C-Max FPG3 Floor Panel 150mm

CEMEX Holdings Limited: C-Max EPS FPG3 Floor Panel 150mm thick

The C-MAX FPG3 Floor Panel 150mm is a prefabricated expanded polystyrene (EPS) panel engineered for floor and roof slab construction where higher load distribution is required. Part of the M2 Emmedue Advanced Building System manufactured locally in Kenya by CEMEX Holdings Limited, the FPG3 features a tighter 400mm centre-to-centre rib spacing compared to the FPG2’s 600mm, increasing the number of reinforced concrete joists per panel width for enhanced structural capacity across longer or heavier-loaded spans. The panel consists of a shaped EPS core enclosed in dual layers of galvanised steel wire mesh, with concrete cast on site to form a composite slab. This construction method achieves approximately 60% less CO2 during construction compared to conventional framed reinforced concrete, while delivering integrated thermal and acoustic insulation.

Technical Specifications

• Panel type: EPS floor/roof slab panel (FPG3 variant, 400mm rib spacing)
• Panel thickness: 150mm (overall thickness varies per structural engineer’s specification)
• Standard panel size (L x W): 3m x 1.2m
• Centre-to-centre rib spacing: 400mm (closer spacing than FPG2 for greater load distribution)
• Polystyrene core density: 15 kg/m3
• Steel wire mesh: Galvanised, 2.5mm diameter longitudinal wires at 75mm centres, 2.5mm diameter transversal wires at 112.5mm centres
• Cross steel wire/joint wire diameter: 3.0mm
• Minimum steel wire yield: 600 N/mm2
• Minimum steel wire fracture: 680 N/mm2
• Shotcrete application: Two layers applied by spraying equipment at 4 to 6 bars pressure
• Minimum shotcrete compressive strength: 25 MPa at 28 days (cement-sand mix ratio 1:4 by volume)
• Reinforcement meshes: Angular (RG1) for wall/ceiling intersections, Flat (RG2) for openings and mesh discontinuities, U-shaped (RG3) for parapets and openings
• Certifications: Passive House, KEBS (Kenya Bureau of Standards)

Sustainability Features

• Achieves approximately 60% reduction in CO2 production during construction compared to conventional reinforced concrete framing
• EPS core provides integrated thermal insulation, reducing operational energy demand for heating and cooling
• Lightweight prefabricated system minimises material consumption and on-site construction waste
• Closer rib spacing optimises structural performance, allowing thinner overall slab depths for equivalent loads and reducing total concrete volume
• Locally manufactured in Ruiru, Kenya, reducing transportation emissions and supporting the local construction supply chain
• Galvanised steel mesh and EPS components are recyclable at end of life
• Panel-to-panel connection system creates monolithic structural behaviour, extending building lifespan and reducing long-term maintenance