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Presentation

on

Techno--economic
Techno

& Construction Advantages


of

RCFs Rapidwall Panels

RCF and Rapidwall Prefab Wall Panel Technology

Rashtriya Chemicals & Fertilizers Limited is a Government of


Indias PSU engaged in manufacture of fertilizers and Industrial
Chemicals since 1965. Details available at our website
www.rcfltd.com.
RCF is setting up a plant at its Trombay Unit for manufacture
of Load Bearing Wall Panels, wall putty and plaster through its
byproduct gypsum by a specialized technology from Australia
called Rapidwall Technology.
12m x 2.8 m panels will be made by calcined gypsum, glass
fibers 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 per
the customized requirement. Panels will be precut as per the
design of the house so that they need to be just assembled and
joined at site.
RCF has built a two storey Demonstration Building by these
panels in early 2006 at its Township in Chembur which is a
point of attraction and can be visited upon request.
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Alternative Building Material


RAPIDWALL . is an

alternative building material to replace


bricks / concrete blocks which will also save
river sand, water etc and protect the environment

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.
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.

reinforced by glass rovings

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

Rapidwall Panel is manufactured in 12 m x 3 m with


120 mm thickness with modular cavities.
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Cutting of panel to required sizes using


automised cutting saw in RW factory

Stillages to transport Rapidwall panels


safely to every building site.

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

Up to 500 m of Rapidwall can be


transported on one truck.

Fire Resistant Testing by IIT Madras


Rapidwall building material is Fire Resistant

4 hrs rating of 700 1000 oC

maximum
temp recorded
using electronic
recorder on the
opposite side is
57 oC on empty
panel

Application of
700-1000 oC
heat for 4 hrs

maximum
temp recorded
using electronic
recorder on the
opposite side is
66.7 oC on panel
with concrete
infill

Application of
700-1000 oC
heat for 4 hrs

Thermal conductivity is very less


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BMTPC / Govt of India approved the product


for construction of buildings upto 10 storeys

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Construction of First Rapidwall


Building in India
in Mumbai in 32 days by RCF
(structural design by IIT Madras & constructed
as per Rapidwall construction manual
prepared by IIT Madras)

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RW panel taken out from container brought from


Australia for construction of demonstration building

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Conventional Building foundation with RCC plinth beams


provided with MS rods as start up rods for erection of
panels as superstructure of building

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Panels cut into various sizes as per building plan are


brought to construction sites by truck or lorry.
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Panel with opening for two windows is being placed over


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RCC plinth beam

While panel is placed over plinth beam, start up rod will


go into cavities, including corner joints. Cavities upto
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required height will be in-filled with concrete

Panel being placed / seated on RCC plinth beam over a


thin layer of cement mortar slurry.
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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.
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First pouring of concrete into wall corner joint.

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

Cutting the panel for required opening to provide RCC


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lintel cum sunshade

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

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For roof/floor, panel to be lifted horizontally / flat as


seen in picture.

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

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RW roof panel placed on walls.

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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.

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

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100 mm x 100 mm, 10 gauge weld mesh provided for 50


mm thick RCC screed. Embedded RCC micro-beams
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act as micro T beams

Side shuttering provided for concreting of RCC


horizontal tie beams and screed floor concrete

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Start up rod for erection of wall


panel for upper floor. Vertical
continuous reinforcement as
per structural design provided
from foundation to upper floor.

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Simultaneous concreting of RCC horizontal tie beams,


micro-beams and screed concrete
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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.

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Erection
of wall
panel over
first floor
is in
progress

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Wall panel with


window and
ventilator
opening is being
placed in first
floor

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Window
frame
with
shutter
in
position

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RCC lintel cum sunshade, architectural band,


parapet wall work completed

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Electrical switch board / junction box in position

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Water supply pipeline work in progress


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Wall corners, ceiling


corners are given fine
finish using special
gypsum plaster
product

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Sanitary fittings,
water supply fittings

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Fan and light fittings in position

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Fixing of facing wall tiles/ cladding on RW panel wall

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Ceramic flooring tiles

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First coat of painting


in progress

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

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Interior
finish,
skirting,
ceramic
floor tiles,
furnishing,
curtain
rods, fan,
light
fittings etc
in position
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Rear view of two storey 1220 sqft RW building in 32


days. MS iron ladder to rooftop

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Front view of completed building. Front compound


wall using RW panel

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

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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
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A view of Rapidwall buildings in


Australia and China

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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
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complex is close to World renowned Sydney Opera House.

Multistoried construction

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


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

A
U
S
T
R
A
L
I
A

Multistoried
Rapidwall
building
CROWN
OF THE
HILL
at Pennant
Hill,
Sydney.

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17
storey

Recently
constructed (2001)
MARBURY of 18
(17+1)
storeys
with rapidwalls in
the
centre
of
Sydney.
Bottom
10 storeys are
RCC
framed
structure walling
with
rapidwall
panels.
Top 8
storeys are made
of Rapidwall load
bearing walls

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Residential

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COMPOUND WALLS

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Rapidwall buildings in China

Six storeyed Guest House building in an industrial park in


Jinan city, Shandong Province, China.
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Rapidwall buildings in China

Seven storey (six storey + pent house) Apartment Gypcrete


building in Tianjin, 150 km from Beijing city.
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India needs millions of small houses for its


suburban areas, small towns and rural areas

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.
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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
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Saving by one panel


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

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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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Strength of Rapidwall building panel at a glance


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

Water absorption

Tensile strength

Ductility

28.8 kN/m

4.11

Fire resistance

Thermal resistance

< 2% (24 hrs)

4 hrs rating
700 oC to 1000 oC.

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 :

Rot
&
termite proof

Light weight
40 Kg / m2

Net Density

(1/8th

1140 Kg / m3

weight of
concrete)

Saving

Water
River
sand
Agri soil

Cemen
t
Steel

Saving
Time of
construction

154 tons

Earthquake
resistant: test
withstood
earthquakes up to
Richter Scale 8
Very low
maintenance cost
Saving in recurring
energy cost for
cooling (air

Eco-friendly
(green material)

(raw material
recycled waste & no
emission
of CO2 )

Cost-effective68
(affordable cost)

Reduction of mass (weight) using


Rapidwall building panels
Weight of 1 sq.m brick wall :
9 thick with 2 sides cement
plastering
Weight of 1 sq.m Rapidwall
panel

Weight
reduction

400 Kg

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 50.0%
(avg)

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Gypsum based wall plaster for


plastering internal brick/concrete walls
& ceiling
Plastering of
brick/concrete walls
and ceiling using
gypsum based wall
plaster as substitute for
cement plastering
saving > cement, sand, water
advantages > superior finish
> less cost than cement
plaster
> cooler inside
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Taking
out wall
plaster
for
mixing in
water to
make
paste

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affixing a

With POP
paste
marking
the levels
by
broken
floor tile
piece

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POP paste
is applied
to mark
vertical
levelling
marks,
which are
provided at
3-4 feet
intervals
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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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Facts Speak:
Population:
Greater Mumbai ppn :
11.97 million (2001 census)
Present population
:
18.0 million
Slum ppn greater Mumbai :6.62 million (2001 census)
Housing scenario:
Indias demand for housing (study by ASSOCHAM 2005)
by 2015 : 80 million
by 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)


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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

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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
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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 plan
2nd pillar
:
Finance
3rd pillar
:
Building materials
4th pillar
:
Construction (builders,
labourers, skills)
Building Materials > growing demand
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Conventional basic building materials


i)
ii)
iii)
iv)
v)

Burnt clay bricks / concrete blocks


its demand is growing
Cement
year by year
Steel
River sand
Water

Cem ent Production in India in m illion tonnes


(source:BMTPC)

300
200

145

160

176

194

100

Projected

0
2005

2006

2007

2008

2009

2010
82

Steel Production in India in million


tonnes
150

110

100
50

Steel Policy

Projected

25

35

45

0
2005 2006 2007 2008 2009 2010
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Brick Production in India in billion

250
200
150

160

140

200

Projected

100

50
0
2005

500
400
300

2006

2007

2008

2009

2010

River Sand use in India in million cum


Estimated

303

334

368

404

200
100
0
2005

2006

2007

2008

2009

2010

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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
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Cost of construction of brick wall Rs per sqm


Rs 106/sft
including both sides cement plastering
1140
1200
900
1000
768
680
800
?
560
500
600
400
200

08
20

20

07

(a
p

r)

v)
06

20

20

06

(m

(n
o

ar
)

05
20

04
20

20

03

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

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Economics of Rapidwall:
Comparison between 2 storey RW building &
conventional bldg (structure only
Conv Bldg
for same carpet area)
RW Bldg
Plinth area
Cement Requirement
Steel requirement
Brick requirement
Water requirement
River sand requirement
Self weight/dead weight
Period of construction
Labour requirement
Cost of construction
Rate of Const per sft

1201 sft
9.36 t
1.434t
Nil
7000 lit
14.5 cum
56.16t
37 days
150 mandays
Rs 5,60,000
Rs 466 /sft

1310 sft
20t
3.518t
55,000
1.7 lakh lit
41.64 cum
204t
165-180 days
720 mandays
Rs 8,60,000
Rs 656 / sft
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Cost of RW dwelling unit of 226 sft : Rs 1,04,000


Cost if row dwelling units : Rs 82,000
(Saving by common wall, its foundation, erection charge,
painting etc.)
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

RW Demo Bldg

Conv Bldg

26275 kWh

1,36,908 kWh

110633 kWh
80%

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Two other products for use in conventional bldg


construction
WALL PLASTER
RAPID WALL PLASTER
alternative to cement
and sand mix
plastering of internal
walls &ceiling

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

Superior finish. No need for


additional layer of plaster with
wall putty to get even &
smooth finish.
Thereby saving substantial
costs

RAPID WALL PUTTY


Gypsum 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
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Benefits to Builders / Developers


1. Very fast construction
2. Reduced hassles of construction with less
materials
3. Saving in transport cost of sand, bricks/concrete
blocks, granite metal, cement, steel, water,
scaffolding & shuttering materials
4. Strong & quality construction
5. Less number of workers
6. Less overhead cost & less project time
7. No problem of disposal of waste / debris
8. Quick turnover with many fold reinvestment per
annum bringing more profit
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Benefits to Builders / Developers


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
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Benefits to Builders / Developers


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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Benefits to Builders / Developers


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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Benefits to Builders / Developers


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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Benefits to Builders / Developers


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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Benefits to Builders / Developers


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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Contacts
Name

Designation

Telephone

email

Shri J. Kohareswaran

Dir (Mktg)

24045455

jkohareswaran@rcfltd.com

Shri Bhunesh Mathur

G.M. (Mktg)

24045031

bhuneshmathur@rcfltd.com

Shri M.M. Patil

D.G.M. (Mktg)

24045125

mmpatil@rcfltd.com

Shri Dilip Deshmukh

Advisor (Projects)

24045173

ddeshmukh@rcfltd.com

Shri P.M.C. Nair

G.M. (Corporate)

24045068

pmcnair@rcfltd.com

Shri P.G. Deshpande

D.G.M. (Corp)

24045045
9820384068

pgdeshpande@rcfltd.com

Marketing

Technical Support

97

Thank You

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