Presentation

on
Techno--economic
Techno
& Construction Advantages
of
RCF’s Rapidwall Panels

1
RCF and Rapidwall Prefab Wall Panel Technology
• Rashtriya Chemicals & Fertilizers Limited is a Government of
India’s 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 it’s 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.

2
 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

3
 Rapidwall is reinforced by glass rovings
Panel is reinforced by micro-strand glass reinforced by glass rovings
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. 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

4
Rapidwall Panel is manufactured in 12 m x 3 m with
120 mm thickness with modular cavities.
5
Cutting of panel to required sizes using
automised cutting saw in RW factory 6
Stillages to transport Rapidwall® panels
safely to every building site.

7
 Rapidwall

After cutting Rapidwall is

loaded onto collapsible
frames, ready for transport.

Up to 500 m² of Rapidwall can be

transported on one truck.

8
 Fire Resistant Testing by IIT Madras
•Rapidwall building material is Fire Resistant
4 hrs rating of 700 – 1000 oC

maximum maximum
temp recorded Application of temp recorded Application of
using electronic 700-1000 oC using electronic 700-1000 oC
recorder on the heat for 4 hrs recorder on the heat for 4 hrs
opposite side is opposite side is
57 oC on empty 66.7 oC on panel
panel with concrete
infill

• Thermal conductivity is very less

9
BMTPC / Govt of India approved the product
for construction of buildings upto 10 storeys

10
 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)

11
12
RW panel taken out from container brought from
Australia for construction of demonstration building

13
Conventional Building foundation with RCC plinth beams
provided with MS rods as start up rods for erection of
panels as superstructure of building

14
Panels cut into various sizes as per building plan are
brought to construction sites by truck or lorry.
15
Panel with opening for two windows is being placed over
16
RCC plinth beam
While panel is placed over plinth beam, start up rod will
go into cavities, including corner joints. Cavities upto
17
required height will be in-filled with concrete
Panel being placed / seated on RCC plinth beam over a
thin layer of cement mortar slurry. 18
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.
19
First pouring of concrete into wall corner joint.

20
All the walls of ground floor are erected in two days. 21
Cutting the panel for required opening to provide RCC
22
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
23
For roof/floor, panel to be lifted horizontally / flat as
seen in picture.

24
Panel for
first floor /
roof being
lifted for
placing in
position

25
RW roof panel placed on walls.

26
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.

27
Before
cutting top
flange,
bottom
support
with ply
wood /
strong MS
sheet with
prop
wherever
required
are to be
provided 28
100 mm x 100 mm, 10 gauge weld mesh provided for 50
mm thick RCC screed. Embedded RCC micro-beams 29
act as micro “T” beams
Side shuttering provided for concreting of RCC
horizontal tie beams and screed floor concrete

30
Start up rod for erection of wall
panel for upper floor. Vertical
continuous reinforcement as
per structural design provided
from foundation to upper floor.

31
Simultaneous concreting of RCC horizontal tie beams,
micro-beams and screed concrete
32
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.

33
Erection
of wall
panel over
first floor
is in
progress

34
Wall panel with
window and
ventilator
opening is being
placed in first
floor

35
Window
frame
with
shutter
in
position

36
RCC lintel cum sunshade, architectural band,
parapet wall work completed

37
Electrical switch board / junction box in position

38
Water supply pipeline work in progress
39
Wall corners, ceiling
corners are given fine
finish using special
gypsum plaster
product

40
Sanitary fittings,
water supply fittings

41
Fan and light fittings in position

42
Fixing of facing wall tiles/ cladding on RW panel wall

43
Ceramic flooring tiles
44
First coat of painting
in progress

45
Staircase, handrail,
marble slab for
staircase steps,
finishing coat of
painting

46
Interior
finish,
skirting,
ceramic
floor tiles,
furnishing,
curtain
rods, fan,
light
fittings etc
in position

47
Rear view of two storey 1220 sqft RW building in 32
days. MS iron ladder to rooftop

48
Front view of completed building. Front compound
wall using RW panel

49
50
RCC plinth beams, RCC column inside wall cavities,RCC tie beam all
around,micro beams & screed constitute monolithic RCC frame structure
inside Rapidwall bldg

51
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
52
A view of Rapidwall buildings in
Australia and China

53
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
54
complex is close to World renowned Sydney Opera House.
Multistoried construction

55
400 Rapidwall® apartments in Alexandria, Sydney. Completed to lockup stage
in one third of the time normally taken by conventional building methods.
56
 HIGH RISE APARTMENTS

Multistoried
Rapidwall
building
A “CROWN
U OF THE
HILL”
S at Pennant
T Hill,
Sydney.
R
A
L
I
A 57
 17 Recently
storey 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
58
Residential 59
COMPOUND WALLS 60
 Rapidwall buildings in China

Six storeyed Guest House building in an industrial park in

Jinan city, Shandong Province, China. 61
 Rapidwall buildings in China

Seven storey (six storey + pent house) Apartment Gypcrete

building in Tianjin, 150 km from Beijing city. 62
 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.

63
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 ……

64
65
 Saving by one panel
• 10000 litres of water . . .
• 2.43 m3 / 86 cft river sand . . . With 6
• 8m3 / a lorry load agri soil . . . panels of
• 0.80 tons of cement . . .
required size, 4
for four walls and
• emission of 2.9 tons CO2 . . . 2 pieces for sloped
With 2 - 3 panels a small roof a small house
can be built by
eco-house can be built. self help within
a days ……

66
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.
67
 Strength of Rapidwall building panel at a glance
Compressive
Flexural Strength
strength Ductility
empty panel : Tensile strength
empty panel :
21.25 Kg/cm2
73.10 Kg/cm2 28.8 kN/m
concrete infill :
concrete infill : 4.11
20.80 Kg/cm2
180.70 Kg/cm2
Water absorption Fire resistance Thermal resistance Sound
4 hrs rating Transmission Class
< 2% (24 hrs) 700 oC to 1000 oC. 0.36 R - STC 40
Axial vertical load
Axial vertical load
on concrete infilled Rot
Free from on empty panel
of 2.85m high x 1m
panel of 2.85m high &
Corrosion x 1m :
: 14.04 tons termite proof
154 tons
Earthquake Eco-friendly
Light weight
Net Density resistant: test (green material)
40 Kg / m2 (raw material
withstood
(1/8th
weight of 1140 Kg / m3 earthquakes up to recycled waste & no
concrete) Richter Scale 8 emission
of CO2 )

Saving • Very low

•Cemen Saving maintenance cost
•Water • Saving in recurring Cost-effective68
•River t • Time of
sand •Steel
energy cost for (affordable cost)
•Agri soil
construction cooling (air
Reduction of mass (weight) using
Weight
Rapidwall® building panels reduction

Weight of 1 sq.m brick wall : 400 Kg

9” thick with 2 sides cement
plastering
Weight of 1 sq.m Rapidwall : 40 Kg 90.0%
panel
Weight of 1 sq.m panel with : 250 Kg 37.5%
concrete infill
Load bearing walls + non : 200 Kg 50.0%
load bearing internal walls (avg)
using filled and unfilled
panels 69
 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
70
Taking
out wall
plaster
for
mixing in
water to
make
paste

71
affixing a
With POP
paste
marking
the levels
by
broken
floor tile
piece

72
POP paste
is applied
to mark
vertical
levelling
marks,
which are
provided at
3-4 feet
intervals

73
74
After 15 minutes,
surface is fine
finished using a
tin plate as
shovel

75
Gypsum based
WALL
PLASTER
can
revolutionise
plastering of
internal walls
and ceiling.
This will save river
sand & water

76
Energy, Environment, & Economic
Values of Rapidwall

77
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:
India’s 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)
78
 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

79
 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

80
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

81
Conventional basic building materials
i) Burnt clay bricks / concrete blocks
ii) Cement its demand is growing
iii) Steel year by year
iv) River sand
v) Water

Cem ent Production in India in m illion tonnes

(source:BMTPC)
300
160 176 194
200 145 ? ?
100
Projected
0
2005 2006 2007 2008 2009 2010
82
Steel Production in India in million
tonnes
150 Steel Policy

110
100 Projected
?
45 ?
50 25 35

0
2005 2006 2007 2008 2009 2010
83
 Brick Production in India in billion
250
200 Projected
200 160 ?
150
140
?
100
?
50
0
2005 2006 2007 2008 2009 2010

River Sand use in India in million cum

500
Estimated 404
400 334
368
? ?
303
300
200
100
0
2005 2006 2007 2008 2009 2010
84
• 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

85
Cost of construction of brick wall Rs per sqm
including both sides cement plastering
Rs 106/sft
1200 1140
1000 900
768
800 680
500
560 ?
600
400
200
0
03

05
04

08
v)

r)
)
ar

p
o
20

20

20

20
(a
(m

(n

07
06
06

20
20
20

1 year from now in 2008 it may cost much more ! 86

Economics of Rapidwall:
Comparison between 2 storey RW building &
conventional bldg (structure only Conv Bldg
for same carpet area) RW Bldg

1310 sft
Plinth area 1201 sft
Cement Requirement
20t
Steel requirement 9.36 t
3.518t
Brick requirement 1.434t
55,000
Nil
Water requirement 1.7 lakh lit
7000 lit
River sand requirement 41.64 cum
14.5 cum
Self weight/dead weight 204t
56.16t
Period of construction 165-180 days
37 days
Labour requirement 720 mandays
150 mandays
Cost of construction Rs 8,60,000
Rs 5,60,000
Rs 656 / sft
Rate of Const per sft Rs 466 /sft
87
 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

RW Demo Bldg Conv Bldg

Estimated embodied
energy 26275 kWh 1,36,908 kWh

Saving /reduction of
energy 110633 kWh
% of embodied energy
saving
80%
88
Two other products for use in conventional bldg
construction
WALL PLASTER RAPID WALL PLASTER
Superior finish. No need for
alternative to cement additional layer of plaster with
and sand mix wall putty to get even &
plastering of internal smooth finish.
walls &ceiling Thereby saving substantial
costs

WALL PUTTY RAPID WALL PUTTY

to get smooth and Gypsum based, superior &
more affordable wall putty as
superior finished wall an alternative to
surface, additional thin
layer of plastering is currently available wall putty
like Birla wall putty or JK wall
done over cement putty that are white cement
plaster in conventional based
brick /concrete wall.
89
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

90
 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

91
 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

92
 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

93
 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

94
 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

95
 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
96
 Contacts
Name Designation Telephone email

Marketing
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

Technical Support
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 pgdeshpande@rcfltd.com

9820384068
97
Thank You

98