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1
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
++ 91 7666717696
• 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?
++ 91 7666717696
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
++ 91 7666717696
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
STANDARD WALL PANEL SPECIFICATION
++ 91 7666717696
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
STANDARD WALL PANEL SPECIFICATION
++ 91 7666717696
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
STANDARD WALL PANEL SPECIFICATION
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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
STANDARD WALL PANEL SPECIFICATION
++ 91 7666717696
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
STANDARD WALL PANEL SPECIFICATION
++ 91 7666717696
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%
Class 2, 124 mm thick 44 ±6%
Class 3, 124 mm thick 44 ±15%
STANDARD WALL PANEL SPECIFICATION
++ 91 7666717696
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
STANDARD WALL PANEL SPECIFICATION
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
++ 91 7666717696
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