader in manufacturing and marketing of
innovative seismic resistant and thermally-insulating building systems. This system has been developed
from previous experiences, carried out in both of the construction and engineering fields. Emmedue
research and development activities aim to continuously improve the products, ensuring the highest
reliability standards. For this reason, Emmedue submits its products to continuous laboratory tests

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(static, dynamic, ballistic, fire resistance, wind tests, etc.) carried out at the most renowned
international laboratories, thus obtaining relevant certifications and approvals. Building constructed
using the Emmedue M2 building system shall be certified by a competent, chartered civil or structural
engineer, with experience in design of buildings and structures incorporating the Emmedue M2 system
as being in accordance with part A of the building regulations 1997 to 2002.
Buildings consume large amounts of energy and the greatest wastes arise from heating and
cooling them. Energy saving is the answer to reduce rising energy costs and CO2 emissions. A good
thermal insulation can halve the energy consumption and the pollution caused by heating and/or
cooling buildings.
The use of EMMEDUE panels allows the construction of less energy-greedy buildings, ensuring
higher energy efficiency and thereby energy savings up to 80% throughout its life cycle. EMMEDUE
offers a complete range of building elements: load bearing walls, floors, roofing, stairs, partitions and
curtain walls. Therefore buildings can be entirely constructed with the same building system,
optimizing different supply and timing phases as well as work force availability.
Numerous laboratory tests carried out in several countries have shown the high load resistance of
the EMMEDUE panels. For example, compression tests with a centred load carried out on a finished
single panel, 270 cm high, have shown a maximum load up to 156 ton/m. The loads to be taken into
account at design stage should be determined in accordance with part A of the building Regulations
1997 to 2002.The Emmedue M2 Building System provides a robust system that has a high resistance to
hard and soft body impacts likely to be associated with normal use situations. The rendered wall is
acceptable for all normal situations. This includes Category B in Table 2 of BS 8200:1985. Category A
involves external walls of houses and public buildings in vandal prone areas - prone to vandalism and
abnormally rough use and some image could be expected to occur to the rendering in this type of
location. The earthquakes are natural calamity, but unsafe buildings are not.
The basic element of the EMMEDUE building system is a modular non prefabricated panel,
made up of two electro-welded steel wire meshes, linked each other by connectors, sandwiching a
polystyrene foam slab suitably shaped. Produced on an industrial scale the panel is then assembled and
cast-in-place using shotcrete. The monolithic joints of the EMMEDUE building system are suitable to
give constructions high structural strength. Laboratory tests carried out on full-scale prototype houses
have shown that the EMMEDUE structures with stand, without damage, earthquakes with intensities
much greater than those considered by current regulations. In fact, during laboratory tests on full-scale
prototypes, natural and artificial accelerograms were simulated up to peaks of more than 1.0 g, and no
damage was detected.
The results obtained during these tests scientifically confirm what has already happened and
often experienced in nature. In fact the structures built with EMMEDUE panels are extremely light, so
with a reduced seismic mass, but are also rigid, thanks to two sheets of reinforced piaster that interact
with each other creating a box-like behaviour of the entire structure.

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3. Experimental investigation
3.1 Properties of materials
3.1.1 Ordinary Portland cement (O.P.C)
Ordinary Portland cement (CEM I 42.5N) was used. Its typical physical properties and
chemical analysis are shown in Table 1. The cement contents were 350, 450 kg/m3.

TABLE 1: PROPERTIES OF USED PORTLAND CEMENT.

Description Value
Physical Properties:
1- Specific gravity 3.15
2- Fineness passing 90 μm% 93%
3- Surface area cm2/gm 3187
Chemical Analysis:
1- Lime Calcium Oxide (CaO) 60 : 67 %
2- Silicon Dioxide (SiO2) 17 : 25 %
3- Aluminium Oxide (Al2O3) 3.0 : 8.0 %
4- Calcium Sulphate (CaSO4) 0.50 : 6.0 %
5- Magnesium Oxide (MgO) 0.10 : 4.0 %
6- Sulphur trioxide (SO3) 2.75 %
7- Alkalis 0.40 : 1.25 %
8- Loss in ignition % 3%
Compressive Strength (Cubes)
1- Age 2 days MPa 19.1
2- Age 7 days MPa 32.4
3- Age 28 days MPa 43.7

3.1.2 Fine Aggregates

Natural sand with medium size was used as a fine aggregate. Its physical properties
were tested as specific gravity of 2.65 t/m3, fineness modulus of 3.65, absorption of 1%, unit
weight of 1.68 t/m3, and voids ratio 31.7%. Sieve analysis had been conducted which its results
are shown in Table 2.
TABLE 2: SIEVE ANALYSIS OF SAND
Sieve Size (mm) 40 20 10 5 2.5 1.25 0.61 0.31 0.15
% Passing 100 100 100 90 70 50 20 5 0

3.1.3 Coarse Aggregates

Two types of coarse aggregates are used: gravel and dolomite.
3.1.3.1 Gravel
Gravel of 7.5 mm maximum size was used. Its physical properties were tested as
specific gravity of 2.69 t/m3; fineness modulus 5.78, absorption 0.5%, the surface area of 2.31
cm2/gm, and crushing factor is equal to 17.78 %. Sieve analysis had been conducted which its
results are shown in Table 3.
TABLE 3: SIEVE ANALYSIS OF GRAVEL
Sieve Size (mm) 40 20 10 5 2.5 1.25 0.61 0.31 0.15
% Passing 98 94 92 38 0 0 0 0 0

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3.1.3.2 Dolomite
Dolomite of 15 mm maximum size was used. Its physical properties were tested as
specific gravity of 2.72 t/m3, fineness modulus of 6.66, absorption 1%, the surface area of 2.06
cm2/gm, and crushing factor is equal to 12.50 %. Sieve analysis had been conducted which its
results are shown in Table 4.
TABLE 4: SIEVE ANALYSIS OF DOLOMITE
Sieve Size (mm) 40 20 10 5 2.5 1.25 0.61 0.31 0.15
% Passing 99 95 35 5 0 0 0 0 0

3.1.4 Components of the Emmedue Panels

3.1.4.1 Foam Polystyrene Core
The used polystyrene is extra high density of 23 kg/m3 which is used for delicate items
or where the weight of the object requires a more robust material. Its compressive strength at
10% deformation is 150 kPa, and thermal conductivity is 0.035 W/mK. The polystyrene
insulation is manufactured to comply with the requirements of BS EN13163:2001 [11].

3.1.4.2 Steel wire meshes

The used steel wire meshes are made of galvanized steel wires placed on both sides of
the polystyrene panel and connected by means of joints of the same material. The steel wire
meshes are manufactured to comply with specification as follows [3]:
 Longitudinal and Transversal steel wires size is 2.5mm diameter
 Joint steel wire size is 3.0mm diameter
 Steel wire yield > 600 MPa, Steel wire fracture > 680 MPa.

3.2 Mixing procedure and moulding

The coarse and fine aggregates were initially fed into the concrete mixer, and then
Portland cement and 3/4 of water were poured into the mixer. While the mixer was operated,
the remaining water was added as necessary. The mixing time was 5.0 minutes started from the
time when all the mixed materials had been charged into the mixer.
The Emmedue panels were installed and aligned in accordance with the plans; panels
were anchored to foundation at ground level with dowel bars. The panels were equipped on
both sides with steel wire mesh, and then panels were cast by concrete mix with cover 3.5 cm
on subsequent layers.
Three wall and slab panels with dimensions of 120×100×15 cm, the panels were cast in
two layers. After casting, all the moulded specimens were covered with plastic sheets and were
left in the casting room for 24 hours at 25oC and 75 % R.H. Afterwards, they were de-moulded
and transferred to the moist curing room at 100% relative humidity until required for testing.

3.3 Concrete mixtures

An experimental program was undertaken to obtain mechanical properties for wall and
slab panels. Three mixes were made in this paper for wall and slab. For all mixtures, the graded
coarse and fine aggregates were weighted in room dry condition, the coarse aggregate was then
immersed in water for 24 hours, the excess water was decanted and the water retained by the
aggregates was determined by the mass difference. A predetermined amount of water was
added to the fine aggregate that was then allowed to stand for 24 hours. The water to cement

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ratios were 50%, 55% and 50%, coarse aggregate content (gravel and dolomite) varies between
1150 to 1275 kg/m3 with 7.5 to 15 mm, fine aggregate content (natural sand) varies between
637 to 770 kg/m3, tap water has been used for mixing and curing, tap water that used in all of
the tests was clean drinking fresh water from impurities. Portland cement was used; the quantity
of cement was 350, 450 and 350 kg /m3 respectively. The mixture proportions of the mixtures
are as shown in Table 5.

Fig. 1: sketch of specimen

TABLE 5: THE MIX PROPORTION OF SPECIMENS

Mix No. M0 M1 M2
Cement (kg/m3) 350 450 350
Fine Aggregate (kg/m3) 637 770 637
Gravel (kg/m3) === === 1274
Coarse Aggregate
Dolomite (kg/m3) 1275 1150 ===
Water (lit) 175 247.5 175
Polystyrene Dimensions (cm) 115×100×4 115×100×8 115×100×8

3.4 Test method

At the age of 28 days, all wall panels (sketch of specimen is shown in Fig. 1) were
conducted to axial compression test as shown in Fig. (2a, 2b), whereas, all slab panels were
conducted to flexural test in mid span as shown in Fig (3a, 3b).

Fig. 2a: Test of Wall Panel Fig. 2b: Cracks of Wall Panel

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 Fig. 3a: Test of Slab Panel Fig. 1b: Cracks of Slab Panel

4. Results and discussion

All wall panels had been conducted to compressive test, and all slab panels had been conducted
to flexural test at hardened state. Table 6 provides an overview of the results. Figures (4 to13) show the
different results for each mix under tests.

TABLE 6: TESTS RESULTS

Panel Parameters M0 M1 M2
Slab Panel Load (KN) 23.82 35.8 42.0
Max Stress (kg/cm2) 15.88 24.00 28.14
Deflection (mm) 18.38 25.8 34.8
Wall Panel Load (KN) 476.3 588.6 382.1
Max Stress (kg/cm2) 22.68 28.03 15.64
Lateral Deflection (mm) 4.2 5.8 5.7

Fig. 4: Load- deflection of Slab Panel at mid span for M0

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 Fig. 5: Vertical load - lateral deflection of Wall Panel at mid height for M0

50
45
40
35
30
Load (kN)

25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55
Deflection (mm)

Fig. 6: Load- deflection of Slab Panel at mid span for M1

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 700

600

500
Load (kN)

400

300

200

100

0
0 1 2 3 4 5 6
lateral Deflection at Mid Height (mm)

Fig. 7: Vertical load - lateral deflection of Wall Panel at mid height for M1

50
45
40
35
30
Load (kN)

25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55
Deflection (mm)

Fig. 8: Load- deflection of Slab Panel at mid span for M2

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 700

600

500
Load (kN)

400

300

200

100

0
0 1 2 3 4 5 6
lateral Deflection at Mid Height (m m )

Fig. 9: Vertical load - lateral deflection of Wall Panel at mid height for M2

700

600 588.6

500 476.3
Total Load (KN)

400 382.1

300

200

100

0
M0 M1 M2
Mix. No.

Fig. 10: Total Load of Wall Panel for all mixes

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 30
28.029

25

22.68

20
Deflection (mm)

15.639
15

10

0
M0 M1 M2
Mix. No.

Fig. 11: Maximum Stress of Wall Panel for all mixes

45
42

40

35.8
35

30 28.82
Total Load (KN)

25

20

15

10

0
M0 M1 M2
Mix. No.

Fig. 12: Total Load of Slab Panel for all mixes

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 40

34.8
35

30

25.8
25
Deflection (mm)

20
18.384

15

10

0
M0 M1 M2
Mix. No.

Fig. 13: Deflection of Slab Panel for all mixes

5. Conclusions and recommendations

From the results of the tests, it is obvious that:
For Wall Panels:
The maximum load increased by 7.21% for using (M1), and decreased by 30.41% for using (M2)
For Slab Panels:
The failure load increased by 50.23% for using (M1), and increased by 76.23% for using (M2)
The Deflection increased by 36.94% for using (M1), and increased by 84.71% for using (M2).

Recommendations:
1 – In the future using of this system (M2 Building System) in the implementation of the buildings,
it is recommend of using a mixture (M1) in the implementation of the wall panels and the
mixture (M2) in the implementation of the slab panels and stairs
2 - Revisit steps of structural design of this system (M2 Building System) to suit the stresses and
loads that tested this research to increasing the number of floors (vertical expansion,
increasing the area of buildings (horizontal expansion) and the addition of new varieties of
buildings could be implemented this system (expansion Specific)
3 - Complete research in further to the original for this sector system (M2 Building System) to
improve performance and get the benefits of increasingly noting the need to examine the
impact of these systems on the cost of facilities and duration of implementation.

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References

[1] A.El-alfy, A.Shalaby, A Comparative Study between Wall Bearing Steel Reinforced Expanded
Polystyrene Composite Wall System and Insulated Concrete Forms, (2011).
[2] Yehia A. M., Sherif. E. Z., Osama. A. S., Tayseer K. M., and Eslam M., Test Results Report on
Innovida Sandwich Panels, Test report made on Concrete Construction Test Laboratory CCTL
on Housing and Building National Research Center HBRC, Egypt October 2008.
[3] Alberto A., Antonio B., Emanuela S., Static Tests of the Emmedue Construction System, Tests
made on Research and Technology Laboratory of Perugia University, September 2000.
[4] ECP 203-2007 “Egyptian Code of Practice for reinforced concrete structures” (2007)
[5] ESS “The Egyptian Standard Specification” (2009)
[6] J. M. Davis, Lightweight Sandwich Construction, University of Manchester, U. K., 2001.
[7] Oscar M. Ramirez, Jose G., Jose S., Eduardo G., Experimental Tests on M2 Panel System, Tests
made on Panama Technology University, September 2003.
[8] M.G. Megahed, Behavior of sandwich wire mesh concrete slabs, thesis for Master degree, Cairo
University, 2009
[9] A. Benayoune, A.A.A Samad., A.A. Abang Ali, D.N. Trikha, Response of Precast Reinforced
Composite Sandwich Panels To Axial Loading, Journal of Construction and Building Materials
(2005).
[10] H. Shaheen, Y. M. Hussein and E. Fouad, Seismic Behavior of 3-D Wall Panel System, Housing
and Building National Research Center HBRC, Egypt 2007.
[11] BS EN 13163: 2001, the European Standard for EPS Thermal Insulation products for the
construction industry.

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