Presentation on Techno Economicand Construction Advantages of Rapid wall Technology Rapid Wall Technology • • • • Introduction Properties of rapid wall panels Advantages of Rapid wall panels Energy, Environment and Economic values of Rapid wall panels • Case- Use of Rapid wall panels in India Alternative Building Material RAPID WALL ....is an alternative building material to replace bricks / concrete blocks which will also save river sand, water etc and protect the environment glass) of 13 microns. . longitudinal and cross wise on inner and outer flanges as well as web to make strong.cross section of Rapidwall® building panel Gypcrete® (made of gypsum plaster and non hazardous chemicals and water repellent emulsions etc) 250mm 13mm 120mm 94mm 20mm thick web 230mm Gypcrete® (made of gypsum plaster and non hazardous chemicals and water repellent emulsions etc) 13mm thick flange Reinforcement by micro-strand glass rovings (e. Panel is reinforced by micro-strand glass rovings (13 microns) by both ways on all four sides both flanges and webs. Reinforcement is provided during the automated hi-tech production process itself. . This reinforcement provide load bearing capability & "confinement property" when cavities filled up with concrete. Tensile strength of glass roving (single filament) is 3100-380 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. This glass roving itself is a hi-tech product manufactured in India. Rapid wall Panel is manufactured in 12 m x 3 m with 120 mm thickness with modular cavities. . Cutting of panel to required sizes using automised cutting saw in factory . After cutting Rapid wall is loaded onto collapsible frames. ready for transport. . 5 million sqm . Mumbai: Rapidwall :1.4 million sqm {15 lakhs sft} Wall Plaster: 30000 tons Wall Putty : 5000 tons PoP : 15000 tons GBIL Plant. Cochin : Rapidwall:1.5 lakhs sft Total capacity to produce Rapidwall= 3.Rapidwall Plants in India ( eco-friendly building materials) Plants: Products & Production Capacity/ year RCF Plant. Chennai Rapidwall: 7.4 million sqm { 15lakhs sft} Wall Plaster: 40000 tons Wall Putty : 15000 tons RCF& FACT. 25 Kg/cm2 b) Concrete infill panel.Properties of Rapid wall panels • Compressive strength a) Empty panel.80 Kg/cm2 • Water absorption.70 Kg/cm2 • Flexural Strength a) Empty panel.40 Kg/m2 b) With concrete infill.< 2 % (24 hrs) • Ductility – 4.21.4 hrs rating 7000c to 10000c • Free from corrosion • Density – 1140 Kg/m3 • Light weight – a) Without concrete infill .11 • Fire resistance.20.73.250 Kg/m2 • Earthquake resistancePanel withstood earthquakes up to 8 Richter scale .10 Kg/cm2 b) Concrete infill panel180. Advantages of Rapid wall panels • • • • • • • Light weight panels Economical Load bearing High quality finish Earthquake resistance Water resistance Termite resistance • Fire resistance • Speedy installations • Environmental positive • Good noise resistance • Accommodates building services . Why it is necessary? Housing is one of the basic human needs along with food. Problem of housing Exponential population growth Fast rate of urbanization Inadequate addition to the existing housing stock Large scale migration of the poor from the villages and small towns . over 33% of the population in developing countries are homeless. India too is presently passing through a phase of acute housing shortage. clothing and education. Like other developing country. According to UN estimate. Urban housing in India present large scale big building but on other hand it also have slums. 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 building: 25% in 3 yrs Size of free dwelling units under various schemes : 225 sft .Maharashtra Govt Housing Policy (draft Nov 2006) Urban Housing const. Maharashtra Govt Housing Policy Clause 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 . W o rk e rs.Building Construction B u ild in g L a n d a n d E n g in e e rin P lan F in a n c e B u ild in g m a te ra il s C o n stru c tio n L a b o u rs. E q u ip m e n t s . . . Brick production in India in Billion 250 200 Billion 200 150 140 160 100 50 ? 0 2005 2006 2007 ? 2008 Year ? 2009 2010 . River sand use in India in Million cum 450 400 350 303 300 250 200 150 100 50 0 2005 334 368 404 ? 2006 2007 2008 Year ? 2009 2010 . Saving by One panel • 10000 Lit of water • 2.80 tons of cement • Emission of 0.696 tons of CO2 .43 m3/ 86 cft of river sand • 8 m3 of soil • 0. Avoid Pollution No Emission of CO2 Recycled Industrial waste Environment friendly Building material Low energy based production process Save river sand. and water Can be re used . soil. Construction of First Rapid wall Building in India in Mumbai in 32 days by RCF (structural design by IIT Madras & constructed as per Rapid wall construction manual) . RW panel taken out from container brought from Australia for construction of demonstration building Conventional Building foundation with RCC plinth beams provided with MS rods as start up rods for erection of panels as superstructure of building Panels cut into various sizes as per building plan are brought to construction sites by truck or lorry. Panel with opening for two windows is being placed over RCC plinth beam . While panel is placed over plinth beam. start up rod will go into cavities. Cavities up to required height will be in-filled with concrete . including corner joints. .Panel being placed / seated on RCC plinth beam over a thin layer of cement mortar slurry. After setting of concrete in-filled. Angles are provided from two sides using nuts& bolts. adjustable slanting prop is provided .2 panels erected as corner walls. these angles are removed. For supporting panel in position. .First pouring of concrete into wall corner joint. . Cutting the panel for required opening to provide RCC lintel cum sunshade . RCC sunshade can be cast over the window . With ply wood / MS sheet as shutter.MS Rods for RCC lintel cum sunshade as per structural design provided. panel to be lifted horizontally / flat as seen in picture.For roof/floor. . . . .Floor / roof panel provided with embedded RCC micro beams. top flange of respective cavities are cut. PVC pipes. fan hooks etc are to be laid. For this. For concealed electrical wiring. cables. bottom support with ply wood / strong MS sheet with prop wherever required are to be provided .Before cutting top flange. 10 gauge weld mesh provided for 50 mm thick RCC screed. Embedded RCC micro-beams act as micro "T" beams .100 mm x 100 mm. Side shuttering provided for concreting of RCC horizontal tie beams and screed floor concrete . Simultaneous concreting of RCC horizontal tie beams. micro-beams and screed concrete . . Walls on 3 sides of staircase and staircase landing to be done.Concreted floor / roof. Start up MS rods (40 cm high) for erection of upper floor wall panel by repeat process. . Window frame with shutter in position . parapet wall work completed .RCC lintel cum sunshade. architectural band. . ceiling corners are given fine finish using special gypsum plaster product .Wall corners. . . handrail.Staircase. marble slab for staircase steps. finishing coat of painting . light fittings etc in position . furnishing. ceramic floor tiles. skirting.Interior finish. fan. curtain rods. MS iron ladder to rooftop .Rear view of two storey 1220 sqft RW building in 32 days. Front view of completed building. Front compound wall using RW panel . . the finishing work carried out in 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 .On completion of structure of the building including parapet wall in 12 days. Bldg was built in 22 days .RW demo bldg built in Kochi by RCF&FACT jointly. RW demo bldg in Cochin given sloped tile roof & car porch etc. (Kerala style) . Demo bldg built in Vizag in 22 days using RW panel made in Chennai plant . 2 3 River sand 20 m3 83.7779 tons 35.45 m3 27.37m3 76 4 Granite metal 36 m3 52.55 5 Bricks - 57200 - 6 Rapidwall 500 sqm - (based on Rapidwall demo bldg built in Cochin by FACT in 2008 .Comparison between conventional & Rapidwall building construction Materials Rapidwall used building Conventional Building Savings in % 1 Cement 15 tons 32.800 tons 2.6 2 Steel 1.55 tons 50. 000 Liter 2.5 .59 Construction 22 days time 120 days 82 11 Total weight 490 tons 65 12 Construction Rs 13.27 lakhs 27.47 (Rs 1100 lakh/Sq ft) 13 Embodied energy 215400 kWh 170 tons 82921 kWh 61.00.Materials used Rapidwall buiding Conventional Building Savings in % 7 Water 50.25 cost lakhs (Rs860/sft) Rs 18.45 m2 8 (1539 (1662 sft) 9 Labour 10 Sft 389 man days 1200 man days 67.000 Liter 75 8 Built area 143 m2 154. contingencies & water) Additional carpet area Total 8% 100% 85% 25% .5% 7.5% 2.5% walling & plastering 37% 30% 7% roofing 20% 17.5% flooring 6% 6% -- doors & steel windows 9% 9% -- electrical 5% 5% -- water & sanitary works 5% 5% -- painting 3% 3% -- cost of water 1% -- -- 2% -- contingencies 1% (transportation.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. A view of Rapid wall buildings in Australia and China . Sydney Park housing complex with 922 apartments. This eight storey building is without RCC columns and beams. . The first phase with 370 apartments was built in 1990. This complex is close to World renowned Sydney Opera House. The entire structure is built on Gypcrete® /Rapid wall panel. Multistoried construction . . . Shandong Province.Six storeyed Guest House building in an industrial park in Jinan city. China. . . 150 km from Beijing city.Seven storey (six storey + pent house) Apartment Gypcrete building in Tianjin. • It is basically used as substitute for cement plaster. sand.Cement. water • Superior finish. Easy mixing and application.Gypsum based wall plaster • Gypsum based wall plaster can revolutionize the plastering of internal walls and ceilings. • Savings. Cool feeling . Taking out wall plaster for mixing in water to make paste . Marking the levels with broken floor tile piece . POP paste is applied to mark vertical levelling marks. which are provided at 3-4 feet intervals . . . M.C.com Shri Bhunesh Mathur G.com Shri M.com Shri P.G. Deshpande D.G. (Mktg) 24045031 [email protected] Name Designation Telephone email Shri J.com Marketing Technical Support Shri Dilip Deshmukh Advisor (Projects) 24045173 ddeshmukh@rcfltd. (Corporate) 24045068 [email protected] Shri P.M. (Mktg) 24045125 [email protected] 24045045 9820384068 . Nair G.M.M. (Corp) pqdeshpande@rcfltd. Kohareswaran Dir (Mktg) 24045455 ikohareswaran@rcfltd. Patil D.G.
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