prefab wallmaking technology

1PresentationPresentationonon

TechnoTechno--economiceconomic& Construction Advantages& Construction Advantages

ofofRCFs Rapidwall PanelsRCFs Rapidwall Panels

2RCF and Rapidwall Prefab Wall Panel Technology Rashtriya Chemicals & Fertilizers Limited is a Government of

Indias 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, glassfibers 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 andjoined 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.

3RAPIDWALL . is analternative building material to replace bricks / concrete blocks which will also saveriver sand, water etc and protect the environment

Alternative Building Material

4Reinforcement 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 glass rovings (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 of

glass roving (single filament) is 3100-3800

Mpa (tensile strength of glass roving is much higher

than even that of steel used for concrete reinforcement

which is maximum @ 500 Mpa)

Elastic Modulus of glass roving is 76-78 Gpa

This provide very high load bearing capability to the panel

making into a composite material.

Micro-strand glass roving role

5Rapidwall Panel is manufactured in 12 m x 3 m with 120 mm thickness with modular cavities.

6Cutting of panel to required sizes using automised cutting saw in RW factory

7Stillages to transport Rapidwall panels safely to every building site.

8Rapidwall

Up to 500 m of Rapidwall can be transported on one truck.

After cutting Rapidwall is loaded onto collapsible frames, ready for transport.

9Fire Resistant Testing by IIT Madras

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

Application of700-1000 oCheat for 4 hrs

maximum temp recorded

using electronic recorder on the opposite side is 57 oC on empty

panel

maximum temp recorded

using electronic recorder on the opposite side is

66.7 oC on panel with concrete

infill

Application of700-1000 oCheat for 4 hrs

Thermal conductivity is very less

10

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 & constructed as per Rapidwall construction manual prepared by IIT Madras)

13

RW panel taken out from container brought from Australia for construction of demonstration building

14

Conventional Building foundation with RCC plinth beams provided with MS rods as start up rods for erection of panels as superstructure of building

15

Panels cut into various sizes as per building plan are brought to construction sites by truck or lorry.

16Panel with opening for two windows is being placed over RCC plinth beam

17

While panel is placed over plinth beam, start up rod will go into cavities, including corner joints. Cavities upto required height will be in-filled with concrete

18

Panel being placed / seated on RCC plinth beam over a thin layer of cement mortar slurry.

19

2 panels erected as corner 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, adjustable slanting prop is provided.

20

First pouring of concrete into wall corner joint.

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

22Cutting the panel for required opening to provide RCC lintel cum sunshade

23

MS Rods for RCC lintel cum sunshade as per structural design provided.

With ply wood / MS sheet as shutter, RCC sunshade can be cast over the window

24

For roof/floor, panel to be lifted horizontally / flat as seen in picture.

25

Panel for first floor / roof being lifted for placing in position

26

RW roof panel placed on walls.

27

Floor / roof panel provided with embedded RCC micro beams. For this, top flange of respective cavities are cut.For concealed electrical wiring, cables, PVC pipes, fan hooks etc are to be laid.

28

Before cutting top flange, bottom support with ply wood / strong MS sheet with prop wherever required are to be provided

29

100 mm x 100 mm, 10 gauge weld mesh provided for 50 mm thick RCC screed. Embedded RCC micro-beams act as micro T beams

30

Side shuttering provided for concreting of RCC horizontal tie beams and screed floor concrete

31

Start up rod for erection of wall panel for upper floor. Vertical continuous reinforcement as per structural design provided from foundation to upper floor.

32

Simultaneous concreting of RCC horizontal tie beams, micro-beams and screed concrete

33

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.

34

Erection of wall panel over first floor is in progress

35

Wall panel with window and ventilator opening is being placed in first floor

36

Window frame with shutter in position

37

RCC lintel cum sunshade, architectural band, parapet wall work completed

38

Electrical switch board / junction box in position

39Water supply pipeline work in progress

40

Wall corners, ceiling corners are given fine finish using special gypsum plaster product

41

Sanitary fittings, water supply fittings

42

Fan and light fittings in position

43

Fixing of facing wall tiles/ cladding on RW panel wall

44Ceramic flooring tiles

45

First coat of painting in progress

46

Staircase, handrail, marble slab for staircase steps, finishing coat of painting

47

Interior finish, skirting, ceramic floor tiles, furnishing, curtain rods, fan, light fittings etc in position

48

Rear view of two storey 1220 sqft RW building in 32 days. MS iron ladder to rooftop

49

Front view of completed building. Front compound wall using RW panel

51

RCC plinth beams, RCC column inside wall cavities,RCC tie beam all around,micro beams & screed constitute monolithic RCC frame structure inside Rapidwall bldg

52

On completion of structure of the building including parapet wall in 12 days, the finishing 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

53

A view of Rapidwall buildings in Australia and China

54

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. This

complex is close to World renowned Sydney Opera House.

55

Multistoried construction

56400 Rapidwall apartments in Alexandria, Sydney. Completed to lockup stage

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

57

AUSTRALIA

HIGH RISE APARTMENTS

Multistoried Rapidwall building CROWN OF THE HILLat Pennant Hill, Sydney.

58

Recentlyconstructed (2001)MARBURY of 18(17+1) storeyswith rapidwalls inthe centre ofSydney. Bottom10 storeys areRCC framedstructure wallingwith rapidwallpanels. Top 8storeys are madeof Rapidwall loadbearing walls

17 storey

59Residential

60COMPOUND WALLS

61

Six storeyed Guest House building in an industrial park inJinan city, Shandong Province, China.

Rapidwall buildings in China

62

Seven storey (six storey + pent house) Apartment Gypcretebuilding in Tianjin, 150 km from Beijing city.

Rapidwall buildings in China

63

Small house of 20 sq.m.India needs millions of such small houses for the poor & low income masses in small towns, suburban areas and rural areas.

With 6 panels pieces a small house can be built in a day or two by self help work by grassroots community.

India needs millions of small houses for its suburban areas, small towns and rural areas

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With 2-3 RW panels a small house can be builtwhich 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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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 6 panels of

required size, 4 for four walls and 2 pieces for sloped roof a small house

can be built by self help within

a days

Saving by one panel

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No one wants to be baked under heat radiating walls and roofing during the summer

Cement plastered walls, concrete roof, AC sheet or tin sheet roofing radiate heat making indoor temperature unbearably high during summer in tropical climates in India.

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Compressive strength

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 resistance4 hrs rating

700 oC to 1000 oC.

Thermal resistance

0.36 R

Sound Transmission Class

- STC 40

Free from Corrosion

Axial vertical load on empty panel

of 2.85m high x 1m : 14.04 tons

Axial vertical load on concrete infilled panel of 2.85m high

x 1m :154 tons

Rot &

termite proof

Light weight40 Kg / m2

(1/8th weight of concrete)

Net Density

1140 Kg / m3

Earthquake resistant: test

withstood earthquakes up to

Richter Scale 8

Eco-friendly(green material)

(raw material recycled waste & no

emission of CO2 )

Saving Water River sandAgri soil

CementSteel

Saving

Time of construction

Very low maintenance cost

Saving in recurringenergy cost for cooling (air

Cost-effective(affordable cost)

Strength of Rapidwall building panel at a glance

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Reduction of mass (weight) using Rapidwall building panels

Weight of 1 sq.m brick wall 9 thick with 2 sides cement plastering

: 400 Kg

Weight of 1 sq.m Rapidwallpanel

: 40 Kg 90.0%

Weight of 1 sq.m panel with concrete infill

: 250 Kg 37.5%

Load bearing walls + non load bearing internal walls using filled and unfilled panels

: 200 Kg(avg)

50.0%

Weight reduction

70

Plastering of brick/concrete walls and ceiling using gypsum based wall plaster as substitute for cement plastering

Gypsum based wall plaster for plastering internal brick/concrete walls

& ceiling

saving > cement, sand, wateradvantages > superior finish> less cost than cement plaster> cooler inside

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Taking out wall plaster for mixing in water to make paste

72

affixing a With POP paste marking the levels by broken floor tile piece

73

POP paste is applied to mark vertical levelling marks, which are provided at 3-4 feet intervals

75

After 15 minutes, surface is fine finished using a tin plate as shovel

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Gypsum based WALL PLASTER

can revolutionise plastering of internal walls and ceiling.This will save river sand & water

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Energy, Environment, & Economic Values of Rapidwall

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Population:Greater Mumbai ppn : 11.97 million (2001 census)Present population : 18.0 millionSlum 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)

Facts Speak:

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Maharashtra Govt Housing Policy (draft Nov 2006)

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

80

Maharashtra Govt Housing PolicyClause 10 of housing policy on housing technology:

Technology development to reduce cost of housing & promote durable housing

To promote eco-housing, low energy consuming construction techniques & building materials

Encourage the use of pre-cast & pre-fabricated building materials for speedy & cost effective construction of mass housing

Enforcement of National Building Code & Earthquake resistant construction guidelines

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As per Planning Commission :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 plan2nd pillar : Finance3rd pillar : Building materials4th pillar : Construction (builders,

labourers, skills)

Building Materials > growing demand

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Conventional basic building materialsi) Burnt clay bricks / concrete blocksii) Cementiii) Steeliv) River sandv) Water

its demand is growing year by year

Cement Production in India in million tonnes (source:BMTPC)

145 160 176 194

0100200300

2005 2006 2007 2008 2009 2010

? ?

Projected

83

Steel Production in India in million tonnes

25 3545

110

0

50

100

150

2005 2006 2007 2008 2009 2010

??

Projected

Steel Policy

84

Brick Production in India in billion

140 160200

050

100150200250

2005 2006 2007 2008 2009 2010

River Sand use in India in million cum

303 334368 404

0100200300400500

2005 2006 2007 2008 2009 2010

??

Projected ?

? ?Estimated

85

Limitation to increase production of bricks & river sand supply will mismatch demand cause Price rise

Growing fuel / energy cost & concern CO2 emission causing climate change, cost of cement & 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 to increase

86

Cost of construction of brick wall Rs per sqm including both sides cement plastering

500 560680 768

9001140

0200400600800

10001200

2003

2004

2005

2006

(mar)

2006

(nov

)

2007

(apr)

2008

?

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

Rs 106/sft

87

RW Bldg

1201 sft

9.36 t1.434tNil7000 lit14.5 cum56.16t37 days150 mandaysRs 5,60,000Rs 466 /sft

Conv Bldg

1310 sft

20t3.518t55,000 1.7 lakh lit41.64 cum204t165-180 days720 mandaysRs 8,60,000Rs 656 / sft

Economics of Rapidwall:Comparison between 2 storey RW building & conventional bldg (structure onlyfor same carpet area)

Plinth areaCement RequirementSteel requirementBrick requirementWater requirementRiver sand requirementSelf weight/dead weightPeriod of constructionLabour requirementCost of constructionRate of Const per sft

88

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 of energy

% of embodied energy saving

Cost of RW dwelling unit of 226 sft : Rs 1,04,000Cost if row dwelling units : Rs 82,000(Saving by common wall, its foundation, erection charge,

painting etc.)

89

Two other products for use in conventional bldg construction

WALL PLASTERalternative to cement and sand mix plastering of internal walls &ceiling

WALL PUTTYto get smooth and superior finished wall surface, additional thin layer of plastering is done over cement plaster in conventional brick /concrete wall.

RAPID WALL PLASTERSuperior finish. No need for additional layer of plaster with wall putty to get even & smooth finish.Thereby saving substantial costs

RAPID WALL PUTTYGypsum based, superior & more affordable wall putty as an alternative to currently available wall putty like Birla wall putty or JK wall putty that are white cement based

90

Benefits to Builders / Developers1. Very fast construction2. Reduced hassles of construction with less

materials3. Saving in transport cost of sand, bricks/concrete

blocks, granite metal, cement, steel, water, scaffolding & shuttering materials

4. Strong & quality construction5. Less number of workers6. Less overhead cost & less project time7. No problem of disposal of waste / debris8. Quick turnover with many fold reinvestment per

annum bringing more profit

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

10. Without extra cost, green building/eco-friendly housing can be given to customers

11. 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 space

14. Less maintenance cost

Benefits to Builders / Developers

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15. Rapid construction will help in rehabilitation scheme /rebuilding projects of unsafe buildings as dwellers can get back fast > builders get more FSI benefits

16. 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


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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 well as metro like Mumbai RW Building will become attractive to people and RW bldg will be much more durable than concrete structures


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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 rail corridor 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


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26. While making more profit, can also contribute to the environment and climate change (high selling point by builders/developers)

27. Help to conserve energy, scarce material like water and 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


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30. Rapidwall can be used as the basic structure for low income, 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 of work/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


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ContactsName Designation Telephone email

Marketing

Shri J. Kohareswaran Dir (Mktg) 24045455 [email protected]

Shri Bhunesh Mathur G.M. (Mktg) 24045031 [email protected]

Shri M.M. Patil D.G.M. (Mktg) 24045125 [email protected]

Technical Support

Shri Dilip Deshmukh Advisor (Projects) 24045173 [email protected]

Shri P.M.C. Nair G.M. (Corporate) 24045068 [email protected]

Shri P.G. Deshpande D.G.M. (Corp) 240450459820384068

[email protected]

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Thank You

prefab wallmaking technology

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