Glass fibre reinforced gypsum Panels
Glass fibre reinforced gypsum Panels
Made by
Md. Raijul IslamDept. of Textile EngineeringBGMEA university of
Fashion & Technology (BUFT)Session: 2013-2017Email:
[email protected]
What is gfrg panel?It is a gypsum based walling panel reinforced
with glass fibre.It was developed by Australia in 1990.Dimension:
12m x 3m x 124mmAlso known as Rapidwall, Gypcrete, etc,.
Why gfrg?Our Bangladesh is still a developing country fighting
with a huge shortage of housing every year.We need a very fast
construction technology which can increase our development
rateConventional methods of construction lead to formation of huge
amount of CO2 (about 40% is developed due to construction industry)
increasing chances of global warming.Fertilizer industries are
facing problems regarding disposal of industrial waste gypsum (2000
tonnes per day)We are not having enough water for ourselves, then
why allow buildings to drink it?
What are the advantages?Waste is used as resource making it very
economical Construction rate is very fast- changes brick by brick
construction to wall by wall constructionGreen Alternative
Technology- Thus Environment FriendlyUses very less Sand, Steel and
WaterBuilding is fire resistantEarthquake resistant (8.0)Much less
labour force neededWeight of structure is very lessMore carpet area
for same built up areaNo need of beams and columnsNo need of
plastering thus cost can be saved in finishing
How much it is Fire resistant?
How much weight can be reduced?
How much can we save?
ECONOMICS (for 2 storey, 1500 sqft)S.No.Materials/ itemsGFRG
BuildingConventional BuildingSaving in %1.Cement16 tons32.55
tons50.82.Steel1800 kg2779 kg35.23.River sand20 cum83.37
cum764.Granite Metal38 cum52.46 cum27.565.Bricks-572006.GFRG
Panel500sqm-7.Water50000 ltr200000 ltr758.Built Area143 sqm154.45
sqm89.Labour389 mandays1200 mandays67.5910.Construction Time21
days120 days8211.Total weight of superstructure179 tons490
tons6512.Construction costTk. 15.44 lakhsTk 21.29
lakhs27.4713.Embodied energy in kWh8292121540061.5
How it is made?It is made from Gypsum, an industrial waste from
fertilizer industries (2000tonnes/day).It takes only 30 minutes to
make a panel.
It is made in three stages:
Stage-1A paste of calcined gypsum and other chemical additives
is poured on the specially designed table.Glass fibres are then
spread evenly by means of screeding and rolling process.
Stage-2Special aluminium plugs are inserted on top of finished
first layer with 20mm gaps in between to form hollow cavities.2nd
pouring of mix is done along with glass fibre with tamping to form
ribs of the hollow panel.
Stage-3Process of 1st Stage is repeated to complete the top
layer of the panel.After 25 minutes plugs are taken out, casting
table is rotated and panel is then taken out for drying using
special fork lift.Then drying is done for 90 minutes in a drier
chamber in which hot air is circulatedAfter that panel is cut into
its dimensions are per the customers design.
Where it is made?FACT Cochin (Fertilizers And Chemicals
Travancore LTD)RCF Mumbai (Rashtriya Chemicals and Fertilizers)
How to make buildings?
FoundationA conventional foundation like spread footing, RCC
column footing, raft or pile foundation is used as per the soil
condition and load factors.All around the building RCC plinth beam
is provided at basement plinth level.For erection of panel as wall,
12 mm dia vertical reinforcement called starter bars of 0.75m
length of which 0.45m protrudes up and remaining portion with 0.15m
angle is placed into the RCC plinth beams before casting.These bars
are kept at a distance of 1m centre to centre to match the cavities
of the panel.
superstructurePre-cut panels are brought to the construction
site.Panels are kept over the starter bars on the plinth beam using
cranes.Grooves are cut into the panels at every joints to
facilitate integral bonding.Appropriate reinforcement bars are
inserted as per design into the cavities.These reinforcements are
then tide to the starter bars.Verticality of panels are checked and
then cavities having reinforcements are filled with concrete.It is
mandatory to reinforce and fill all the joints with concrete.Other
cavities can be filled with any inert materials (e.g. quarry dust
mixed with 5% cement and water)
Superstructure cont.After completing the walls, doors and
windows are fixed in position at there respective locations where
panels are cut and the it is fixed by filling the cavities with
concrete.Then shuttering for sunshades are kept in position and
concreting is done.Staircase is constructed by using panel as waist
and landing slabs with reinforcement in all the cavities.
Roof SlabFormworks are erected. Tie beams are constructed all
along the walls to provide bond between roof slab and walls.Panels
are then placed in position.Every third cavity is then cut open
from the top and reinforcement cages are inserted for concrete
micro beams.Electrical conduits are then placed in position. Welded
wire mesh is then kept all over the panel.Then concreting is done
with thickness 50mm.Subsequently waterproofing of roof is done.
Where we can use it?We can use for:Institutional
BuildingsResidential BuildingsHospital BuildingsHotelApartments
Some projects
Mp-4
conclusionGFRG Panel provides a new method of building
construction in fast track. By this process, man power, cost and
time of construction can be reduced. The use of scarce natural
resources like river sand, water and agricultural land can be
significantly reduced. We can save our environment by reducing CO2
production in conventional construction method. And the most
important, this new technology is having potential to provide
shelter to the Homeless PEOPLE.
Thank you
