Presentation on Techno Economic

and 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
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.
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.
 Properties of Rapid wall panels
• Compressive strength
a) Empty panel- 73.10 Kg/cm2
b) Concrete infill panel-
180.70 Kg/cm2
• Flexural Strength
a) Empty panel- 21.25 Kg/cm2
b) Concrete infill panel- 20.80
Kg/cm2
• Water absorption- < 2 %
(24 hrs)
• Ductility – 4.11
• Fire resistance- 4 hrs rating
7000c to 10000c
• Free from corrosion
• Density – 1140 Kg/m3
• Light weight –
a) Without concrete infill - 40
Kg/m2
b) With concrete infill- 250
Kg/m2
• Earthquake resistance-
Panel withstood
earthquakes up to 8 Richter
scale
 Advantages of Rapid wall panels
• Light weight panels • Fire resistance
• Economical • Speedy installations
• Load bearing • Environmental
• High quality finish positive
• Earthquake resistance • Good noise resistance
• Water resistance • Accommodates
• Termite resistance building services
 Why it is necessary?

 Housing is one of the basic  Problem of housing

human needs along with food,
clothing and education.
 Exponential population
 According to UN estimate, over growth
33% of the population in  Fast rate of urbanization
developing countries are  Inadequate addition to the
homeless.
existing housing stock
 Like other developing country,
India too is presently passing  Large scale migration of the
through a phase of acute housing poor from the villages and
shortage. small towns
 Urban housing in India present
large scale big building but on
other hand it also have slums.
Population:
Greater Mumbai Population : 11.97 million (2001 census)
Present population : 18.0 million
Slum Population in Mumbai :6.62 million (2001 census)
Housing scenario:
India's demand for housing As per Planning Commission at Present
by 2015: 80 million Housing demand by Higher income group- 18 %
by 2020 : 90 million Housing demand by middle income group- 36 %
Housing demand by lower income group- 46 %

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)

 Maharashtra Govt Housing Policy
(draft Nov 2006)

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 building: 25% in 3 yrs

Size of free dwelling units under various schemes : 225 sft

 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
 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, W o rk e rs, E q u ip m e n t s
 Cement Production in India in Million Tonnes

250
194
200 176
160
145
Tonnes

150

100

50
? ?
0
2005 2006 2007 2008 2009 2010
Year
 Steel production in India in Million Tonnes

120 110
100
80
Tonnes

60 45
35
40 25
20
? ?
0
2005 2006 2007 2008 2009 2010
Year
 Brick production in India in Billion

250
200
200
160
140
150
Billion

100

50
? ? ?
0
2005 2006 2007 2008 2009 2010
Year
 River sand use in India in Million cum

450 404
400 368
334
350 303
300
250
200
150
100
50 ? ?
0
2005 2006 2007 2008 2009 2010
Year
 Cost of production of brick wall Rs. per sqm including
both sides plastering

1140
1200
1000 900
768
800 680
560
600 500
Rs

400
200
0
2003 2004 2005 2006 2006 2007 2008
(Mar) (Nov)
Year
 Saving by One panel
• 10000 Lit of water
• 2.43 m3/ 86 cft of river sand
• 8 m3 of soil
• 0.80 tons of cement
• Emission of 0.696 tons of CO2
 Recycled
Avoid Industrial
Pollution waste

Environment
No friendly Can be
Emission re used
of CO2 Building
material

Low energy Save river

based sand, soil,
production and water
process
 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, including corner joints. Cavities up to required
height will be in-filled with concrete
Panel being placed / seated on RCC plinth beam over
a thin layer of cement mortar slurry.
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
First pouring of concrete into wall corner joint.
Cutting the panel for required opening to provide
RCC 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
For roof/floor, panel to be lifted horizontally /
flat as seen in picture.
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.
Before cutting top
flange, bottom
support with ply
wood / strong MS
sheet with prop
wherever required
are to be provided
100 mm x 100 mm, 10 gauge weld mesh provided
for 50 mm thick RCC screed. Embedded RCC
micro-beams act as micro "T" beams
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
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.
Window
frame
with
shutter
in
position
RCC lintel cum sunshade, architectural band,
parapet wall work completed
Wall corners,
ceiling corners are
given fine finish
using special
gypsum plaster
product
Staircase,
handrail,
marble slab
for staircase
steps,
finishing coat
of painting
Interior
finish,
skirting,
ceramic
floor tiles,
furnishing,
curtain
rods, fan,
light
fittings etc
in position
Rear view of two storey 1220 sqft RW building in
32 days. MS iron ladder to rooftop
Front view of completed building. Front
compound wall using RW panel
On completion of structure of the building
including parapet wall in 12 days, 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
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 entire structure is built on
Gypcrete® /Rapid wall panel. The first phase with 370 apartments was built
in 1990. This complex is close to World renowned Sydney Opera House.
Multistoried construction
Six storeyed Guest House building in an
industrial park in Jinan city, Shandong Province,
China.     
Seven storey (six storey + pent house) Apartment
Gypcrete building in Tianjin, 150 km from
Beijing city.       
 Gypsum based wall plaster
• Gypsum based wall plaster can
revolutionize the plastering of internal walls
and ceilings.
• It is basically used as substitute for cement
plaster.
• Savings- Cement, sand, water
• Superior finish, Easy mixing and
application, 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
 Contacts
Name Designation Telephone email

Marketing
Shri J. Kohareswaran Dir (Mktg) 24045455 ikohareswaran@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 pqdeshpande@rcfltd.com

9820384068