Download - Rapid Wall

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RAPIDWALL ………...!!

REVOLUTION IN

CONSTRUCTION INDUSTRY

MASS HOUSING AT

AFFORDABLE COST++ 91 7666717696

• Rashtriya Chemicals and Fertilizers Limited is a PSU of GOI engaged in the field of Fertilizers and Chemicals.

• We manufacture about 26 Lakh MT of fertilizers per year and about 20 Industrial Chemicals. We sell 50 Lakh MT fertilizers.

• We are ISO-9001, 14001 and OHSAS 18001 certified company.

• We are one amongst top 10 MOU signing PSUs of India

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ABOUT RCF

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• These are wall panels of 12 m x 3 m made from gypsum, glass rowings and special chemicals.

• Australian Technology (RBS).• As compared to conventional building

material, these are More Carpet Area strongerFast constructionlight-weight, (just 12% of conventional)Earthquake / Corrosion / fire / termite proofCheaper

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WHAT IS RAPID WALL?

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Rapidwall – A Revolutionary Building Material

• RCF produces Phosphoric Acid as an intermediate for Complex Fertilizers

• Phospho-gypsum is a by product of Phosphoric Acid Plant.

• Disposal of phospho-gypsum – only to a limited extent.

• Rest is accumulated over years.

• Value addition to this by-product by making

useful building material - Rapidwall ++ 91 7666717696

RapidwallPlant

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1} WALL PANELS (SIZE – 12 M. X 3 M. X 124 MM THICK)

2} WALL PUTTY

3} WALL PLASTER

4} PLASTER OF PARIS++ 91 7666717696

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Rapidwall – An alternative Building Material

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reinforced by glass rovingsPanel is reinforced by micro-strand glass rovings (13 microns) by both ways on all four sides - both flanges and webs.

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

Structure of Rapidwall Panels

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•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

FIRE RESISTANT TESTING BY IIT MADRAS

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

Rapidwall for Mass Housing

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With 2-3 RW panels a small house can be built which is strong and durable with more cool and living comfort.

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

Eco-housing

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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 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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one panel of 36 sq. m can replace 3960 bricks (a lorry load of bricks)

4000 bricks

World’s largest load bearing building panels

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Compressive strengthempty 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 filled

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 sand•Agri soil

•Cement•Steel

Saving

• Time of construction

• Very low maintenance cost

• Saving in recurring energy cost for cooling (air conditioning) [88%]

Cost-effective(affordable cost)

Strength of Rapidwall building panel at a glance

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Cost reduction by Gypcrete houses / buildings :

item breakup to total cost of conventional bldg

breakup to total cost of Rapidwall bldg

% of saving

foundation 15% 7.5% 7.5%

walling & plastering 37% 30% 7%

roofing 20% 17.5% 2.5%

flooring 6% 6% --

doors & steel windows 9% 9% --

electrical 5% 5% --

water & sanitary works

5% 5% --

painting 3% 3% --

cost of water 1% -- --

contingencies 1% (transportation, contingencies &

water) 2% --

Additional carpet area 8%

Total 100% 85% 25%

* 8% more carpet areaFor repetitive & large projects saving will be 25 - 30%.++ 91 7666717696

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RAPIDWALL PANEL IS MANUFACTURED IN 12 M X 3 MWITH 124 MM THICKNESS WITH MODULAR CAVITIES.

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CUTTING OF PANEL TO REQUIRED SIZES USING AUTOMISED CUTTING SAW MACHINE

IN RAPID WALL PLANT

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STILLAGES TO TRANSPORT RAPIDWALL PANELS SAFELY TO EVERY BUILDING SITE.

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Up to 500 m² of Rapidwall can be transported on one truck.

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

TRANSPORTATION

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FIG. 1

STANDARD DIMENSIONS The current nominal manufactured dimensions of each Rapidwall panel are: -• Length 12,020 millimetres;• Height 3000 millimetres; and• Thickness 124 millimetres

STANDARD WALL PANEL SPECIFICATION

1515

124

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WATER RESISTANT RAPIDWALL PANEL Water resistant Rapidwall panels are the same as ordinary Rapidwall panels in appearance. However the ingredients of the water resistant Rapidwall are modified specifically to provide water resistance when used externally or in wet areas such as bathrooms or laundries, etc.

EXTERNAL SKINThe two 13mm thick faces making up the panel are collectively defined as external skins as shown in Fig.1

INTERNAL RIB The 20mm thick ribs inside the panel connecting the two external skins are called internal ribs as shown in Fig.1

CAVITY The internal hollow cores inside the panel are called the cavity as shown in Fig.1


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PANEL LENGTH The panel length is the maximum horizontal dimension of a single wall without vertical joint as indicated in Fig.1

PANEL THICKNESS The panel thickness is the distance between the external faces of the two external skins, as shown in Fig.1.

PANEL HEIGHT The panel height is the maximum vertical dimension of a single wall without a horizontal joint

A AND B SIDE The smoother side of the Rapidwall panel cast against the machine bed in the manufacturing process is called the A side. The B side is screeded and is relatively rougher than A side


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GRADE CLASSIFICATION Rapidwall panel is supplied in three grade classifications:-1). Class 1 - Water Resistant grade – panels that can be used

for external walls, in wet areas and/or as floor and wall formwork for concrete filling;2). Class 2 - General grade – Rapidwall panels that can be used structurally or non- structurally in dry areas. These panels are generally unsuitable for use as wall or floor formwork; and3). Class 3 - Partition grade – Rapidwall panels that can only be used as non- structural internal partition walls in dry only areas


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PRODUCT CODING Rapidwall panels are coded using the following convention:-

Where panel type is indicated as ‘G’ for general grade, ‘W’ for water resistant grade or ‘P’ for partition grade. For example a Water resistant l grade panel made in RCF, Trombay plant in Chembur , Mumbai 21st Feb 2010 is coded as: - RAPIDWALL® 124G-12X3-21FEB10/TROMBAY


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DIMENSIONAL TOLERANCES The manufactured dimensional tolerances for a full sized Rapidwall panel shall satisfy Tables 1 and 2:-Table 1. Overall Dimensional Tolerance

Length Height Thickness

Nominal length±3mm

Nominal height±3mm

Nominal thickness+3 to –0 mm

Table 2 Cross-sectional Dimensional TolerancePanel Classification External Skin

ThicknessInternal RibThickness

Cavity Width CavityDepth

General Grade&

Water ResistantGrade

NominalThickness

±3

NominalThickness

±2

NominalWidth

±4

NominalDepth

±3

Partition Grade Minimum 8 NominalThickness

±5

NominalWidth

±7

NominalDepth

±7


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WATER CONTENT The water content of panels measured immediately after the drying process (without moisture intake after drying) shall be less than 1% when tested.

PANEL WEIGHT The weight of the dried and empty hollow core Rapidwall® panel shall satisfy Table 3:-

Table 3 Empty Panel Weight

Panel Classification(mm)

Nominal Weight(kg/m2)

Tolerance%

Class 1, 124 mm thick 44 ±6%




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OUT-OF-PLANE FLEXURAL CAPACITY When tested in accordance with Clause 10.4.7 or 10.4.8, the out-of-plane flexural strength of the panel shall satisfy the minimum requirements as given in Table 5. Table 5 Acceptance criteria for flexural strengthMinimum Flexural Strength per metre width

General or WaterResistant Grade

Partition Grade

2.0 kNm 1.3 kNm


Water Absorption Rate When tested in accordance with Clause 10.4.6, the cross-sectional compression strength of the panel shall satisfy the minimum requirements as given in Table 4. Table 4 Acceptance criteria for compression strength Minimum compression strength (kN/m)

General or water resistant grade Partition grade

160 90++ 91 7666717696

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

: 400 Kg

Weight of 1 sq.m Rapidwall panel : 44 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

REDUCTION OF MASS (WEIGHT) USINGRAPID WALL BUILDING PANELS

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WALL PLASTER alternative 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 PLASTER Superior 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 which are white cement based

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TWO OTHER PRODUCTS FOR USE INCONVENTIONAL BUILDING CONSTRUCTION

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++ 91 7666717696

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