GFRG BUILDING SYSTEM

MARKETED BY : BILTECH BUILDING ELEMENTS LTD.

PRESENTED BY : RAJDEEP CHOWDHURY

Avantha Group is one of India’s leading business conglomerates. Having footprint in 90 countries. US$ 4 billion Avantha Group has 25,000 employees worldwide.

Its successful entities includes :

BILT – Paper & Pulp

Crompton Greaves –Power Equipment

The Global Green Company- Food processing

Biltech Building Elements Ltd. – Building Material

Avantha Power & Infrastructure – Power generation

Avantha Technologies – IT & ITES.

Biltech Painting

Biltech Building Elements Ltd.

Design and Build structures with GFRG / Rapid wall Panel system

Biltech Prefab Biltech AAC

Manufacturing & Marketing of AAC

Industrial & Decorative

Conventional building materials are :

Energy intense

Demand is growing

Materials like river sand & water is scarce

Cost’s spiraling up

Increases CO2 emission & impact on environment

&

Construction is time consuming

Therefore , there is a need for an alternative building materials & fast construction methods for housing

RATIONALE

Pospho-gypsum is produced as byproducts of chemical , fertilizer

industries and due to its limited usage , this waste is becoming an

environmental problem.

The Rapidflow Calciner and Rapidwall Technology can help to

overcome these problems by turning waste into plaster and the

plaster into homes that are environmentally friendly, non-

polluting, energy efficient and aesthetically pleasing.

PHOSPHO GYPSUM

PLASTER BUILDING MATERIAL

(RAPIDWALL)

GFRG / RAPIDWALL - A REVOLUTIONARY BUILDING MATERIAL

GFRG/ Rapid wall is load bearing pre-fabricated walling panel. This

is suitable for rapid mass scale building construction was originally developed and used since 1990 in Australia.

GFRG/ Rapid wall is manufactured using Gypsum as a core

material , which is generated as by product in the process of manufacturing fertilizers

GFRG/ Rapid wall is manufactured at RCF , Mumbai and FRBL ,

Kochi. GFRG/ Rapid wall is suitable for load-bearing applications and as

well as hybrid Construction in multi-storey buildings.

Environmental friendliness

reinforced by glass rovings

Micro-strand glass roving role

• Rapidwall panels are 12m

long , 2.85m high and

0.124m thick.

• Made from Gypsum, Glass

Rowing, and Special

Chemicals.

• Made from Australian

Technology

GFRG / Rapid wall Panel

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.

Glass Fiber Reinforced Gypsum (GFRG) Panel, called RAPIDWALL . It is an ideal alternative building material to replace conventional walling system.

MATERIAL

Advantage of GFRG/ Rapid wall Building system

• Light weight

• Less Input material i.e. Steel , cement . sand and water

• More Carpet area

• Faster Construction

• Less Labor Input

• Eco Friendly , controls CO2 Emission

• Saving of recurring energy cost

• Resistant to Earthquake , Cyclone & fire

• Free from Corrosion , rot & termite

Compressive strength (Empty panel ): 73.10 Kg/cm2

(Concrete infill ): 180.70 Kg/cm2

Flexural Strength empty 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 resistance

4 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 weight 40 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 top soil

•Cement •Steel

Saves time of construction

• Low maintenance cost •Saving in recurring

energy cost

Cost-effective (affordable cost)

Properties of GFRG/ Rapid wall Panel

TESTS ON GFRG / RAPIDWALL

List of tests : ( carried out by IIT Chennai )

Water absorption Test Rain Water Penetration Test

Compressive Strength Test

Fire Resistance Test

Durability Test

Corrosion Test

Impact Test

Nailing & pull out Test

Sound Transmission Test Test to find Elastic Modulus

Tests carried out by SERC, CSIR Chennai ( 2002)

1. Seismic performance of Rapid wall building system 2. Investigations of behavior of Rapid wall Panel

3. Compressive strength with and without concrete in-fill

Flexural test with Single Point Load on large panel with & without concrete infill

Flexural Test by double point load with or without concrete infill

Axial Compression{ Vertical Load test} on high panel with & without concrete in-fill

Structural Design Manual & PACS

Applications • In apartment buildings, some up to 14 storey's, concrete filled Rapidwall

panels have been used very successfully in load-bearing construction to support combined lateral and vertical loads and to support vertical loads only.

Load-bearing walls in multi-storey construction

• Rapidwall panels, either unfilled or concrete filled, can be used to support domestic structures. Unfilled Rapidwall can be used to support domestic structures up to two storey's providing the suspended floor is constructed from timber.

Individual Dwelling Construction

• Unfilled 100 millimeter Rapidwall (current panels are 124 mm) will provide an FRL of 180/120/60 and concrete filled Rapidwall an FRL of 240/240/240.

Walls that require high fire rating

• Insulation filled Rapidwall panels have been successfully used in cottage construction as structural roof elements over which battened roof sheeting is placed.

Roof panels

• When used as permanent-formwork for suspended concrete slabs, services such as electrical or plumbing can be carried in the cells, noise attenuation between floors is improved and a finished plaster ceiling is obtained.

Permanent formwork for suspended slabs

• Rapidwall has been used extensively for domestic fencing providing a high

quality finish to both neighboring properties. Uniquely Rapidwall can be placed directly in trenches and sand filled to provide solid foundation free fences up to two meters high.

Compound Walling

Manufacturing Process & Plant

Section of GFRG/ Rapid wall Panel

Various construction joints in GFRG/ Rapid wall

Design of Floor Slab

GFRG panel with reinforced concrete micro beams and screed concrete can be used as a slab both as floor slab as well as roof slab for buildings. The basic design philosophy as the same is that given in IS: 456-2000, corresponding to slab behavior .

2Y-12 + 1Y-8

Micro-beams

120

Inside face

Joint sealant

Powder coated steel /

aluminium window /

door frameJoint sealant

Outside face

FixerClamps

(b) TYPICAL WINDOW OPENING / WINDOW FRAME FIXING

(a) TYPICAL DOOR OPENING / DOOR FRAME FIXING

FFL

Section A - A

A A AA

Typical door opening /

door frame fixing

DOOR & WINDOW FIXING

SECTION

Basin - mounted tapware - Note :- wall plumbing

should not be placed inside Rapidwall

party walls

Wall - mounted basin

Rapidwall cores to be concrete filled.

Basin bracket to be bolted through to

outer face of panel with fixing to

manufactuers recommendations.

Countersink and flush finish to face.

120mm Rapidwall panel

Waterproof membrane by others

Floor level

Rapidwall panel to sit

setdwon, not in setdown

120mm Rapidwall panel

concrete fill cores immediately

behind basin.

Fixing to extend through

concrete - flush over bolt

SECTIONAL PLAN

Wall - mounted basin

Base for fixing tiles.

Water pipe

Bridging tap / body screw fixed to

blocking using galvanised metal straps

and 6g x 25 Bugle head screws.

Provide flexible sealant or

approved selected gasket

Provide flexible sealant or

approved selected gasket

Wadding (note the formed hole must

be large enough to accommodate the

positioning of the C - section member)

Waterproof membrane

Wall tiles - direct stick

Provide wadding to 60mm long section

of steel (100.12. (102 x 51 nom)

Screw fix steel member to Rapidwall

using 2 Nos 8g x 30 Bugle head screws

50m

m f

ixin

g c

entr

es

120mm Rapidwall panelR

SECTIONAL PLAN

R

Fixing of

sanitary ware

& piping

BASIN AND URINAL FIXING

METHOD & SEQUENCE OF CONSTRUCTION OF HYBRID SYSTEM

GFRG panels in RCC framed Structure

GFRG/ Rapid wall panels can be used as infill walls / slabs in conventional RCC Framed construction . This system is suitable for low rise to high rise building without any limitation in the number of storey's. The use of GFRG/ Rapid wall panels and composite floor panels can be integrated with the construction of column & beams

GFRG panel in Hybrid Building

Some Projects with GFRG / Rapid wall

Picture Gallery

HIGH RISE APARTMENTS

“CROWN OF THE HILL” at Pennant Hill, Sydney.

MARBURY, Sydney.

Boundary Walling with GFRG

Demo Building after completion

Service matrix offered by BILTECH

• Project Planning

• Designing & Estimation

• Construction & commissioning

• Project Management

Sequence of Construction of G+1 storied Demo Building in IIT Madras campus

• Structural design by IIT Madras & BMTPC • R&D support by Dept. of Science & Technology

Various stages of Construction

THANK YOU !

For any Queries Please Contact Rajdeep Chowdhury M:- +91-9811076657 E:- rajdeep.chowdhury@bilt.com