Presence of water in liquid or vapor form leads to mould growth in building materials, weakening the building's structural integrity. Excess moisture in non-breathable materials also impacts thermal properties and performance over time. Hygrothermal analysis and understanding moisture movement within walls are crucial for comprehending wall assemblies in the enclosed spaces of buildings. Numerous commercial software packages are available for estimating moisture risk in wall assemblies. However, it's essential to recognize that these software tools are primarily designed for conventional insulation walls and may not be suitable for materials like EPS-based concrete, which incorporate expanded polystyrene particles. Since micro-level analysis of moisture flow is largely unexplored, this study used mass diffusion theory with ABAQUS-CAE. The study found that EPS beads increased moisture levels in walls by 2–6%. Additionally, due to the porous nature of concrete, moisture penetration and fluctuations were lower compared to other materials. Accumulated moisture made the wall impermeable and weakened the load-bearing material over time. To mitigate moisture effects of 20–28 %, it's recommended to use cement-fiberboard (CFB), which can be replaced if damaged without affecting structural integrity. SEM and EDX/EDAX analyses were used to show moisture accumulation at the micro level. It was observed that more oxygen elements were present at the border of the EPS-bead-mortar mix. The fuzzy-based MCDM method helped mitigate uncertainty in parameter selection, while ABAQUS model analysis considered different scenarios with variations in parameters. This research helps developers and practitioners choose materials with low concrete solubility and high concrete vapor diffusion factors for EPS-based panels, reducing moisture damage.
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