2. A prefabricated walling panel Made using gypsum plaster or phospho-gypsum, reinforced with chopped glass fibers Technology developed by Rapid Building Systems Pty Ltd (RBS), an Australian company, in 1990. It owns the world-wide patent for the same Suitable for exterior walls, interior walls, floor slab and roof slab

3. Gypsum Plaster or Phospho gypsum Glass Fibers

6. Mechanical PropertyCharacteristic ValueRemarks Unit Weight40 kg/m 2 Unfilled Single leaf GFRG Panel. Uni-axial Compressive Strength 160 kN/m Uni-axial Tensile Strength35 kN/m Elastic Modulus3000 – 6000 MPa Coefficient of Thermal Expansion 12 x 10 -6 mm/mm/ 0 C Water Absorption< 5% By weight after 24 h of immersion Thermal Resistance0.36 m 2 K/WUnfilled Panel Sound transmission coefficient 28 45 Unfilled panel Concrete filled panel Fire Resistance Level> 3 hFor Structural adequacy

7. Plaster feed hoppers Casting tables Core-tables that insert and remove the plugs that form the cells in the Rapidwall panel A travelling gantry or crab assembly that mixes and dispenses the plaster as well as the chopped glass-fibre rovings onto the casting tables, over which it passes A Rapidcure drying oven used to cure the panels A Rapidsaw for process panels to design specifications

8. With 2-3 gypsum 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 ……

9. PHOSPHO GYPSUM PHOSPHO GYPSUM CALCINATION GYPSUM WALL PRODUCTION DRYING GLASS ROWINGS WATER ADDITIVES CUTTING PANELS & DESPATCH

10. Product Benefits Load-bearing for multi-story construction Earthquake resistant - ideal for seismic-prone areas Lightweight Fire-proof Good sound attenuation Produced from cost-effective, naturally occurring raw materials Water and rot resistant Termite resistant High quality finish Cyclone Resistant

11. Construction Benefits Greater speed of on-site construction Lower on-site labour requirements Simpler methods of on-site fixing Low transportation and cranage costs Space saving Environmental Benefits Uses Waste Materials Low Embodied Energy Can be produced from waste products 100% Recyclable Manufacturing Process Emits Little Carbon Dioxide Carbon Credits

12. Operational Issues: Heavy panels: The large weight of the panels (40 kg/sq m) makes installation of the product difficult without the use of crane. On site cutting: The product need to be cut on both sides of the panel with high precision if required on site cutting. There could be mismatch in dimensions of cutting on either side of the panel. Customer Perception: Due to the gaps in the panel, it shall sound on knocking. It shall createa a perception of inferior quality in the minds of customer.

13. Market Limitations: Unsuitable as filler in frame structures: Difficult to use as replacement of blocks/ bricks in non-load bearing frame structures, as the panel needs to be fit with adjacent beams and columns, limiting the application and market of the product. Lobbying with government: Product seen largely as alternative for affordable housing for EWS and LIG. Owing to large government control of the sector, lobbying needs to be done to market the product. Resistance to change: The construction industry, India in particular, is highly resistive to changes/ development in building materials due to various factors, including the risk of quality of product and its usage.

14. Manufacturers: Rashtriya Chemicals and Fertilizers (RCF), Mumbai Fertilizers and Chemical Travancore Limited (FACT), Kochi In partnership with RCF Gypcrete Building India Limited, Chennai Marketers: Biltech, Delhi

15. Government of India’s PSU engaged in manufacture of fertilizers and Industrial Chemicals since 1965 Plant at 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’.

16. Joint venture of FACT and RCF (both public sector undertakings under the department of fertilizers,Govt. of India) Plant at Kochi, Kerala using technology from Rapidwall, Australia

17. Plant Location: NH 45, 70 kms from Chennai Land used: 18.5 acres Plant parts and capacity: Three Gypsum Wall manufacturing plants : 3 12m X 3m panels/hour Fluidized Bed Calciner: Produces Gypsum plaster at 10 M Tons/hour Drying unit: to quick dry the wall panels at the rate of 6 panels per hour Saw Mill: for sanding and cutting the panels at the rate of 12m/min to the required size with provisions for cutting the door and window positions.

18. LECA

19. LECA stands for : Light Expanded Clay Aggregate. Leca consists of small, lightweight, bloated particles of burnt clay. The thousands of small, air-filled cavities give Leca its strength and thermal insulation properties. The base material is plastic clay which is extensively pretreated and then heated and expanded in a rotary kiln. Finally, the product is burned at 1100 °C to form the finished Leca product. Imported in India by GBC India (Gujarat based company)

20. Lightweight: density - 400 to 800 kg/m3 (depend on size) Sound Insulation Thermal Insulation: Thermal conductivity coefficient - 0.07 to 0.10 w/mk Fire Resistance: Non decomposability: Resists acid and alkaline substances Water Absorption: 18% of volume in saturated state in 72 hours

21. Leca lightweight concrete block: Leca block (back) is produced by mixing of Leca aggregates, Cement, sand and water. Using of Leca aggregate decreases the concrete density. Raw materials for other building materials: Panels, Concrete Ornamentation

22. Rs 11/ liter 1 bag = 100 liters = 0.1 m3 = 28-30 kg Size: 4-10 mm Supplier: GBC India