Mega Panel consists of reinforced zinc coated steel wire mesh electronically welded together onto an expanded
polystyrene (EPS) insulated core with steel wire truss that is pierced through the polystyrene. The polystyrene that
is sandwiched in between the wire steel mesh is both fire retardant and insulated. This panel is light weight yet has
the characteristics that make it a very strong and durable building material. It is faster to install yet stronger than
bricks and hollow blocks.
2. Where do you use a Mega panel as compared to bricks and hollow core?
Mega Panel can be used to replace both bricks and hollow core in building walls, floors and even roofs. The application
is the same but the installation is faster and cheaper. As it is light weight and can be easily formed, its uses
are limitless to the imagination of the designer.
3. What is the configuration of the boards?
Mega panels come in 2 basic dimensions – 2800mm X 1200mm and 3000mm X 1200mm. Our wire mesh is 2.5mm
in diameter with 3.0mm trusses for wall application and 3.5mm trusses for floor slabs. Custom dimensions are also
available on request.
4. What is the cost difference between Mega Panels and conventional materials?
When comparing conventional material like solid blocks to Mega Panel wall to wall per SQM, Solid Blocks is 30% to
35% cheaper than Mega Panels per SQM walling complete with plaster. Looking at the entire structure cost, Mega
Panel proves to be cost efficient due to its lightweight properties and faster construction time. For Double Storey
building, Mega Panel is 20% to 25% cost effective and for Ground Floor structures its 5% to 10% cost effective when
compared to conventional system. For high rise building, Mega Panel is cost effective when adapted as in fill walling
rather than Solid Blocks, it can obtain net savings of 10% on the overall structure cost due to savings on lighter
foundation as a result of reduced weight load.
5. How are doors & windows installed?
First create the openings for the doors and windows. Openings for doors and windows can be cut before or after
attaching the panels. To cut the openings, cut the wire mesh first with cutters followed by a handsaw to cut the
polystyrene or by using an angle grinder. Remove the cut wire mesh and polystyrene. Place a U wire mesh over the
newly cut openings and secure it with steel wires to reinforce the opening. Place a strip of wire mesh over the 4 corners
of the openings to prevent corner cracks. Install door and window frames as in the conventional method before
installing the doors and windows.
6. How do you install piping’s & electrical conduits?
Run the pipes and conduits between the spaces between the wire mesh and the polystyrene. Cut or remove only whatever is necessary. You can also use a butane torch to create a cavity on the polystyrene if the space is not enough. The heat will not burn through but will just melt the polystyrene. Another alternative for large pipes is after cutting ducts, they can be meshed over after the pipes are installed.
7. Can you hang heavy fittings into this wall?
Yes, using wall plugs. If you want to install heavy fittings, just use a bigger drill bit and create a bigger hole. Insert some ready mixed cement to protect the polystyrene inside and fix in the wall plug. Wait for the cement to set and dry and you are ready to fix your fittings.
8. Is it possible to make slabs through these panels?
Definitely. Mega Panels slabs are used for residential structures. Please request for Mega panels (Slab) when you order.
9. Is the polystyrene safe from fire, bugs, rats and fungi?
This panel has fire resistant characteristics well within the building requirements. It has a monolithic design, i.e. uninterrupted concrete "skin" inside and outside, therefore is termite and fungus proof.
10. Can the steel wire mesh corrode over the years?
Unlikely. Mega Panels only uses top grade zinc coated galvanized steel wire mesh. To ensure quality the mesh is produced in our factory in Tanzania with strict quality control. Also it is protected with a 1-inch layer of cement mortar mix.
11. Is Mega Panels water resistant?
Yes. The polystyrene core is water-resistant. The ASTM test proved maximum water absorption of 2.5% for 1 lb density.
12. Is this good for construction in remote areas?
The panel is lightweight and is easy to transport. With few construction elements, this allows for semi-skilled labour to install thereby reducing site costs considerably, making it ideal for construction work in remote areas.
13. Can I mix Mega Panels with conventional blocks?
Yes, conventional blocks can be added onto Mega Panels wall and vise-versa (Mega Panels can be added on to an existing conventional foundation).
14. Where else is this technology used?
This system has been around for more than 35 years but is only made popular recently due to its insulation properties and fast construction techniques. It is now widely used all over the world particularly in USA, Europe, Japan, Korea, China and over 35 other countries.
15. What are benefits for the homeowners?
The greatest benefit is that the wall’s structure is very strong and home can stand for over 60 years on original design and structures. Cracks are minimum and the materials used on the walls and floor allows for a wide array of material to beautify the home, e.g. tiles, paint, wall papers, etc. As Mega Panels wall is insulated, the residence will have lots of privacy in their home. Electrical and plumbing is placed between the wire mesh and polystyrene, so there are fewer wall penetrations, which keep thermal loss at a minimum. This saves about 50% to 80% of heating and cooling costs. You can also settle for a smaller HVAC System compared to when conventional brick or hollow block walls are being used.
16. How do you make a bond beam?
A bond beam is used to create large openings, or to strengthen large areas of ceiling or to help support roof structures. All bond beams created should be pre approved by a certified engineering firm. Removing the polystyrene core and installing rebar creates the bond beam. The best method for removing the polystyrene core is a high-pressure water blaster; it takes only a matter of minutes. For further information please see the instruction manual.
17. How do you build curved or radius walls?
You can build curved or radius walls by cutting the eleven gauge wires on one side of the panel. This will allow the panel to bend to the desired shape or radius. It is very important not to cut through the heavier nine- gauge truss wire so that wall strength and integrity remain intact. The cut sections are then meshed together to regain the integrity of the panels.