Prefab Wall Making Technology New

8/10/2019 Prefab Wall Making Technology New

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Presentationon

Techno-economic& Construction Advantagesof

RCFs Rapidwall Panels


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RCF and Rapidwall Prefab Wall Panel Technology

Rashtriya Chemicals & Fertilizers Limited is a Government ofIndias PSU engaged in manufacture of fertilizers and IndustrialChemicals since 1965. Details available at our websitewww.rcfltd.com.

RCF is setting up a plant at its Trombay Unit for manufactureof Load Bearing Wall Panels, wall putty and plaster through itsbyproduct gypsum by a specialized technology from Australiacalled Rapidwall Technology.

12m x 2.8 m panels will be made by calcined gypsum, glass

fibers and chemicals to make them load bearing, water proof,fire proof, corrosion proof, termite proof, earthquake resistant,environmentally friendly and rapidly building wall panels as perthe customized requirement. Panels will be precut as per thedesign of the house so that they need to be just assembled and

joined at site.

RCF has built a two storey Demonstration Building by thesepanels in early 2006 at its Township in Chembur which is apoint of attraction and can be visited upon request.


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RAPIDWALL . is analternative building material to replacebricks / concrete blocks which will also save

river sand, water etc and protect the environment

Alternative Building Material


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Reinforcement is provided during the

automated hi-tech production process

itself.

reinforced by glass rovings

Rapidwall is reinforced by glass rovings

Panel is reinforced by micro-strand glassrovings (13 microns) by both ways on all

four sides - both flanges and webs. This

glass roving itself is a hi-tech product

manufactured in India.

This reinforcement provide load

bearing capability & confinement

property when cavities filled up

with concrete. Tensile strength ofglass roving (single

filament) is 3100-3800Mpa (tensile strength of

glass roving is much higherthan even that of steel used

for concrete reinforcementwhich is maximum @ 500 Mpa)

Elastic Modulus of glassroving is 76-78 Gpa

This provide very high loadbearing capability to the panel

making into a composite material.

Micro-strand glass roving role


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Rapidwall Panel is manufactured in 12 m x 3 m with

120 mm thickness with modular cavities.


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Cutting of panel to required sizes using

automised cutting saw in RW factory


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Stillages to transport Rapidwallpanels

safely to every building site.


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Rapidwall

Up to 500 m of Rapidwall can be

transported on one truck.

After cutting Rapidwall is

loaded onto collapsibleframes, ready for transport.


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Fire Resistant Testing by IIT Madras

Rapidwall building material is Fire Resistant4 hrs rating of 700 1000 oC

Application of700-1000 oCheat for 4 hrs

maximumtemp recorded

using electronicrecorder on theopposite side is57 oC on empty

panel

maximumtemp recorded

using electronicrecorder on theopposite side is

66.7 oC on panel

with concreteinfill

Application of700-1000 oCheat for 4 hrs

Thermal conductivity is very less


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BMTPC / Govt of India approved the product

for construction of buildings upto 10 storeys


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Construction of First RapidwallBuilding in India

in Mumbai in 32 days by RCF

(structural design by IIT Madras & constructedas per Rapidwall construction manual

prepared by IIT Madras)


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RW panel taken out from container brought from

Australia for construction of demonstration building


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Conventional Building foundation with RCC plinth beams

provided with MS rods as start up rods for erection ofpanels as superstructure of building


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Panels cut into various sizes as per building plan are

brought to construction sites by truck or lorry.


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16Panel with opening for two windows is being placed over

RCC plinth beam


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While panel is placed over plinth beam, start up rod will

go into cavities, including corner joints. Cavities uptorequired height will be in-filled with concrete


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Panel being placed / seated on RCC plinth beam over a

thin layer of cement mortar slurry.


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2 panels erected ascorner walls. Angles

are provided from two

sides using nuts&

bolts. After setting of

concrete in-filled,

these angles are

removed.

For supporting panel

in position, adjustableslanting prop is

provided.


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First pouring of concrete into wall corner joint.


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21All the walls of ground floor are erected in two days.


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22Cutting the panel for required opening to provide RCC

lintel cum sunshade


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MS Rods for RCC

lintel cum

sunshade as per

structural designprovided.

With ply wood /MS sheet as

shutter, RCC

sunshade can becast over the

window


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For roof/floor, panel to be lifted horizontally / flat as

seen in picture.


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Panel for

first floor /

roof being

lifted forplacing in

position


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RW roof panel placed on walls.


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Before

cutting topflange,

bottom

supportwith ply

wood /

strong MSsheet with

prop

whereverrequired

are to be

provided


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100 mm x 100 mm, 10 gauge weld mesh provided for 50

mm thick RCC screed. Embedded RCC micro-beamsact as micro T beams


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Side shuttering provided for concreting of RCC

horizontal tie beams and screed floor concrete


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Start up rod for erection of wall

panel for upper floor. Vertical

continuous reinforcement as

per structural design provided

from foundation to upper floor.


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Simultaneous concreting of RCC horizontal tie beams,

micro-beams and screed concrete


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Concreted floor / roof. Start up MS rods (40 cm high) for

erection of upper floor wall panel by repeat process. Walls on

3 sides of staircase and staircase landing to be done.


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Erection

of wall

panel over

first floor

is in

progress


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Wall panel with

window and

ventilator

opening is being

placed in first

floor


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RCC lintel cum sunshade architectural band


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RCC lintel cum sunshade, architectural band,

parapet wall work completed


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Electrical switch board / junction box in position


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Water supply pipeline work in progress


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Wall corners, ceiling

corners are given fine

finish using special

gypsum plasterproduct


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Sanitary fittings,

water supply fittings

F d li ht fitti i iti


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Fan and light fittings in position

Fi i f f i ll til / l ddi RW l ll


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Fixing of facing wall tiles/ cladding on RW panel wall


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Ceramic flooring tiles


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First coat of painting

in progress


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Staircase, handrail,

marble slab for

staircase steps,

finishing coat ofpainting


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Interior

finish,

skirting,

ceramicfloor tiles,

furnishing,

curtainrods, fan,

light

fittings etcin position

Rear view of two storey 1220 sqft RW building in 32


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Rear view of two storey 1220 sqft RW building in 32

days. MS iron ladder to rooftop

Front view of completed building. Front compound

ll i RW l


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wall using RW panel


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RCC plinth beams, RCC column inside wall cavities,RCC tie beam all


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p , ,

around,micro beams & screed constitute monolithic RCC frame structure

inside Rapidwall bldg

On completion of structure of the building


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On completion of structure of the building

including parapet wall in 12 days, thefinishing work carried out 20 days Architectural band all around

RCC sunshade

Weathering course

Drainage pipeline work

Ceramic tile laying

Marble slab for staircase Glazed tiles for bathrooms

Finishing work of ceiling and wall corners

Electrical

Sanitary Water supply

Painting


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A view of Rapidwall buildings in

Australia and China


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Sydney Park housing complex with 922 apartments. This eight storey building is

without RCC columns and beams. The entire structure is built on Gypcrete /

Rapidwall panel. The first phase with 370 apartments was built in 1990. Thiscomplex is close to World renowned Sydney Opera House.

M lti t i d t ti


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Multistoried construction


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400 Rapidwall apartments in Alexandria, Sydney. Completed to lockup stage

in one third of the time normally taken by conventional building methods.

HIGH RISE APARTMENTS


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AU

S

TR

A

L

I

A

MultistoriedRapidwallbuilding

CROWNOF THEHILL

at Pennant

Hill,Sydney.


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Recently

constructed (2001)

MARBURY of 18

(17+1) storeys

with rapidwalls inthe centre of

Sydney. Bottom

10 storeys are

RCC framed

structure walling

with rapidwall

panels. Top 8storeys are made

of Rapidwall load

bearing walls

17

storey


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59Residential


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60COMPOUND WALLS


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India needs millions of small houses for its

b b ll d l


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Small house of 20 sq.m.India needs millions ofsuch small houses forthe poor & low incomemasses in small towns,

suburban areas andrural areas.

With 6 panels pieces asmall house can be built

in a day or two by selfhelp work by grassrootscommunity.

suburban areas, small towns and rural areas

With 2-3 RW panels a small house can be built


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p

which is strong and durable with more cool andliving comfort.

By cutting into required sizes, 4 for four walls, 2 pieces as roofing panelsfor sloped roof, a small house can be built by self help within days


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Saving by one panel


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10000 litres of water . . .

2.43 m3 / 86 cft river sand . . .

8m3 / a lorry load agri soil . . .

0.80 tons of cement . . . emission of 2.9 tons CO2 . . .

With 2 - 3 panels a small

eco-house can be built.

With 6panels of

required size, 4for four walls and2 pieces for slopedroof a small house

can be built byself help within

a days

Saving by one panel

No one wants to be


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No one wants to be

baked under heatradiating walls and

roofing during the

summerCement plastered

walls, concrete roof,

AC sheet or tin sheet

roofing radiate heat

making indoor

temperature

unbearably highduring summer in

tropical climates in

India.

Strength of Rapidwall building panel at a glance


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Compressivestrength

empty panel :73.10 Kg/cm2

concrete infill :

180.70 Kg/cm2

Flexural Strengthempty panel :21.25 Kg/cm2

concrete infill :20.80 Kg/cm2

Tensile strength

28.8 kN/m

Ductility

4.11

Water absorption

< 2% (24 hrs)

Fire resistance

4 hrs rating700 oC to 1000 oC.

Thermal resistance

0.36 R

SoundTransmission Class

- STC 40

Free fromCorrosion

Axial vertical load

on empty panelof 2.85m high x 1m

: 14.04 tons

Axial vertical load

on concrete infilledpanel of 2.85m highx 1m :

154 tons

Rot&termite proof

Light weight

40 Kg / m2(1/8th weight of

concrete)

Net Density

1140 Kg / m3

Earthquakeresistant: test

withstoodearthquakes up to

Richter Scale 8

Eco-friendly(green material)

(raw materialrecycled waste & no

emissionof CO2 )

SavingWater

Riversand

Cemen

tSteel

Saving

Time of

Very lowmaintenance cost

Saving in recurringenergy cost forcoolin air

Cost-effective(affordable cost)

Strength of Rapidwall building panel at a glance

Reduction of mass (weight) using


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( g ) g

Rapidwall building panels

Weight of 1 sq.m brick wall

9 thick with 2 sides cementplastering

: 400 Kg

Weight of 1 sq.m Rapidwall

panel

: 40 Kg 90.0%

Weight of 1 sq.m panel withconcrete infill

: 250 Kg 37.5%

Load bearing walls + nonload bearing internal wallsusing filled and unfilled

panels

: 200 Kg(avg)

50.0%

Weightreduction

Gypsum based wall plaster for


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Plastering of

brick/concrete wallsand ceiling using

gypsum based wall

plasteras substitute for

cement plastering

yp p

plastering internal brick/concrete walls& ceiling

saving > cement, sand, water

advantages > superior finish> less cost than cement

plaster

> cooler inside


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affixing a With POP

paste


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p

markingthe levels

by

broken

floor tile

piece

POP paste


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POP paste

is applied

to mark

verticallevelling

marks,

which areprovided at

3-4 feet

intervals


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After 15 minutes,


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surface is finefinished using a

tin plate as

shovel


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Gypsum basedWALL

PLASTER

can

revolutionise

plastering of

internal walls

and ceiling.

This will save river

sand & water


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Population:

Facts Speak:


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Greater Mumbai ppn : 11.97 million (2001 census)

Present population : 18.0 million

Slum ppn greater Mumbai :6.62 million (2001 census)

Housing scenario:

Indias demand for housing (study by ASSOCHAM 2005)

by 2015 : 80 millionby 2020 : 90 million

Estimate on housing shortage by Govt

urban housing shortage (2007) : 24.71 million (NBO)

rural housing shortage (2007) : 31.1 million (NHB)total housing shortage (2007) : 55.81 million

Housing shortage in Maharashtra : 3.2 million(NBO)

Maharashtra Govt Housing Policy(draft Nov 2006)


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Salient points:

Urban Housing const. for low income: 5 lakh units in 3 yrs

Rural Housing construction : 2 lakh units in 3 yrs

Rehabilitation of eligible slum dwellers : 25% in 3 yrs

Renovation of old & dilapidated cess building: 25% in 3 yrs

Size of free dwelling units under various schemes : 225 sft

Maharashtra Govt Housing Policy


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Clause 10 of housing policy on housingtechnology:

Technology development to reduce cost ofhousing & promote durable housing

To promote eco-housing, low energyconsuming construction techniques & buildingmaterials

Encourage the use of pre-cast & pre-fabricatedbuilding materials for speedy & cost effectiveconstruction of mass housing

Enforcement of National Building Code &Earthquake resistant construction guidelines

As per Planning Commission :


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Housing demand by higher income group : 18 %Housing demand by middle income group : 36%

Housing demand by weaker sections : 46%

Four Pillars of Building Construction :

1st pillar : Land & Building/Engg plan

2nd pillar : Finance

3rd pillar : Building materials4th pillar : Construction (builders,

labourers, skills)

Building Materials > growing demand

Conventional basic building materials

i) Burnt clay bricks / concrete blocks


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ii) Cement

iii) Steel

iv) River sand

v) Water

its demand is growingyear by year

Cement Production in India in million tonnes

(source:BMTPC)

145 160 176 194

0

100

200300

2005 2006 2007 2008 2009 2010

? ?

Projected

Steel Production in India in million


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tonnes

25

3545

110

0

50

100

150

2005 2006 2007 2008 2009 2010

??

Projected

Steel Policy

Brick Production in India in billion

140160

200200

250

Projected ?


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140

0

50

100

150

2005 2006 2007 2008 2009 2010

River Sand use in India in million cum

303334

368 404

0

100

200

300

400

500

2005 2006 2007 2008 2009 2010

? ?

? ?Estimated

Limitation to increase production of bricks &

river sand supply will mismatch demand cause


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Price rise

Growing fuel / energy cost & concern CO2

emission causing climate change, cost ofcement & steel will drive further

Building construction require potable water.Water is becoming scarcer & cost will go up

So the cost of all building materials are bound toincrease

Cost of construction of brick wall Rs per sqm

including both sides cement plasteringRs 106/sft


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500 560

680768

9001140

0200

400

600

800

1000

1200

2003

2004

2005

2006(m

ar)

2006(

nov)

2007

(apr)

2008

?

1 year from now in 2008 it may cost much more !

Economics of Rapidwall:Comparison between 2 storey RW building &

ti l bld ( t t l


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RW Bldg

1201 sft

9.36 t

1.434t

Nil7000 lit

14.5 cum

56.16t

37 days150 mandays

Rs 5,60,000

Rs 466 /sft

Conv Bldg

1310 sft

20t

3.518t

55,000

1.7 lakh lit

41.64 cum

204t

165-180 days

720 mandays

Rs 8,60,000

Rs 656 / sft

conventional bldg (structure onlyfor same carpet area)

Plinth areaCement Requirement

Steel requirement

Brick requirement

Water requirementRiver sand requirement

Self weight/dead weight

Period of construction

Labour requirement

Cost of construction

Rate of Const per sft

Cost of RW dwelling unit of 226 sft : Rs 1,04,000

Cost if row dwelling units : Rs 82,000


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RW Demo Bldg

26275 kWh

110633 kWh

80%

Conv Bldg

1,36,908 kWh

Embodied energy of 1sqm brickwall & 1sqm of Rapidwall :

Embodied energy of 1sqm brickwall : 194.38 kWh

Embodied energy of 1sqm Rapidwall : 35.59 kWh

Estimated embodied

energy

Saving /reduction ofenergy

% of embodied energy

saving

(Saving by common wall, its foundation, erection charge,

painting etc.)

Two other products for use in conventional bldg

construction

WALL PLASTER

RAPID WALL PLASTER


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WALL PLASTER

alternative to cementand sand mix

plastering of internalwalls &ceiling

WALL PUTTYto get smooth andsuperior finished wallsurface, additional thin

layer of plastering isdone over cementplaster in conventionalbrick /concrete wall.

RAPID WALL PLASTERSuperior finish. No need foradditional layer of plaster withwall putty to get even &

smooth finish.Thereby saving substantialcosts

RAPID WALL PUTTYGypsum based, superior &more affordable wall putty asan alternative to

currently available wall puttylike Birla wall putty or JK wallputty that are white cementbased

Benefits to Builders / Developers

1 Ver fast constr ction


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1. Very fast construction2. Reduced hassles of construction with less

materials

3. Saving in transport cost of sand, bricks/concreteblocks, granite metal, cement, steel, water,

scaffolding & shuttering materials

4. Strong & quality construction

5. Less number of workers

6. Less overhead cost & less project time

7. No problem of disposal of waste / debris

8. Quick turnover with many fold reinvestment per

annum bringing more profit

9 More carpet area (8 10% more) & superior building



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9. More carpet area (8-10% more) & superior buildingwill bring more return

10. Without extra cost, green building/eco-friendly

housing can be given to customers11. Earthquake resistant, Fire Proof and other disaster

resistant bldg at no extra cost. In conventional

const. requires 15-20% additional cost

12. High thermal efficiency of Rapidwall provides more

comfortable indoor

13. Less recurring cost for cooling or heating of indoor

space14. Less maintenance cost

15 Rapid construction will help in rehabilitation



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15. Rapid construction will help in rehabilitationscheme /rebuilding projects of unsafe buildings as

dwellers can get back fast > builders get more FSI

benefits16. Fast construction will help to rehabilitate displaced

families from various infrastructure projects

17. Lightweight and rapid construction will help to put

up additional storey over existing buildings within

no time, will be an opportunity to builders /

customers

18. Single storey to multi-storey construction

19 Can use as walling for RCC framed construction &



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19. Can use as walling for RCC framed construction &save costs, cement plastering time etc & reduce

total self weight/ dead weight which will educe

foundation cost , size of RCC columns and beams >

save money

20. Can re-use panel whenever Rapidwall buildings are

demolished

21. Since free from corrosion , in coastal region as wellas metro like Mumbai RW Building will become

attractive to people and RW bldg will be much more

durable than concrete structures

22 When required specially as per structural design



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22. When required specially, as per structural design,double or triple panel can be used

23. Ideal for large compound wall/security wall for

campuses, free economic zones, to separate railcorridor etc.

24. No wastage as even cut pieces of door/window

openings can be used for parapet or other uses

25. Use of panel in combination with concrete and steel

as composite material enhances the strength and

value of both RW panel and RCC

26 While making more profit can also contribute to



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26. While making more profit, can also contribute tothe environment and climate change (high selling

point by builders/developers)

27. Help to conserve energy, scarce material like waterand river sand and reduce pollution

28. Modern & hi-tech superior material. Opportunity to

achieve world class construction & to begin

organised & industrialised housing construction

29. Most reliable product with assured quality &

strength

30 Rapidwall can be used as the basic structure for low



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30. Rapidwall can be used as the basic structure for lowincome, middle income & high income, rich or

affluent segment; finishing work to their desire &

affordability & wealth

31. Opportunity to upgrade the skills of existing

construction workers

32. Simultaneous construction of same type of buildings

at various sites & places can increase volume ofwork/turnover to any extent

33. Teaming up of Architects, Structural Engineers, &

Builders utilising the advantage and benefits of

Rapidwall & Rapid Construction system can make

profit, help deliver mass housing fast & contribute to

the transformation of Mumbai

ContactsN D i i T l h il


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Name Designation Telephone email

Marketing

Shri A.B.Ghasghase CGM(IPD) 25523156 [email protected]

Shri R.P.Srivastava GM(GBP) 25523161 [email protected]

Technical Support

Shri S.A.C.Rajah Dy.GM

(Rapidwall)

98694 10205 [email protected]

Shri J.M.Sudame Chief Engr.(Civil) 98696 50547 [email protected]


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Thank You

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Prefab Wall Making Technology New