GLASS FIBRE REINFORCED

GYPSUM PANELSPRESENTED BY: RAVI SHANKAR

REDG. NO. 11130060

WHAT IS GFRG PANEL?

• It is a gypsum based walling panel reinforced with glass fibre.

• It was developed by Australia in 1990.

• Dimension: 12m x 3m x 124mm

• Also known as Rapidwall, Gypcrete, etc,.

WHY GFRG?

• Our India is still a developing country fighting with a huge shortage of housing every year.

• We need a very fast construction technology which can increase our development rate

• Conventional methods of construction lead to formation of huge amount of CO2 (about 40% is developed due to construction industry) increasing chances of global warming.

• Fertilizer industries are facing problems regarding disposal of industrial waste gypsum (2000 tonnes per day)

• We are not having enough water for ourselves, then why allow buildings to drink it?

WHAT ARE THE ADVANTAGES?• Waste is used as resource making it very economical

• Construction rate is very fast- changes brick by brick construction to wall by wall construction

• Green Alternative Technology- Thus Environment Friendly

• Uses very less Sand, Steel and Water

• Building is fire resistant

• Earthquake resistant

• Much less labour force needed

• Weight of structure is very less

• More carpet area for same built up area

• No need of beams and columns

• No need of plastering thus cost can be saved in finishing

HOW MUCH IT IS FIRE RESISTANT?

HOW MUCH WEIGHT CAN BE REDUCED?

HOW MUCH CAN WE SAVE?

CementSte

elSa

ndWater

Built Area

Labour

Time

Weight Of S

uperstructu

re

Cost of C

onstructi

on

50.835.2

76 75

8

67.5982

65

27.47

Savings in %Savings in %

ECONOMICS (for 2 storey, 1500 sqft)S.No. Materials/ items GFRG Building Conventional Building Saving in %

1. Cement 16 tons 32.55 tons 50.8

2. Steel 1800 kg 2779 kg 35.2

3. River sand 20 cum 83.37 cum 76

4. Granite Metal 38 cum 52.46 cum 27.56

5. Bricks - 57200

6. GFRG Panel 500sqm -

7. Water 50000 ltr 200000 ltr 75

8. Built Area 143 sqm 154.45 sqm 8

9. Labour 389 mandays 1200 mandays 67.59

10. Construction Time 21 days 120 days 82

11. Total weight of superstructure 179 tons 490 tons 65

12. Construction cost Rs 13.25 lakhs Rs 18.27 lakhs 27.47

13. Embodied energy in kWh 82921 215400 61.5

HOW IT IS MADE?• It is made from Gypsum, an industrial waste from fertilizer industries (2000tonnes/day).

• It takes only 30 minutes to make a panel.

It is made in three stages:

STAGE-1• A paste of calcined gypsum and other chemical additives is poured on the specially designed table.

• Glass fibres are then spread evenly by means of screeding and rolling process.

STAGE-2• Special aluminium plugs are inserted on top of finished first layer with 20mm gaps in between to form hollow

cavities.

• 2nd pouring of mix is done along with glass fibre with tamping to form ribs of the hollow panel.

STAGE-3• Process of 1st Stage is repeated to complete the top layer of the panel.

After 25 minutes plugs are taken out, casting table is rotated and panel is then taken out for drying using special fork lift.

Then drying is done for 90 minutes in a drier chamber in which hot air is circulated

After that panel is cut into its dimensions are per the customers design.

WHERE IT IS MADE?

• FACT Cochin (Fertilizers And Chemicals Travancore LTD)

• RCF Mumbai (Rashtriya Chemicals and Fertilizers)

HOW TO MAKE BUILDINGS?

FOUNDATION

• A conventional foundation like spread footing, RCC column footing, raft or pile foundation is used as per the soil condition and load factors.

• All around the building RCC plinth beam is provided at basement plinth level.

• For erection of panel as wall, 12 mm dia vertical reinforcement called “starter bars” of 0.75m length of which 0.45m protrudes up and remaining portion with 0.15m angle is placed into the RCC plinth beams before casting.

• These bars are kept at a distance of 1m centre to centre to match the cavities of the panel.

SUPERSTRUCTURE• Pre-cut panels are brought to the construction site.

• Panels are kept over the starter bars on the plinth beam using cranes.

• Grooves are cut into the panels at every joints to facilitate integral bonding.

• Appropriate reinforcement bars are inserted as per design into the cavities.

• These reinforcements are then tide to the starter bars.

• Verticality of panels are checked and then cavities having reinforcements are filled with concrete.

• It is mandatory to reinforce and fill all the joints with concrete.

• Other cavities can be filled with any inert materials (e.g. quarry dust mixed with 5% cement and water)

SUPERSTRUCTURE CONT.

• After completing the walls, doors and windows are fixed in position at there respective locations where panels are cut and the it is fixed by filling the cavities with concrete.

• Then shuttering for sunshades are kept in position and concreting is done.

• Staircase is constructed by using panel as waist and landing slabs with reinforcement in all the cavities.

ROOF SLAB

• Formworks are erected.

• Tie beams are constructed all along the walls to provide bond between roof slab and walls.

• Panels are then placed in position.

• Every third cavity is then cut open from the top and reinforcement cages are inserted for concrete micro beams.

• Electrical conduits are then placed in position.

• Welded wire mesh is then kept all over the panel.

• Then concreting is done with thickness 50mm.

• Subsequently waterproofing of roof is done.

WHERE WE CAN USE IT?

We can use for:

• Institutional Buildings

• Residential Buildings

• Hospital Buildings

• Hotel

• Apartments

SOME PROJECTS

CONCLUSION

• GFRG Panel provides a new method of building construction in fast track.

• By this process, man power, cost and time of construction can be reduced.

• The use of scarce natural resources like river sand, water and agricultural land can be significantly reduced.

• We can save our environment by reducing CO2 production in conventional construction method.

• And the most important, this new technology is having potential to provide shelter to the “Homeless Indians”.

Thank you