Comparison of GFRG Rapid Wall

With conventional wall systems

A DISSERTATION REPORT

Submitted by

SHIVACHANDRAN S
Reg. No: 714714566015
in partial fulfillment for the award of the degree
of

MASTER OF ARCHITECTURE
(GENERAL)
IN

RVS SCHOOL OF ARCHITECTURE

ANNA UNIVERSITY: CHENNAI 600 025

OCTOBER 2015

Chapter1

Introduction

ABSTRACTHEADING
The housing sector is the second largest energy consumer in India with 95 percent
of urban population lying in the middle and lower income categories. Considering this
demand for affordable housing, there is a strong potential for energy saving in the
affordable housing sector. The given study delineates the gap in past research in
creating comprehensive sustainable rating systems for energy efficient interventions
in buildings and analyses the trade-offs in energy gains, economic cost and thermal
comfort due to walling material substitution in warm-humid climate for an affordable
housing unit. The study takes a government delivered affordable housing unit as case
example. The DEROB-LTH software is used to simulate the hourly internal
temperature throughout a day with six alternative walling systems. Hereafter, the
three parameters the embodied energy, cost of construction and the thermal comfort
in terms of number of discomfort hours are compared to get a comprehensive
sustainability assessment for the choice of walling materials. Flyash brick walls
proved to be most efficient with respect to all three factors.
Rapidwall, also called gypcrete panel is an energy efficient green building
material with huge potential for use as load bearing and non load bearing wall panels.
Rapidwall is a large load bearing panel with modular cavities suitable for both
external and internal walls. It can also be used as intermediary floor slab/roof slab in
combination with RCC as a composite material. Since the advent of innovative
Rapidwall panel in 1990 in Australia, it has been used for buildings ranging from
single storey to medium - high rise buildings. Light weighted Rapidwall has high
compressive strength, shearing strength, flexural strength and ductility. It has very
high level of resistance to fire, heat, water, termites, rot and corrosion. Concrete infill
with vertical reinforcement rods enhances its vertical and lateral load capabilities.
Rapidwall buildings are resistant to earthquakes , cyclones and fire.

INTRODUCTION

Being an emerging economy with rapidly rising per capita energy consumption
and an increased dependency on energy imports, India is exposed to international
energy market volatility and energy insecurity. As the urban housing sector of rapidly
urbanizing India is facing a massive shortage of affordable housing, in order to
address inclusive growth in the country, various affordable housing schemes are being
planned by the Government of India in its five year plans. However all such policies
and schemes, coming with hefty investments, fall silent upon energy consumption and
conservation. The report of the high level task force on affordable housing chaired by
Deepak Parekh in 2008 defined the concept of affordable housing in terms of size of
tenement, multiples of household income and in terms of percentage of household
income for rented accommodation. In this report, an affordable house in
Economically Weaker Section (EWS) or Low Income Group (LIG) category is
defined as a unit with a carpet area between 300 and 600 sq feet, with the cost not
exceeding four times the household gross annual income and EMI/rent not exceeding
40 percent of the households gross monthly income.
Evidently, such a nationally accepted benchmark also defined the capital cost
components associated with affordable housing, but overlooked the factors related to
sustainability and the associated recurring cost savings.
The building sector in India consumed 29 percent of the total primary energy
demand in 2009. This energy consumption in affordable housing is small compared to
high income residences, commercial and institutional buildings. However, the
demand for affordable housing constitutes about 95 percent of the housing market in
India and hence forms a significant share of energy consumption in the household
energy sector in the future.
The threat of climate change caused by the increasing concentration of
greenhouse gases in the atmosphere is pushing the whole world into a catastrophic
crisis situation with universal concern. The need of the 21 st century is for energy
efficient and eco-friendly products. The building industry accounts for 40% of CO 2
emissions. Building construction causes CO2 emissions as a result of embodied
energy consumed in the production of energy intensive building materials and also the
recurring energy consumption for cooling and heating of indoor environment.
Significant studies have been carried in Indian context by The Energy and
Resources Institute of India (TERI) which promotes and defines the concept of green
buildings through its own building rating system named GRIHA (Green Rating for
Integrated Habitat Assessment) [6], adopted as the national rating system for green
buildings by the Government of India since 2007.

However the GRIHA guidelines give a sustainability scoring framework only and
exclude the economic cost and comfort parameters that may be associated with
energy efficient interventions for formulating a more holistic sustainable rating
system achievable by the affordable housing sector. The Bureau of Energy Efficiency
(BEE), which is a statutory body set up under the provision of Energy Conservation
Act 2001, launched the Energy Conservation Building Code (ECBC) in 2007 [7]
which sets minimum standards for energy efficient design, construction and retrofitting. GRIHA has 34 criteria based upon which rating of a green building project is
performed, of which the ECBC makes up three criteria (criteria 6, 13 and 14). But the
primary target of the ECBC is limiting energy consumption of HVAC systems that
consume about 30-45 percent of operational energy in mechanically ventilated
buildings.
Considering this gap in the study of energy efficient interventions for affordable
housing with naturally ventilated interior environment in hot countries, the given
research explores a model for meeting a threefold target of improving life cycle
energy consumption, minimizing cost and decreasing the perceived discomfort inside
such housing units.

ENERGY CONSUMPTION FROM LIFE CYCLE ENERGY POINT OF VIEW

Life cycle assessment (LCA) is a technique which is defined by the International
Standardization Organization as to measure the environmental aspects and impacts of
product systems, from raw material acquisition to final disposal, in accordance with
the stated goal and scope as in ISO 14040 [8]. For building industry, LCA measures
the overall impact of a building and its components on the environment in three
different phases the construction or the pre-use phase, the operation or the postoccupancy phase and the demolition phase of the building in a cradle-to-grave
analysis. Out of these three phases, the energy consumption in the third, i.e. the
demolition phase is negligible compared to the first two phases. However relative
energy consumption in the first two phases depends upon the functional type of
building, choice of materials and the choice of ventilation for the interior
environment. Past studies on comparing LCA for various types of residential
buildings have shown that in case of a single family residential unit, the right choice
of materials in the pre-use phase with a slight possible increase in embodied energy
may lead to very high amount energy saving in the use-phase [9][10]. It has also been
seen that there exists a linear relationship between the operational energy use and the
total energy use in a building life span, but a similar relation is not applicable with the
embodied energy of the building. Hence a solar house or a passive house proved to be
more energy efficient from life cycle energy point of view compared to a house built
with the commitment to use green materials [11]. Therefore, while choosing
materials in the pre-use or the construction phase, the numerical value for embodied
energy should not be the sole criterion for introducing green interventions in whole
lifecycle perspective of the building.
Moreover, in Indian context, the concept of affordable housing is given by
naturally ventilated buildings, since the cost of air conditioning adds considerably to
the operation and maintenance cost, making it beyond affordability limits for the
middle and lower income groups. As a result, the pre-use phase is an important target
phase for energy efficient interventions for our aimed group of buildings, having an
immense potential to provide an optimal thermal comfort during the buildings usephase.
The given study explores walling material interventions which form an important
factor for heat gain inside naturally ventilated building in predominantly hot climates.
The given methodology can be extended to study the performance of other building
elements in a sustainability framework.

PROPOSED METHODOLOGY
Goal and scope of research
The objective of this study is to derive a model that will help to choose a particular
walling intervention from a number of available options by assessing the performance in
three different aspects economic cost, thermal comfort and net energy saving in terms
of embodied energy. Though the given study does not perform a whole building LCA, the
methodology aims at assessing the performance of a building material in whole life cycle
of the building, owing to involvement of comfort parameters which bears relation with
energy usage in operating phase for combating thermal discomfort.
Functional unit - According to ISO 14040, the functional unit is the unit of
comparison in the Life Cycle Inventory. In this study one square meter (m 2) of walling
system is chosen as a unit and all energy consumptions and costs are expressed in terms
of this functional unit e.g., MJ/m2 and Rupees/m2.
System boundaries - The system studies the embodied energy of the walling
materials during the pre-use phase. The recurrent embodied energy for maintenance and
replacement during the use-phase, which recurs yearly about 1 to 3 percent of the initial
embodied energy depending upon the building lifespan [12], is excluded. Though wind
speed is an important determinant for thermal comfort in warm humid climate, it is a
comfort parameter regulated by the size and location of window openings. Hence the
effect of convective wind speed on internal temperature has been excluded in this study.
Thermal perceptions and adaptive comfort equation
Comfort standards on thermal comfort are essentially based upon either heat balance
or adaptive models. While the previous model is suited for conditioned environments, the
latter is more appropriate for naturally ventilated buildings [13]. Toe and Kubota
developed an adaptive thermal comfort equation for naturally ventilated buildings in hothumid climates [14] using a statistical meta-analysis of the ASHRAE RP-884 database.
Tneutop = 13.8 + 0.57 Toutdm

(1)

Where Tneutop denotes neutral operative temperature and T outdm denotes the daily mean
outdoor temperature. This regression equation is applicable within a daily mean outdoor
temperature range between 19.4 and 30.5 degree Celsius, with low (<0.3m/s) or moderate
(<0.65m/s) wind speed at the neutral operative temperature, and with no required limit for
relative humidity [16]. Equation (1) will be used to calculate the number of discomfort
hours inside buildings in this study due to use of different walling materials.
Alternative walling systems
A walling system forms the vertical envelop of a building. The walling systems that have
been compared in this study have been enlisted below:

Ordinary brickwork 215 mm thick external and 115mm thick internal walls with
1:6 mortar bonds and 1:4 sand cement plaster.

Solid plain cement concrete (PCC) in-situ wall with 200 mm thick plastered external
wall and 100 mm thick internal wall with 1:4 sand cement plaster
215 mm thick external and 115 mm thick internal fly ash brick walls with 1:6 mortar
bonds and 1:4 sand cement plaster
Brick cavity wall with 115mm thick external and internal brickwork with 1:6 mortar
bonds and 1:4 sand cement plaster and an air gap of 30mm in between
Autoclaved aerated concrete (AAC) brick walls 200mm thick with 1:6 mortar bonds
and 1:4 sand cement plaster, both for external and internal walls
Glass fibre reinforced gypsum (GFRG) rapid walling system [15], consisting of glass
fibre reinforced gypsum board panels 124mm thick with hollow cavities in filled by
reinforced cement concrete for structural strength both for external and internal walls.
The walling system does not require plastering.

Chapter2

GFRG
WORKABILITY
CONSTRUCTIONMETHODOLOGIES
USES
PROPERTIES

Rapid wall Definition

GFRG is the abbreviation for glass fibre reinforced gypsum. It is the name of a new building
panel product, made essentially of gypsum plaster, reinforced with glass fibres, and is also
known in the industry as Rapid wall. This product, suitable for rapid mass-scale building
construction, was originally developed and used since 1990 in Australia. GFRG is of
particular relevance to India, where there is a tremendous need for cost-effective mass-scale
affordable housing, and where gypsum is abundantly available as an industrial by-product
waste. The product is not only eco-friendly or green, but also resistant to water and fire.
GFRG panels are presently manufactured to a thickness of 124 mm, a length of 12m and a
height of 3m, under carefully controlled conditions. The panel can be cut to required size.
Although its main application is in the construction of walls, it can also be used in floor and
roof slabs in combination with reinforced concrete. The panel contains cavities that may be
filled with concrete and reinforced with steel bars to impart additional strength and provide
ductility. The panels may be unfilled, partially filled or fully filled with reinforced concrete as
per the structural requirement.
GFRG building panels are
presently manufactured as Rapid
wall, for the typical dimensions
and material properties described
in
the
manual.
Typical
dimensions of a GFRG building
panel
are
12.0m 3.0m
0.124 m, as shown in Fig.1.

Figure 1: Typical Cross Section of GFRG Panel

Source: GFRG/RAPIDWALL BUILDING STRUCTURAL DESIGN

MANUAL

Each 1.0 m segment of the panel contains four cells. Each cell is 250 mm wide and
124 mm thick, containing a cavity 230mm94 mm, as shown in Fig. 2. The
various cells are inter- connected by solid ribs (20 mm thick) and flanges (15 mm
thick), comprising gypsum plaster, reinforced with 300 - 350 mm glass fibre roving,
located randomly but centrally. The skin thickness is 15 mm and rib thickness is 20
mm.
Figure 2:
Enlarged View of
a Typical Cell
Source:
GFRG/RAPIDWA
LL BUILDING
STRUCTURAL
DESIGN
MANUAL

Rapid wall Uses

In typical multistoried constructions
involving the use of GFRG as
load bearing structural walling, the
connections between cross walls
and with the foundations and
floor/roof are achieved through
reinforced concrete filling or R.C
beams. All GFRG wall panels at the
ground floor are to be erected over a
network of RC plinth beams
supported on suitable foundation.
GFRG panel can also be used for
intermediate floor slab/roof slab in
combination with RC (Refer Figs
Figure 3: Erection of GFRG panels over plinth
4.4). The strength of GFRG slabs
beam at site
can be significantly enhanced by
embedding reinforced concrete
micro beams.
For providing
embedded micro beams, top flange
of the respective cavity is cut and removed in such a way that minimum 25 mm
flange on both end is protruded as shown in Fig. 4.4. RC concrete screed of
minimum 50 mm thickness is provided above the GFRG floor panel, which is
reinforced with weld mesh of minimum size of 10 gauge 100 mm 100 mm. This
RC screed and micro beam act together as series of embedded Tbeams. The
thickness of the RC screed, reinforcement and interval of embedded RC micro
beams depends on the span and intensity of imposed load. The connectivity
between the horizontal tie beam, embedded RC micro beams, concrete screed
and vertical rods in GFRG wall, and ensures perfect connection between floor/roof
slab and walling system.

Fig.1 : Worlds largest load bearing lightweight panel being used in Australia
PHYSICAL AND MATERIAL PROPERTIES
Rapidwall panel is worlds largest loadbearing lightweight panels. The panels are
manufactured with size 12 m length, 3m height and 124 mm thickness. Each panel has 48
modular cavities of 230 mm x 94 mm x 3m dimension. The weight of one panel is 1440 kg
3
or 40 kg/sqm. The density is 1.14g/cm , being only 10-12% of the weight of comparable
concrete /brick masonry. The physical and material properties of panels are as follows:
Weight- light weight
40 Kg/ sqm
Axial load capacity
160 kN/m{ 16 tons/ m}
Compressive strength
73.2 Kg/cm2
Unit Shear strength
50.90 kN/m
2
21.25 kg/cm
Flexural strength
Tensile Strength
35 KN/ m
Ductility
4
0
4 hr rating withstood 700-1000 C
Fire resistance
Thermal Resistance R
0.36 K/W
U Value
2.85W/M2K
Thermal conductivity
0.617
Elastic Modulus
3000-6000Mpa
Sound transmission{STC}
40
Water absorption
< 5%
The vertical and lateral load capability of Rapidwall Panel can be increased many
fold by infill of concrete after placing reinforcement rods vertically. As per structural
requirement, cavities of wall panel can be filled in various combinations (See Fig.2.)
JOINTS:
Wall to wall L, T, + angle joints and horizontal wall joints are made by cutting
of inner or outer flanges or web appropriately and infill of concrete with vertical
reinforcement with stirrups for anchorage. Various constructio n joints are illustrated in
Fig.3.

Fig.2 : RCC infill to increase load capability

Fig.3 Various construction joints

Rapidwall Panel can also be used for intermediary floor slab / roof slab in combination
with embedded RCC micro-beams and RCC screed concrete (Fig.4).

Fig.4 GFRG embedded with RCC micro beams and RCC screed concrete

FOUNDATION:
For Rapidwall buildings/ Housing 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 of 0.75m long of
which 0.45m protrudes up and remaining portion with
0.15m angle is placed into the RCC plinth beams before
casting. Start up rods are at 1m centre to centre.
Fig 5 : Foundation
RAPIDWALL FOR RAPID CONSTRUCTION
Rapidwall enables fast track method of construction. Conventional building
construction involves various cumbersome and time consuming processes, like i) masonry
wall construction ii) cement plastering requiring curing, iii) casting of RCC slabs
requiring centering and scaffolding and curing iv) removal of centering and scaffolding
and v) plastering of ceilings and so on. It also contributes to pollution and environmental
degradation due to debris left on the site.
In contrast, Rapidwall construction is much faster and easier. There will be no
debris left at site. Construction time is minimized to 15-20%. Instead of brick by brick
construction, Rapidwall enables wall by wall construction. Rapidwall also does not
require cement plastering as both surfaces are smooth and even and ready for application
of special primer and finishing coat of paint.
Rapid Construction Method
As per the building plan, each wall panel will be cut at the factory with millimeter
precision using an automated cutting saw. Door/window/ventilator, openings for AC unit
etc will also be cut and panels for every floor is marked relating to building drawing.
Panels are vertically loaded at the factory on stillages for transport to the construction sites
on trucks.
Each stillage holds 5 or 8 pre-cut panels. The stillages are placed at the
construction site close to the foundation for erection using vehicle mounted crane or other
type of crane with required boom length for construction of low, medium and high rise
buildings. Special lifting jaws suitable to lift the pane l are used by inserting into the
cavities and pierced into webs, so that lifting/handling of panels will be safe. Panels are
erected over the RCC plinth beam and concrete is infilled from top. Protruded start up rods
go inside cavities as can be seen from Fig. 5.
All the panels are erected as per the building plan by following the notation. Each
panel is erected level and plumb and will be supported by lateral props to keep the panel
in level, plumb and secure in position. Once wall panels erected, door and window frames
are fixed in position using conventional clamps with concrete infill of cavities on either
side. Embedded RCC lintels are to be provided wherever required by cutting open external
flange. Reinforcement for lintels and RCC sunshades can be provided with required
shuttering and support.
5

Concrete infill
After inserting vertical reinforcement rods as per the structural design and clamps
for wall corners are in place to keep the wall panels in perfect position, concrete of 12 mm
size aggregate will be poured from top into the cavities using a small hose to go down at
least 1.5 to 2 m into the cavities for directly pumping the concrete from ready mix
concrete truck. For small building construction, concrete can be poured manually using a
funnel. Filling the panels with concrete is to be done in three layers of 1m height with an
interval of 1 hr between each layer. There is no need to use vibrator because gravitational
pressure acts to self compact the concrete inside the water tight cavities.
Embedded RCC tie beam all around at each level floor/roof slab:
An embedded RCC tie beam to floor slab is to be provided at each floor slab level,
as an essential requirement of national building code against earth quakes. For this, web
portion to required beam depth at top is to be cut and removed for placing horizontal
reinforcement with stirrups and concreted.
Rapidwall for floor/ roof slab in combination
with RCC
Rapidwall for floor/roof slab will also be
cut to required size and marked with notatio n.
First the wall joints and other cavities and
horizontal RCC tie beams are in- filled with
concrete ; then wooden plank of 0.3 to 0.45 m
wide is provided to room span between the walls
with support wherever embedded micro beams
are there; finally roof
panels will be lifted by
crane using strong sling tied at mid-diagonal
point, so that panel will float perfectly horizontal
(See Fig.5)
Fig 5 Floor/roof panel
Each roof panel is placed over the
wall in such a way that there will
be at least a gap of 40 mm. This is
to enable vertical rods to be placed
continuously from floor to floor
and
provide monolithic RCC
frame
within
Rapidwall.
Wherever embedded micro-beams
are there, top flanges of roof panel
are cut leaving at least 25mm
projection. Fig 6 : Cutting of top flange

Fig 7 : Reinforcement
6

Reinforcement for micro-beams is placed and weld mesh as reinforcement is placed (Fig
7). Concrete is poured for miro-beams and RCC slab. This results in the embedded RCC
micro beams and 50 mm thickness screed concrete becoming a series of T beams.
Erection of wall panel and floor slab for upper floor
The following day, erection of wall panels for the upper floor can be arranged.
Vertical reinforcement of floor below is provided with extra length so as to protrude to
0.45 m to serve as start up rods and lap length for upper floor. (See Fig.8)
Once the wall panels are erected on
the
upper
floor,
vertical
reinforcement rods are provided,
door/window frames fixed and RCC
lintel cast. Then concrete is filled
where required and joints are filled.
Then RCC tie beam all around are
concreted. Roof panel for upper
floor is repeated same as ground
floor. For every upper floor the same
method is repeated.
Fig 8 : Erection of upper floor panel
Finishing work
th

Once concreting of ground floor roof slab is completed, on the 4 day, wooden
planks with support props in ground floor can be removed. Finishing of internal wall
corners and ceiling corners etc can be done using wall putty or special plaster by
experienced POP plasterers. Simultaneously, electrical work, water supply and sanitary
work, floor tiling, mosaic or marble works, staircase work etc can also be carried out.
Every upper floor can be finished in the same way.
Monolithic RCC framed structure inside Glass Fiber Reinforced Gypsum Panel.
In Rapidwall building an embedded monolithic, thin RCC framed structure is
formed by i) bottom RCC plinth beams,
ii) vertical columns of infilled cavities, iii)
vertical wall corner joints
iv) inter-connected horizontal RCC tie beams, integrated
with v) embedded RCC micro-beams and RCC screed in all floors. In effect this RCC
frame is moulded inside the GFRG Panel. (See Fig. 9)

Fig 9 :Monolithic
RCC framed structure
Testing of Rapidwall in Australia and by Tianjin University, in Zhandong Province, China
found thatthe lateral resistance of the concrete filled GFRG walls come from two
different actions viz i) the shear resistance of the Rapidwall and ii) the lateral resistance
7

of internal reinforced concrete coresas per the paper published by Yu-Fei Wu and Xiang
in RILEM 2007(1) .
The strength of building to take care of axial load and lateral/ flexural/ shear loads
from wind or cyclone or earthquakes is due to the combination of insid e RCC frame and
Rapidwall Panel. Since the reinforced steel also encased within the GFRG panel, it is
protected from corrosion.
Rapidwall building/ housing is cooler
Conventional building materials like concrete have high thermal conductivity and
low thermal resistance. Conventional concrete roof and walls radiate heat inside the
building. Heavy electrical energy is to be used to maintain indoor comfort level. There
will be high electric energy for heating the indoor during winter.
In contrast Rapidwall panel have low thermal conductivity and high thermal
resistance. A comparative research study by Mohd Peter Davis et al in 2000 in Universiti
Putra Malaysia, Selangor, found that in summer indoor temperature of Glass Fiber
Reinforced Gypsum Panel building is cooler by 5 to 6 degrees Celsius as compared to
concrete building (2). The high thermal resistance of Rapidwall will keep interiors cooler
in summer and warmer in winter, saving substantial recurring energy use.
Rapidwall is energy efficient
Low energy consumption for mass production of building material and reduced
use of recurring energy for operational use is very critical to achieve carbon emission
reduction to save the environment and fight global warming. This is the need of the
century.
The main raw material is calcined superior quality gypsum plaster with purity
more than 90%. Gypsum plaster, also called Plaster of Paris, is produced by calcining
natural mineral gypsum rock (CaSO 42H2O) or by calcining industrial waste by-product
gypsum available abundantly in India at various locations across the country. The use of
advanced low energy based green & cleaner technology in reprocessing / recycling the
raw material into GFRG panels consumes very low energy and helps to protect the
environment. Environmental protection is economically priced now through carbon
emission reduction (CER) trading under Kyoto Protocol linked through special market
mechanism (CDM - Clean Development Mechanism).
This makes Rapidwall Panel mass production very suitable to meet the challenge
of affordable housing for the deprived. According to the Ministry of Housing, Govt of
India in Dec 2007 urban housing shortage has been estimated at about 24.7 million units at
t h
the end of the 10 Five Year Plan (2006-07) and 99% of the shortage pertains to the
economically weaker sections and low income groups.
Rapidwall is for affordable quality housing
Access to adequate shelter at affordable cost by low income section and common
people is very important for India for inclusive development.. The booming of real estate
and construction industry has indeed shot up the cost of construction due to the ever
increasing cost of cement, steel, bricks, river sand, concrete materials and labour cost. In
this situation, safe and good quality housing will become unaffordable to all the sections.

Trends in cost (INR) of brick masonry/sqm with 2 sides

cement plastering 2003-8
2000
1500

1700

1000
500

1140
460

510

2003

2004

1300

780

0
2005

2006

2007

2008
May

Fig.10 Cost of construction of 1 sqm (10.76 sft or 8.12 cft) 9 thick quality brick wall in
cement mortar 1:6 and both sides (2 sqm or 21.52sft) plastered in cement mortar 1:5
Commonly used walling in India is brick masonry. Cost of brick wall with two
sides cement plastering has increased by almost 4 times during the last 5 years as seen in
Fig.10. Brick wall construction cost was Rs 460/sqm in 2003. This increased to Rs 1700
/sqm in 2007. In view of likely increase in cost of energy, bricks, cement, river sand,
water, labour and hire charges for scaffolding etc, the cost of masonry made of bricks or
concrete blocks will continue to rise in future. This will make Rapidwall panel much
cheaper and affordable to the building industry while it will also help to protect the
environment, as one sqm panel will save carbon emission reduction of about 80Kg.
Rapidwall panel has excellent acoustic properties. Testing of panel by IIT Madras
found that the panel belongs to a class of STC 40 with respect to air-borne sound
insulation. Infill of cavities with locally available cheaper materials like quarry dust mixed
with cement (1:20) and water or sand and cement (1:20) up to lintel/ window height can
make the wall solid and address security-related concerns.
Other than Australia and China, India is set to benefit from the technology as
Rapidwall panels are to be manufactured and marketed in Mumbai within few months by
RCF, one of the largest fertiliser company of Govt of India . FACT, another large public
undertaking fertiliser company in joint venture with RCF is also setting up another
Rapidwall plant in Cochin. A Rapidwall plant near Chennai is also commissioning and
marketing the product shortly.
In Rapidwall construction, especially in repetitive type mass housing, time for
construction will be reduced by 75-80% thereby reducing overall overhead establishment
costs with reduced lock up investment period and less labour component. Comparative
study of Rapidwall building and conventional building (2 storey 1500 sft) shows
significant savings in Rapidwall buildings. Embodied energy of Rapidwall building is only
82921 kWh, while conventional same size building would have 215400 kWh, thereby
saving 61.5% embodied energy. (See Table 1)

Materials/ items

Rapidwall Building

Saving in %

16 tons
1800 kg
20 cum
38 cum
500sqm
50000 ltr
143 sqm
389 mandays
21 days
170 tons

Conventional
Building
32.55 tons
2779 kg
83.37 cum
52.46 cum
57200
200000ltr
154.45sqm
1200 mandays
120 days
490 tons

Cement
Steel
River sand
Granite metal
Bricks
GFRG Panel
Water
Built Area
Labour
Construction Time
Total Weight of
superstructure
Construction Cost
Embodied energy
in kWh

Rs 13.25 lakhs
82921

Rs 18.27 lakhs
215400

27.47%
61.5

50.8
35.2
76
27.56

75
8
67.59
82
65

Table 1: Comparison of Rapidwall vs conventional building

Uses of Rapidwall
The most valuble use of Rapidwall is its use as load bearing wall in multi- storey
construction in combination with RCC. Rapidwall can also be used as non load
bearing and partition wall in RCC framed structures. IIT Madras has recently
developed method of fixing panel in between RCC columns, beams and floor slab with
clamping system. By this panel can be fixed to floor slab and panel at bottom using
screws, which will be embedded within flooring and skirting. At top clamps will be
fixed to panel and ceiling slab or beam. On sides also clamped at bottom to RCC
column, floor slab and panel. Plastering of walls can also be saved thereby saving time
and cost. If this is taken into account at design stage itself, dead load reduction of more
than 50% can be made.This will save in foundation, RCC columns and beams, in turn
steel and concrete. This will make substantial savings in cost of construction .
RCC Columns, beams with Rapidwall floor and walls in high rise building:
One of the leading architects based in Mumbai proposed an innovative method of
construction of high rise building with RCC columns and beams to take load, while
panel is to be used for walls and floor slab with micro beams. For this specially
designed shuttering for RCC columns and beams will be in position in such a way that
wall panel and floor slab panel of ground floor will be in position. Concreting of
columns, beams, infill of required cavities, micro beams, and screed will be done
simultaneously. This process will be repeated on each upper floor. Walls of each floor
construction will be done along with rising up structure. It is estimated that this
method will reduce 50% dead load which will reduce substantial steel and cement, 8%
increased carpet area and saving of 60-70 % time.

Scattered small and row houses:

Quality small houses and row houses for low income and common people which can
resist natural disasters at affordable cost is essential for inclusive development.
Housing of the masses as well as other segments along with infrastructure alone will
determine growth and development of the society or the nation. One BHK housing
from 300-500 sft at affordable cost @ Rs 600-700/ sft can be a reality with Rapidwall.
At a time when the real estate market is on the downslide due to the economy in
recession, many builders who have embarked on mega residential schemes may find
affordable housing as a catalyst to tide over the recession period. It need not mean that
they need to build houses for low income or middle class alone, but with structures
built at affordable cost using Rapidwall and carry out superior finish to meet the
requirement of up market and luxury segment may be a good solution and response .
While provide more comfortable living , this will also save energy , contribute to
environmental protection and fight global warming.
Construction of compound wall:
Rapidwall can be used for construction of compound wall and security wall.
Gypsum based wall plaster and wall putty will be alternative to cement plaster for
interior walls and ceiling. This will save river sand , cement and water. It will also
provide fine finish. Gypsum based wall putty will be superior product than currently
marketed brands of wall putty. These products will also be very useful to the real
estate and housing industry.

RTIFICATION
System in Brief

Glass Fibre Reinforced Gypsum (GFRG) Panel known as Rapidwall is a building panel made-up of
calcined gypsum plaster, reinforced with glass fibers. The panel was originally developed by GFRG
Building System Australia and used since 1990 in Australia for mass scale building construction.
Now, these panels are being produced in India and the technology is being used in India.
The panel, manufactured to a thickness of 124mm under carefully controlled conditions to a length
of 12m and height of 3m, contains cavities that may be unfilled, partially filled or fully filled with
reinforced concrete as per structural requirement. Experimental studies and research in Australia,
China and India have shown that GFRG panels, suitably filled with plain reinforced concrete
possesses substantial strength to act not only as load bearing elements but also as shear wall,
capable of resisting lateral loads due to earthquake and wind. GFRG panel can also be used
advantageously as in-fills (non-load bearing) in combination with RCC framed columns and beams
(conventional framed construction of multi-storey building) without any restriction on number of
storeyes. Micro-beams and RCC screed (acting as T-beam) can be used as floor/ roof slab.
The GFRG Panel is manufactured in semi-automatic plant using slurry of calcined gypsum plaster
mixed with certain chemicals including water repellent emulsion and glass fibre rovings, cut, spread
and imbedded uniformly into the slurry with the help of screen roller. The panels are dried at a
temperature of 275oC before shifting to storage area or the cutting table. The wall panels can be cut
as per dimensions & requirements of the building planned.
It is an integrated composite building system using factory made prefab load bearing cage panels &
monolithic cast-in situ RC in filled for walling & floor/roof slab, suitable for low rise to medium
rise (single to 10 storeys) building.

Classification

Application

Class 1 Water resistant grade GFRG panel for external walls, in

wet areas and /
or as floor and wall formwork for concrete filling.
Class 2 General Grade GFRG panels for structural application or
nonstructural
application in dry areas. These panels are general unsuitable for use as
wall or floor
formwork and
Class 3 Partition Grade GFRG panel as nonstructural internal
partition walls
in dry areas only.
GFRG panels may generally be used in following ways:
As load Bearing Walling With cavities filled with reinforced concrete is
i) suitable
for multi storeyed housing. In single or two storeyed construction,
the cavities
can remain unfilled or suitably filled with non structural core filling
such as
insulation, sand, quarry dust, polyurethane or light weight concrete.
As partition walls in multi storeyed frame buildings. Panels can also
ii) be filled
suitably. Such walls can also be used as cladding for industrial buildings
or sport
facilities etc.
iii) As compound walls / security walls.
As horizontal floor slabs / roof slabs with reinforced concrete micro
iv) beams and
screed (T-beam action). This system can also be used in inclined
configuration,
such as staircase waist slab and pitched roofing.

Dimension

Typical Dimension of GFRG building panel are 12.0m x 3.0m x 0.124m

Each 1.0m segment of the panel contains four cells. Each cell is 250mm
wide and
124mm thick (see Fig.1).

Fig 1 Enlarged view of a Typical Cell

Mechanical Properties (unfilled panels) - based on test results:

Mechanical Properties

Nominal Value

Unit weight
Modulus of elasticity, E
G

0.433 kN/m2
7500 N/mm2

Uni-axial compressive strength, Puc

160 kN/m (4.77 mPa)

Uni-axial tensile strength, Tuc

34 37 kN/m

Remarks

Strength obtained from

longitudinal
compression / tension tests
with
ribs extending in the
longitudinal
direction.

Ultimate shear strength, Vuc

Out-of-plane moment capacity, Rib

21.6 kN/m
2.1 kNm/m

parallel to span, Muc

Out-of-plane moment capacity, Rib
0.88 kNm/m
perpendicular to span, Muc , perp
Mohr hardness
Out-of-plane flexural rigidity, EI, Rib

1.6
3.5 x 1011 Nmm2/m

parallel to span
Out-of-plane flexural rigidity, EI, Rib
1.7x1011Nmm2/m
perpendicular to span
Coefficient of thermal expansion, Cm

12x10-6mm/mm/oC
1.0% : 1 hr

Water absorption

Average water absorption by

weight % after certain hours of

3.85% : 24 hrs
immersion.
Fire resistance :
Structural adequacy / integrity /
insulation

140/140/140 minutes

CSIRO, Australia/ IS
3809:1979

Sound transmission class (STC)

40 dB
ISO 10140-3:2010*
* ISO 10140-3:2010 - Acoustics -- Laboratory measurement of sound insulation of building
elements -- Part 3: Measurement of impact sound insulation
Source: GFRG/Rapidwall Building Structural Design Manual

Structural Design
The design capacities are based on limit state design procedures, considering, the ultimate limit
state for strength design, treating the 3.0 m high GFRG building panel as the unit material and
considering the strength capacity as obtained from the test results. The design should be such that
the structures should withstand safety against all loads (as per relevant Indian Standards) likely to
act on the structure during its lifetime. It shall also satisfy the serviceability requirements, such as
limitations of deflection and cracking. In general the structure shall be designed on the basis of the
most critical limit state and shall be checked for other limit states.
Detailed design Guidelines are given in Use of Glass Fibre Reinforced Gypsum (GFRG) Panels
in Buildings - Structural Design Manual prepared by IIT Madras and published by BMTPC. It
may be obtained on request from BMTPC.
Experimental studies and research have shown that GFRG Panels, suitably filled with reinforced
concrete, possess substantial strength to act not only as load bearing elements, but also as shear
wall, capable of resisting lateral loads due to earthquake and wind. It is possible to design such
buildings upto 10 storeys in low seismic zone. (and to lesser height in high seismic zone).
However, the structure needs to be properly designed by a qualified structural engineer.
Manufacture of GRFG Panels with increased thickness (150 mm 200 m) with suitable flange
thickness can facilitate design and construction of taller buildings.

The basis arrangement of GFRG Panel Building System

is as follow:

Transportation

Construction

The GFRG panels are transported from factory to generally through trucks
site,
or
trailers. The panels are kept in a vertical position stillages so as to avoid
using
any
damage during transportation. The panels after
the site are taken out
reaching
from
trucks using cranes. Forklifts can be used for easier movement of panels from one
area to another.
The foundation used in the construction is conventional and is designed generally as
strip footing depending upon the soil condition.
For superstructure plinth beams are cast all around the floor, where walls have to
be erected. The superstructure is entirely based on prefabricated panels. The procedure mainly include fixing of wall panels and roof panels using mechanical means,
preferably a crane and filling the required joint with reinforced cement concrete as
per structural design.
Waterproofing is an essential requirement of the construction at different stages.
Detailed guidelines for waterproofing is require to be followed while constructing
the building.

Limitation of Use

The shorter span of slab (floor / roof) should be restricted to 5 m.

Is ideal if the same floor / roof is replicated for all floors in multi storeyed structure.
For any variations, structural designer needs to be consulted.
Curved walls or domes should be avoided. In case it is essential, use masonry /
concrete for that particular area.
The electrical / plumbing drawing should be such that most of the pipes go through
the cavities (in order to facilitate minimum cutting of panel)

f the System

Green Technology
It makes use of industrial waste gypsum. Does not
need any
plastering. Uses much less cement, sand, steel and water
than
conventional building. It consumes much less embodied
energy
and less carbon footprint.
Reduced built area Panels being only 124 mm thick, for the same carpet
area, the built
up area and the building footprint is much less than
conventional
buildings. This is particularly advantageous in multi storey
mass housing.
Versatility
roofs and

Panels can be used not only as walls but also as floors,

staircase.

Speed of Construction
Using the system, the construction of a building
can be very
fast compared to the conventional building. One building
of two storeyed (total 1981 sqft with four flats) was
constructed in IIT Madras in one month.
Lightness of structures These panels are very light weight only 43 kg/m 2.
Even after
filling some of the cavi-bringing safety against ties with
concrete, the overall building weight is much less,
contributing to significant earthquake forces reduction
in design earthquake forces and savings in foundation and
overall buildings
cost especially in multi storeyed buildings.
Manufacturing Plants
Presently two plants are working in India:
1) Rashtriya
Chemicals
and
Fertilizers
Limited,
Priyadarshini, Eastern Express Highway, Sion,
Mumbai.
2) FACT RCF Building Products Ltd., FACT Cochin Division
Campus, Ambalamedu, Kochi (Kerala).
The panels manufactured at the above plants are based
on the technology transferred through collaboration with
GFRG Building System, Australia.
BMTPC under Performance Appraisal Certification Scheme
has evaluated the Panel manufactured at RCF Mumbai and
FRBL Cochin and issued PAC No. 1008-S/2011 and PAC No.
1009-S/2012 respectively. (Available for download from
BMTPC website www.bmtpc.org).

Constructed at IIT Madras Campus, in one month duration.

Few Building Constructed in India are:
i) Residential buildings at Udipti Karnataka owner Mr. Satish Rao, built by
Harsha Pvt. Ltd., Udipi, Bangalore.
ii) Utility Building for Konark Railways at Madgao, South Goa, built by Harsha
Pvt. Ltd., Udipti, Banga-lore.
iii) Residential building at Udipti by Harsha Pvt. Ltd.
iv) 3 storey residential building at Calicut by NMS Rapidwall Construction
Company, Calicut (2014).
v) Two storeyed building at IIT Madras.
vi) Residential building at RCF Mumbai.
Model house at Cochin

Chapter3

InvestigationonthePerformanceof
AlternativeWallingMaterialsinan
AffordableHousingUnitsituatedinWarm
HumidClimate

Casestudybuilding
The case study is a low income group housing complex located in the Rajarhat
area, an eastern metropolitan extension of Kolkata. The region comes under subtropical warm humid climate zone owing to its latitude and proximity to the sea.

(a)
Figure 1 -

(b)
(a) Front side view and (b) back side view of building blocks

Figure 2 - Typical floor plan of a Starlit housing block highlighting the bedroom
in the south-west oriented unit, simulated for hourly internal temperature

Thecasestudybuildings, asshowninfigure1, werebuiltinanaffordablehousingscheme

namedStarlitHousinganddeliveredbytheStateHousingBoardin2011.Thebuildingshavebeen
occupiedsincethenbylowincomegroupofresidents.Eachblockisafourstoriedbuildingandthe
entranceofeachisorientedintheeastwestdirectioninthesiteplan.Eachfloorhasonebedroom
units,fourinnumber,orientedinthefourdifferentintercardinaldirections.Thestudytookasouth
westorientedunitascaseexampleforcarryingoutsimulations,asshowninfigure2.
Simulations
Forsimulatingtheinternalroomtemperaturesinthecasestudyunit,thestudyusedtheDEROB
LTHsoftwareoriginatingfromtheUniversityofTexasatAustin,USAandfurtherdevelopedbythe
DepartmentofEnergyandBuildingDesignattheLundUniversity,Sweden.Thesoftwareusesthe
CrankNicholsonsDifferencemethodforheatingdiffusionequationsinwallsandtheGaussSeidel
methodissimultaneouslyusedtosolvethetemperaturedifferenceinnodes.Nodesareassignedto
walls and windows for energy transmission. The hourly internal temperature simulation has been
validatedinseveralpaststudies.

Figure3DEROBmodelshowingthebedroomwhoseinternaltemperaturehasbeensimulatedwith
alternativebuildingmaterials
Choice of orientation The southwest corner was chosen for simulation. The chosen
orientationisduetothesunpathfromeasttowestviasouthinthenorthernhemisphere,andthewest
facingroomshavingmaximumdiscomfortduringthedaytimeduetoexcessglarefromsunlight.
th

Choiceofdate ThechosendayforhourlyindoortemperaturesimulationisMarch20 ofa

typicalyearfromtheMeteonormclimatedatabasefedintheDEROBLTHsoftware.Thisisthespring
equinoxdayinthenorthernhemispherewithequaldaysandequalnightswhichindicatestheonsetof
summer.
ParametricmodellingTheDEROBprogramcanhandleuptoeightvolumesanduptohundred
walls.Duetothesemodellinglimitations,onlyoneoftheunitshasbeenmodelledandtheinternal
temperatureinthesouthwestfacingbedroomhasbeensimulatedasshownintheFigure3.
Theparametricsimulationshavebeenruninaclosedwindowscenarioassuming30percent
absorptivityforthewallsandtheroof,whichisthehighestabsorptivityforwhitepaintedsurface[18].
SimulationshavebeencarriedoutforagroundfloorunitusingthestandardRCCroof,singleglazed
windowsandplywooddoors.
MaterialdatabaseThematerialdatabasesforsimulationhavebeenderivedfromforflyash,
forautoclavedaeratedconcrete,forGFRGrapidwallandtherestfromtheDEROBLTHdatabase.

RESULTS
Theembodiedenergiesofthealternativebuildingmaterialswerecalculatedfrom.Thecostof
constructionareasperWestBengalPublicWorksDepartmentscheduleratesfor2010tillitsfourth
amendment.TheratesforGFRGpanelsandAACblockshavebeenderived.Thecostscompared
belowincludethecostofplasteringbutexcludethecostofpainting.

Figure4

Simulatedroomtemperatureinvariouswalltypeswithalternativebuildingmaterials

Thefigure4showstheinternalsimulatedtemperatures(T s)forallthewallingsystemsusedin
this study, done in the DEROBLTH software. The number of discomfort hours is obtained by
comparingthevalueofTsforeachhourwiththeneutraloperativetemperature(T neutop)onthegiven
date(March20)ofatypicalyear,whichwas29.38degCagainstadailymeanoutdoortemperature
(Toutdm)of27.3degC.Thedegreesofdiscomfortwerecalculatedbytakingthecumulativeofthe
excesstemperaturesabovetheTneutopduringthediscomforthours.Thegraphsclearlydelineatethetime
laginheatcontentofthebuildingmaterials,havinghigherinternaltemperaturesinthelaterpartsofthe
day.The Table1 givesacomparativeanalysisofthewallingelementsincost,comfortandenergy
savingscale.Brickcavitywallseemstogivemarginallybetterthermalcomfortthanordinarybrick
wall.Thermaldiscomfortseemstobehighestinaeratedconcretewalls.Flyashbricksarefoundtobe
mostefficientintermsofallthreefactors.
Table1. Materialpropertiesintermsofcost,comfortandenergysaving

Wallingsystem
OrdinaryBrickwall
Brickcavitywall
SolidPCCinsituwall
Flyashbrickwall
AACwall
GFRGrapidwall

Embodied
Energy
(MJ/sqm
construction)

Construction
Cost
(Rs/sqm
construction)

1231.0
1118.5
441.36
376.5
369.0
474.0

1451.46
1462.39
1675.60
1272.34
1028.00
1620.00

No.of
Degreesof
DiscomfortHrs Discomfort
0
(Tneutop=29.38 C)
8
7
7
5
10
9

4.06
2.84
2.04
0.9
10.2
14.7

DISCUSSIONS

Thegivenstudyiscarriedoutinwarmhumidclimatecharacterizedbyuncomfortablesummers
whereitisimportanttosimulatethepeaksummertemperaturesforthermalcomfort.Howeverthe

st

averageoutdoortemperaturefor21 June,whichmarksthesummersolsticeorthepeakofsummer,didnotfallinthe
temperaturerangeforwhichtheadaptivethermalcomfortequation,usedinthisstudy,isapplicable.Hencethisdatecould
th

notbetakenforthestudy.Insteadthespringequinoxdayoccurringon20 Marchwasassumedfordemonstratingthe
thermalcomfortperformanceofthebuildingwallingmaterialsintermsofnumberofdiscomforthours.Thisparticular
shortcoming was addressed by introducing two indicators of thermal discomfort number of discomfort hours and
cumulativeofthedegreesabovetheneutraloperativetemperatureontheparticulardaygivenbydegreesofdiscomfort.
st

Flyashbrickswereseentoexcelinboththethermalperformanceindicators.ThesimulatedtemperaturesforJune21 gave
discomforthoursroundtheclockforalmostallthematerials,theT neutopinsuchcasebeingassumedfromtheupperlimitof
the Toutdm for the equation (1), which is 30.5 degC. Hence these results were not shown in the study. However the
comparativerankingofvariouswallingmaterialson
th

rhermalcomfortonthisdaybaseduponthedegreesofdiscomfortindicatorfollowedatrendsimilarto20 March.
Thecomparativeperformanceassessmentforthermalcomfortforvariouswallingmaterialsinthegivenstudyis
alsodependentuponthespecificheat,densityandthermalconductivityofthewallingmaterials.Thesethreephysical
propertiesareoftenseentovarywiththemanufactureofthematerialandtheproportionofitscomposites.The
thermalpropertiesofAACblocksforexamplearelargelydependentupontheproportionofflyashinablock.Hence
theseresultsaresubjecttovariationsdependinguponchangingmaterialcompositionsandproperties.Thusthetarget
ofthegivenstudyistodelineateamethodologyforsustainabilityassessmentofvariouswallingmaterialsbasedupon
theavailabledatainputs.

Chapter4

ManufacturersStandards
By
FACTINDIA,Cochin

DESCRIPTION OF SYSTEM

Name of the System Glass Fibre Reinforced Gypsum Building Panel System
Market Name: Rapidwall Panel
Glass Fiber Reinforced Gypsum (GFRG) Panel branded as Rapidwall is
a building panel product, made of calcined gypsum, plaster, reinforced
with glass fibers, for Mass-scale building construction, was originally
developed and used since 1990 in Australia.
The panel, manufactured to a thickness of 124mm under carefully
controlled conditions to a length of 12 m and height of 3m, contains
cavities that may be unfilled, partially filled or fully filled with
reinforced concrete as per structural requirement. Experimental studies
and research in Australia, China and India have shown that GFRG
panels, suitably filled with plain reinforced concrete possesses
substantial strength to act not only as load bearing elements but also as
shear wall, capable of resisting lateral loads due to earthquake and
wind. GFRG panel can also be used advantageously as in-fills (nonload bearing) in combination with RCC framed columns and beams
(conventional framed construction of multi-storey building) without
any restriction on number of stories micro-beams and RCC screed
(acting on T-beam) can be used as floor/ roof slab.
Grade and Type- GFRG panel may be supplied in any of the following
three grades :
3)
4)
5)

Class 1- Water Resistant grade panels that may be used for

external walls, in wet areas and/or as floor and wall formwork for
concrete filling;
Class 2 General grade -- panels that may be used structurally or
non-structurally in dry areas. These panels are generally
unsuitable for use as wall or floor formwork; and
Class 3 Partition grade panels that may only be used as nonstructural internal partition walls in dry areas only.

ASSESSMENT
Scope of Assessment
Scope of assessment included conformance of manufactured panel
to the specified requirements for use in building construction as:
i)
Load bearing wall panel
ii)
Shear Wall
iii) Floor/ roof slab
Basis of Assessment
Assessment of the suitably of panels manufactured at FRBL, Cochin as
load bearing wall, shear wall, floor/ roof slab is based on
vii) Satisfactory test results of testing of the samples drawn from
manufacturing line of FRBL plant for dimensions, weight,
compressive strength, water absorption, flexural strength and fire
resistant vis--vis requirements contained in the specification for
Glass fiber Reinforced Gypsum Building Panel.
viii) Construction of the two room single apartment using the panels
as wall unit and roof slabs construction.
ix)
GFRG/Rapidwall Building structural Design Manual, developed
by IIT, Madras.
x)
Quality Assurance scheme followed by the Certificate holder for
process control.
xi)
Construction Manual for Building using GFRG/ Rapidwall
Panels.
USE OF THE GFRG PANELS AND LIMITATION
The panel may be used generally in the following ways:
1)
As lightweight load bearing walling in building (single or double
storey construction) up to two storey construction: the panel may
be used with or without non-structural core filling such as
insulation, sand polyurethane or lightweight concrete.
2)
As high capacity vertical and shear load bearing structural
walling in multi-storey construction: the panel core shall be filled
with reinforced concrete suitably designed to resist the combined
effect of lateral and gravity loading.
3)
As partition infill wall in multi-storey framed building: Panel
may also be filled suitably.
4)
As Horizontal floor/ roof slabs with reinforced concrete micro
beams and screed (T-beam action)
5)
As pitched (sloped) roofing
6)
As cladding for industrial building
7)
As compound wall
2

Special Aspects of use:

1)

2)
3)

4)

The building to be constructed using GFRG panel

manufactured in accordance with the specifications prescribed
in this PAC shall be designed by Competent Structural
Engineers on the basis of GFRG/ Rapidwall Building
Structural Design Manual, developed by IIT, Madras. It is
advisable to get design of important projects vetted by IIT
Madras initially on mutually agreed terms.
Plumbing and Electrical services shall be governed by the
provisions and details given in the Construction Manual
developed by the manufacturer.
GFRG building systems should be constructed only with
technical support or supervision by qualified engineers and
builders, based on structural designs carried out to comply
with prevailing standards; this is applicable even for low-rise
and affordable mass housing to provide safety of structures.
It is strongly recommended that structural engineers and
building designers associated with GFRG panel construction
should be thoroughly familiar with the various structural
aspects outlined in the Design Manual. It is also recommended
that Architects and Constructions Engineers who undertake
GFRG/ Rapidwall building design and Construction gain
familiarity with the properties and materials, characteristic of
GFRG and its application and construction system.

Limitation of Use:
i)
Cannot be used for wall with circular or higher curvature
ii)
Clear span shall be limited to 5m for residential buildings, for
non residential buildings, the span shall be limited to as
specified in Designs Manual.

Scope of Inspection Scope of inspection included the verification of

production, performance and testing facilities at the factory
including competence of technical personnel and status of quality
assurance in the factory.

TECHNICAL SPECIFICATIONS
Raw Materials
(i)
Phosphogypsum Shall be > 90% purity as CaSO4
(ii)
Glass Roving E glass shall be > 98% purity
(iii) Ammonium Carbonate Shall be of 99.14% purity as NH4CO3

Manufacturing process
Phosphogypsum which is a byproduct of phosphoric acid plant is
0
calcined in calciner at 140-150 C at the rate of 15MT/hr of
calcined plaster. This calcined plaster is stored in product silo
having capacity of 250MT.
The plaster is then transferred to batch hopper by screw
conveyors and through Entoleter in wall panel manufacturing
area.
This area consists of 6 casting tables having dimensions of 3m x
12m, one crab having mixer and glass roving delivery system is
for delivering slurry and glass roving for three tables. The
chemicals are added in water & mixed and then plaster is added
& mixed to form slurry.
One layer of slurry is laid on the table by the crab followed by a
layer of glass roving. This glass roving is embedded in to the
slurry with the help of screen roller.
Another layer of slurry is poured followed by a layer of glass
roving this layer is pushed inside the ribs with the help of
temping bar. Finally a layer of glass roving is laid for the top face
of the wall panel.
After getting final Gilmore wall panel is lifted from the casting
table to ACROBA frame and shifted to dryer for drying. The wall
O
panel is dried at a temperature of 275 C for 60 minutes.
After drying, the wall panel is either shifted to storage area or on
the cutting table. The wall panel is cut as per dimensions
supplied by the consumer and the cut pieces are transferred to
stillages which are specially made for transporting wall panel.
The liquid effluent generated during manufacturing process is
recycled back in the system for manufacturing of new wall
panels.
The solid waste which is generated while manufacturing wall
panels is recycled back to the calciner after crushing and
separating plaster & glass roving in recycle plant.
The above system is a batch process. Six wall panels can be
manufactured in eight hour shift per table. Similarly, 36 wall
panels can be manufactured in eight hour shift with 6 tables.
Flow diagram of the system showing the manufacturing process
is attached herewith.

The above system is a batch process. Six wall panels can be

manufactured in eight hour shift per table. Similarly, 36 wall
panels can be manufactured in eight hour shift with 6 tables.
Flow diagram of the system showing the manufacturing process
is attached herewith.
Inspections & Testing are done at appropriate stages of manufacturing
process. The inspected panels are stored & packed to ensure that no
damage occurs during transportation.
Construction & workmanship

(i)

Rapidwall for rapid construction

Building shall be designed on the basis of Design Manual* by a
qualified structural Engineer. As per the building plan and design,
each wall panel shall be cut at the factory using an automated
cutting saw. Door/window/ventilator and `openings for AC unit
etc. shall also be cut and panels for every floor marked as per the
building drawing. Panels are vertically loaded at the factory on
stillages for transportation to the construction site on trucks. The
stillages shall be placed at the construction site close to the
foundation for erection using crane with required boom length
for construction of low, medium and high rise buildings. Panels
shall be erected over the RCC plinth beam and concrete is
infilled from top. All the panels shall be erected as per the
building plan by following the notation. Each panel shall be
erected level and plumb and shall be supported by lateral props to
keep the panel in level, plumb and secure in position. Embedded
RCC lintels shall be provided wherever required by cutting open
external flange. Reinforcement for lintels and RCC sunshades
shall be provided with required shuttering and support.

(ii)

Concrete infill
After inserting vertical steel reinforcement as per the structural
design and clamps for wall corners are in place to keep the wall
panels in perfect position, concrete having 12mm aggregate shall
be poured from the top into the cavities using a small hose to go
down at least 1.5 to 2m into the cavities for directly pumping the
concrete from ready mixed concrete truck. For small building

construction, concrete can be poured manually using a funnel.

Filling the panels with concrete shall be done in three layers of
1m height with an interval of 1 hour between each layer. There is
no need to use vibrator because gravitational pressure acts to self
compact the concrete inside the water tight cavities.
(iii)

Embedded RCC tie beam all around at each floor/roof slab

level
An embedded RCC tie beam is provided at each floor slab level
as an essential requirement, web portion to required beam depth
at top shall be cut and removed for placing horizontal
reinforcement with stirrups and then concrete to be filled.

(iv)

GFRG panel for floor/roof slab in combination with RCC

GFRG panel for floor/roof slab shall be cut to required size and
marked with notation. First, wall joints, other cavities and
horizontal RCC tie beams are in-filled with concrete; then
wooden plank 0.3 to 0.45m wide shall be provided to room span
between the walls with support wherever embedded micro beams
are there and then roof panels shall be lifted by crane. Each roof
panel shall be placed over the wall in such a way that there will
be a gap of at least 40mm. This is to enable vertical rods to be
placed continuously from floor to floor and provide monolithic
RCC frame within Rapidwall. Wherever embedded micro-beams
are there, top flanges of roof panel shall be cut leaving at least
25mm projection. Reinforcement and weld mesh is placed for
micro beams and then concrete shall be poured for micro beams
and RCC slab.

(v)

Erection of wall panel and floor slab for upper floor

Vertical reinforcement of floor below shall be provided with
extra length so as to protrude to 0.45m to serve as start up rods
and lap length for upper floor. Once the wall panels are erected
on the upper floor, vertical reinforcement rods, door/window
frames fixed and RCC lintels shall be casted. Then concrete
where required and joints shall be filled. Thereafter, RCC tie
beams all around shall be concreted.

(vi)

Water proofing
The PAC holder shall provide to the client details of water
proofing treatment required at different levels of construction
such as foundation, sunshade and flooring etc.

(vii)

Finishing work
Once concreting of ground floor roof slab is completed, wooden

th

planks with support slabs shall be removed after 4 day.

Finishing of internal walls and ceiling corners shall be done
using wall putty by experienced POP plasterers. Simultaneously,
electrical work, water supply and sanitary work, floor tiling,
mosaic or marble works, staircase work etc. shall also be carried
out for each upper floor.
INSTALLATION
.
GFRG panel erection Methods of erection of GFRG Panel shall vary depending
upon the use of the panels recommended. The method of erection of the panel is as
follows:
1)
Align the wall by marking with chalk line, where wall is to be
erected.
2)
Then fix the hold fast (regular door frame hold fast of 150mm)
by plumbing wall. Two nos. of hold fasts are required for each
panel.
3)
Simultaneously cut the pocket of electrical points & electrical
conduits to be inserted inside cavity of Rapid wall.
4)
Then erect the panel by supporting with props.
5)
Fix electrical switch boxes.
6)
Fix other panels same as per the above method up to required
length
7)
Check the plumb & line of the wall.
8)
Fill the holdfast gap with concrete.
9)
Finish the joints of two panels by fixing fiber tape with stucco as
follow:
i) Make a slot of 8mm wide & 2mm deep at the joint of Rapid
wall.
ii) Fix the jointing fiber tape and finish the surface with stucco.
10) Joints of Rapid wall with RCC column/ beam shall be finished
by stucco with reinforcing fiber of used cement bags.
11) Finish the gap around electrical points and between Rapid wall &
slab/beam by stucco.
Maintenance requirements
A proper maintenance guide is provided by all manufacturing companies
to the client. When building is to be repainted with fresh coat of paint
after scraping existing paint, check for joint sealant, pipe joint, sun
shade etc. and carry out required maintenance and apply primer before
paint is applied.

ENT PROCEDURE

Tests done in independent laboratory

S.No. Parameters

Test Method

1.

BMBA PC3:2011

6.

Dimensions
Length
Height
Thickness
Water Content
Weight
Water
absorption
Compressive
strength
Flexural strength

7.

Fire resistance

2.
3.
4.
5.

Clause 10.4.2
Clause 10.4.3
Clause 10.4.4
Clause 10.4.5
Clause 10.4.6
Clause
10.4.7/10.4.8
Clause 10.4.10

Requirement

Results
Obtained

12.02m
3.05m
124mm
Less than 1%
2
40 kg/m
Max. 5% by
weight
Min. 160
kN/m
Min. 2.1 kN/m

Within specified
tolerances

4 hr rating
withstood
o
700-1000 C

Satisfactory
2
44.10 kg/m
1.51% (Avg.)
164.50 kN/m
(Avg.)
2.158 kN /m
(Avg.)
Satisfactory

Chapter5

Standards & Norms by

BUILDING MATERIALS & TECHNOLOGY

PROMOTION COUNCIL
For India

QUALITY ASSURANCE PLAN FOR GFRG PANEL

S.No. Parameters to
Requirement Specified
Test Method
be inspected
A. Rapidwall/GFRG Panel
1.
Visual
Shall be free from defects like
As per BMBA
Appearance
cracks, corrugations, ripples,
PC-3:2011
stains, pockmarks, loose corners Clause10.4.1
etc.
2.
Overall
Length & height shall be within
Clause10.4.2
Dimensional
tolerance limit of 3mm &
Tolerances
thickness +3mm to 0mm
3.
External Skin
Shall be 3mm (General /Water Clause10.4.2
thickness
resistance grade)
tolerance
Min 8mm Partition grade
4.
Internal Rib
Shall be 2mm (General /Water Clause10.4.2
thickness
resistance grade)
tolerance
Shall be 5mm (Partition grade)
5.
Cavity Width & Shall be 3mm (General / Water Clause10.4.2
Depth Tolerance resistance grade)
Shall be 7mm (Partition grade)
6.
Unevenness
Shall be less than 1mm (Side A) Clause10.4.2
Shall be less than 3mm (Side B)
7.
Panel weight
Shall be 40 Kg/m 6% (Class 1
& 2)
Clause10.4.4
Shall be 40 Kg/mm15%
(Class 3)
8.
Water Content
Shall be less than 1% (measured Clause 10.4.3
immediately after drying
process)
9.
Water
Shall be less than 5% by weight Clause 10.4.5
Absorption Rate (after 24 hrs of immersion in
water)
10.
Vertical Load
Shall be more than160 kN/m
bearing capacity (General / Water resistance
Clause 10.4.6
(Compressive
grade)
strength)
Shall be more than 90 kN/m
(Partition grade)
11.
Out of plane
Shall be more than 2.1kN/m
Flexural capacity (General /Water resistance
Clause 10.4.7/
(Flexural
grade)
Clause 10.4.8
strength)
Shall be more than1.3 kN/m
(Partition grade)
12.
U Value
Shall be 2.85W/M C
IS3346:1980
13.
Thermal
Shall be 0.617 W/m C
IS3346:1980
Conductivity (K)
14.

Sound
transmission

Shall be 40 (STC)

ISO 140-3:1996

Frequency of
Testing
Once in every ten
panels
Once in every fifty
panels
Once in every fifty
panels
Once in every fifty
panels
Once in every fifty
panels
Once in every fifty
panels
Once in every fifty
panels
Once in every fifty
panels
Once in every fifty
panels
Once in every fifty
panels

Once in every fifty

panels

Once in a year or
when the
composition
changes and
initially at the time
of approval

15.

Durability
i.wetting &
drying
ii. Salt spray

16.

Fire Resistance

Average compressive strength

shall not be less than 7.52
2
N/mm
Shall not suffer any apparent
damage after 20 cycles
Shall withstand 700-10000C

Clause10.4.9

Clause10.4.10

Once in a year or
when the
composition
changes and
initially at the time
of approval

after 4hr
1.

B. Raw Materials
Calcined
Gypsum

2.

Ammonium
Carbonate

3.
4.
5.

Glass Roving
BS-94 M
Retarder D-50

i.Shall be more than 90% as

Calcium Sulphate
ii. Combined moisture shall not
be more than 6.2%
Shall not be less than 99.14% as
purity

As per
Company
Standard

i.Once in a day
ii. Once in a shift

As per
Once on delivery at
Company
site
Standard
These raw materials are performance based. Test Certificates provided by
the manufacturers are verified at the time of delivery.

BMTPC
Specification for
Glass Fibre Reinforced Gypsum Building Panel

Table of Contents
1.
2.
3.
4.

5.
6.
7.

8.
9.
10.

SCOPE....................................................................................................

23
23
APPLICATION ..................................................................................................
23
REFERENCED DOCUMENTS ........................................................................
23
DEFINITIONS ..................................................................................................
4.1.
23
STANDARD GFRG PANEL .........................................................................
4.2.
WATER RESISTANT GFRG PANEL ............................................................. 24
4.3.
24
EXTERNAL SKIN ........................................................................................
4.4.
24
INTERNAL RIB ...........................................................................................
4.5.
25
CAVITY ....................................................................................................
4.6.
25
PANEL LENGTH .........................................................................................
4.7.
25
PANEL THICKNESS ....................................................................................
4.8.
25
PANEL HEIGHT ..........................................................................................
4.9.
25
A AND B SIDE ...........................................................................................
25
GRADE CLASSIFICATION .............................................................................
25
STANDARD DIMENSIONS .............................................................................
6.1.
26
PRODUCT CODING ...............................................................................
PERFORMANCE REQUIREMENTS ............................................................. 26
APPEARANCE
7.1.
26
REQUIREMENT .....................................................................
DIMENSIONAL
7.2.
26
TOLERANCES ......................................................................
7.3.
27
WATER CONTENT .....................................................................................
7.4.
28
PANEL WEIGHT .........................................................................................
7.5.
28
WATER ABSORPTION RATE ........................................................................
7.6.
VERTICAL LOAD BEARING CAPACITY ........................................................ 28
7.7.
OUT-OF-PLANE FLEXURAL CAPACITY ........................................................ 28
28
MARKING ....................................................................................................
QUALITY SYSTEM AND QUALITY CONTROL PROCEDURES .............. 29
QUALITY PROCEDURE BY STATISTICAL SAMPLING........................... 29
10.1. GENERAL ..................................................................................................
29
10.2. SAMPLING .................................................................................................
29
10.2.1. Sampling for Routine Tests .........................................................
29
10.2.2. Sampling for Flexural Tests .........................................................
31
CRITERIA OF
10.3. COMPLIANCE .........................................................................
31
10.4. TEST METHODS .........................................................................................
32
10.4.1. Appearance Inspection.................................................................
32
10.4.2. Measurement of Dimensions and Flatness ................................... 32
32
10.4.2.1 Apparatus ......................................................................

11.

10.4.2.2 Measurements ............................................................... 32

10.4.3. Measurement of Water Content ................................................... 33
10.4.3.1 Apparatus ...................................................................... 33
10.4.3.2 Test procedure ............................................................... 34
10.4.3.3 Calculation of Results ................................................... 34
10.4.4. Measurement of Density .............................................................. 34
10.4.4.1 Apparatus ...................................................................... 34
10.4.4.2 Test procedure ............................................................... 34
10.4.4.3 Calculation of Results ................................................... 34
10.4.5. Measurement of Water Absorption Rate ....................................... 35
10.4.5.1 Apparatus ...................................................................... 35
10.4.5.2 Test procedure ................................................................ 35
10.4.5.3 Calculation of Results ................................................... 35
10.4.6. Measurement of Vertical Load-bearing Capacity ........................ 35
10.4.6.1 Apparatus ...................................................................... 36
10.4.6.2 Test procedure ................................................................ 36
10.4.6.3 Calculation of results ..................................................... 36
10.4.7. Flexural Bending Test .................................................................. 36
10.4.7.1 Apparatus ...................................................................... 37
10.4.7.2 Test procedure ................................................................ 38
10.4.7.3 Calculation of results ..................................................... 38
10.4.8. Alternative Flexural Bending Test ............................................... 39
10.4.8.1 Apparatus ...................................................................... 40
10.4.8.2 Test procedure ................................................................ 40
10.4.8.3 Calculation of results ..................................................... 41
10.4.9 Durability Test ........................................................................... 41
10.4.9.1 Wetting and drying test .................................................. 41
10.4.9.2 Salt spray test ................................................................. 41
10.4.10 Fire Resistance Test ..................................................................... 41
10.5.
TEST REPORT ............................................................................................ 42
CUTTING, HANDLING, STORAGE AND DELIVERY ................................ 42
11.1.
CUTTING .................................................................................................. 42
11.2.
HANDLING ................................................................................................ 42
11.3.
STACKING ................................................................................................. 42
11.4. PROTECTION FROM WEATHER .................................................................... 43
11.5.
DELIVERY ................................................................................................. 43

Specifications
for
Glass Fibre Reinforced Gypsum (GFRG) Building Panel
1
SCOPE
This document forms the product specification for manufactured GFRG panels designed
for use in the construction industry for walling, ceilings, suspended floor formwork and
partitions. The specified technical and mechanical property requirements refer to the
finished product, that is, the final manufactured GFRG panel dried and ready for
installation. Specified also is the quality control procedure and the associated
mechanical tests necessary to ensure an acceptable quality of the finished GFRG panel
product.
2
APPLICATION
This specification is intended for use by licensed manufacturers of GFRG to ensure a
uniform, quality controlled global product suitable for its intended purpose. The details
of this document also assists the end users, such as engineers, architects and builders,

both in their designs using GFRG and in specifying the physical properties of the
GFRG panel in their contract documents.
3
REFERENCED DOCUMENTS
The following documents are referred to in this specification: Report by IIT, Madras on Testing of GFRG panel dt29th March,2012
GFRG/Rapidwall Building Structural Design Manual,IIT Madras
ISO 9004.1 Quality Management and Quality System Elements, Part 1:Guidelines;
4
DEFINITIONS
For the purpose of this specification the following definitions apply: 4.1 Standard GFRG Panel
GFRG panel is a factory manufactured walling product used in the construction industry
to provide habitable enclosures for residential, commercial and industrial buildings. The
124mm thick hollow-core panels are machine-made using formulated gypsum-plaster
reinforced with chopped glass-fibre. A typical cross-section and isotropic view of the
wall panel is shown in Fig.1.

Length

External
skin

124

Thickness

Internal
rib

Glass
fibre

15

Gypsum
plaster

15

Cavity

(a) Cross-section

Fig.1 Standard GFRG panel

Water Resistant GFRG Panel

panels in
Water resistant GFRG panels are the same as ordinary GFRG
appearance. However the ingredients of the water resistant GFRG are modified
specifically, to provide water resistance when used externally or
in wet areas such as
bathrooms or laundries, etc.
External Skin
The two 13mm thick faces making up the panel are collectively defined as external skins
as shown in Fig.1.
Internal Rib
The 20mm thick ribs inside the panel connecting the two external skins are called internal
ribs as shown in Fig.1.

Cavity
The internal hollow cores inside the panel are called the cavity as shown in Fig.1.
Panel Length
The panel length is the maximum horizontal dimension of a single wall without vertical
joint as indicated in Fig.1.
Panel Thickness
The panel thickness is the distance between the external faces of the two external skins, as
shown in Fig.1.
Panel Height
The panel height is the maximum vertical dimension of a single wall without a horizontal
joint.
A and B Side
The smoother side of the GFRG panel cast against the machine bed in the manufacturing
process is called the A side. The B side is screeded and is relatively rougher than A side.
GRADE CLASSIFICATION
GFRG panel is supplied in three grade classifications:1). Class 1 - Water Resistant grade panels that can be used for external walls, in wet
areas and/or as floor and wall formwork for concrete filling;
2). Class 2 - General grade GFRG panels that can be used structurally or nonstructurally in dry areas. These panels are generally unsuitable for use as wall or
floor formwork; and
3). Class 3 - Partition grade GFRG panels that can only be used as non-structural
internal partition walls in dry only areas.
STANDARD DIMENSIONS
The current nominal manufactured dimensions of each GFRG panel are: Length 12,020 mm
Height 3050 mm, and
Thickness 124 mm

Product Coding
GFRG panels are coded using the following convention:GFRG

TS-

LH

D ate and place of manufacture

Panel height
Panel length
Panel thickness
& classification
R registered
Trademark

Where panel type is indicated as G for general grade, W for water resistant grade or P
for partition grade. For example a Wat er resist ant l grade panel made in RCF, Tro mbay p
st
lant in Chembur , Mumbai 21 Feb 2010 is coded as: - GFRG 124G-12X321FEB10/TROMBAY

PERFORMANCE REQUIREMENTS
Appearance
The two external faces of GFRG panels should be free from defects such as corrugations,
ripples, pockmarks, stains, loose corners, cracks or any other defects which would
adversely affect a painted decorative surface finishes.
It is a requirement that paint can be directly applied to the A-side of GFRG without the
need for extensive rendering or plastering. The quality of finish on the B-side of the panel
can be controlled by the operation of the final screeding in the manufacturing process. The
ap pear ance r equ ir ement s o n the B -side ar e u sua lly d ecid ed t hro ugh negotiation
between the manufacturer and its client. However, the minimum requirements for the Bside are that a 3.5mm texture coating or a trowelled-on coating will cover all the defects.
7.2

Dimensional Tolerances

The manufactured dimensional tolerances for a full sized GFRG panel shall satisfy
Tables 1 and 2:Table 1. Overall Dimensional Tolerance
Length
Height
Thickness
Nominal length
Nominal height
Nominal thickness
3mm
3mm
+3 to 0 mm
Table 2 Cross-sectional Dimensional Tolerance
External Skin
Internal Rib
Panel Classification
Cavity Width
Thickness
Thickness
General Grade
Nominal
Nominal
Nominal
&
Thickness
Thickness
Width
Water Resistant
3
2
4
Grade
Nominal
Nominal
Partition Grade
Minimum 8
Thickness
Width
5
7

Cavity
Depth
Nominal
Depth
3
Nominal
Depth
7

The flatness of the panel shall satisfy the following: The maximum local unevenness of protruding or recessing belessthan1mmon the A
side and 3mm on the B side, as shown in Fig.2(a); and
For the overall curvature of the surface the deviation of any point on the panel face
from a 2.5m straight edge shall not exceed k=3mm in any part of the panel and in
both of the two orthogonal directions, as shown in Fig.2(b)&(c).

Rapidwall panel

(a) Local unevenness

12020mm FULL PANEL
48 CAVITY CELLS

3050

STRAIGHT
EDGE
STRAIGHT EDGE
(b) Measurement of curvature in both
directions 2.5m

Straight edge

GFRG panel
(c) Overall curvature
Fig. 2 Measurement of flatness

Water Content
The water content of panels measured immediately after the drying process (without
moisture intake after drying) shall be less than 1% when tested in accordance with Clause
10.4.3.
The maximum acceptable water content after production is referred to in Section 7.5.

Panel Weight
The weight of the dried and empty hollow core GFRG panel shall satisfy Table 3:Table 3 Empty Panel
Weight
Panel Classification
(mm)
Class 1, 124 mm thick
Class 2, 124 mm thick
Class 3, 124 mm thick

Nominal Weight
2
(kg/m )
40
40
40

Tolerance
%
6%
6%
15%

7.5 Water Absorption Rate

The water absorption rate for water resistant grade GFRG panels shall not be greater
than 5% by weight after 24 hours of immersion in water when tested in accordance
with Clause 10.4.5. No test is needed for other grades of GFRG panels.
7.6 Vertical Load Bearing Capacity
When tested in accordance with Clause 10.4.6, the cross-sectional compression strength of
the panel shall satisfy the minimum requirements as given in Table 4.
Table 4 Acceptance criteria for compression strength
Minimum compression strength (kN/m)
General or water
resistant grade
160

Partition grade
90

Out-of-Plane Flexural Capacity

When tested in accordance with Clause 10.4.7 or 10.4.8, the out-of-plane flexural strength
of the panel shall satisfy the minimum requirements as given in Table 5.
Table 5 Acceptance criteria for flexural strength
Minimum Flexural Strength per meter width
General or Water
Partition Grade
Resistant Grade
2.1 kNm
1.3 kNm
MARKING
Each manufactured GFRG panel shall be clearly marked with the following particulars:
Product code in accordance with Clause 6.1;
The manufacturers name, address and trademark;
Quality checked mark and identification of the checker; and
Signs for packaging and transportation.

QUALITY SYSTEM AND QUALITY CONTROL PROCEDURES

Quality of the finished product is assured by a proper quality control system, it is needed to
demonstrate the compliance with this specification and to supply products that conform to
the full requirements of this specification. Generally, one of the following four quality
procedures shall be adopted:

Evaluation by means of statistical sampling;

The use of a product certification scheme;
Assurance using the acceptability of quality system; and

For reference a procedure for statistical sampling is provided in Clause 10 of this

specification.
QUALITY PROCEDURE BY STATISTICAL SAMPLING
General
Sampling and the establishment of a sampling plan should be carried out in accordance with
Clause 10.2
Sampling

Sampling for Routine Tests

Three GFRG panels should be randomly selected from a batch of panels for tests
described in Sections10.4.1to10.4.6. Grouping of panels to form a batch shall follow the
following rules: 1). Every 500 panels of same grade classification form a batch, when there is no
variation in mix design, ingredient materials, manufacturing conditions, and dryer
conditions;
2). Two different grade classifications i s into two different batches even when the
number of panels in a batch is less than 500;
3). When the ingredients of gypsum, glass fibre, water and any other additives changes,
new batch should be formed whenever such a change takes place. The same
principal of forming a different batch applies when any other change is made in the
manufacturing and drying process such as change of recipes or any other activity
that may affect the property or quality of the finished panels; and
4). When significant variations exist in the manufacturing process that may affect the
quality or properties of the panels, such as significant variation in the quality of
plaster, batch is formed with a much smaller number of panels depending on the
magnitude and extent of variations. Forming batch is on daily (or shift) basis in
such kind of situations, i.e. panels produced in the same day (or shift) are
considered as a batch.
Three test sample plates (520580) are to be cut from each selected panel. The
positions for cutting these three test plates are shown in Fig.3. Two different test
specimens are to be cut from each test plate in accordance with the layout of Fig.4. The
specimens shall be machine cut to the dimensions with a tolerance of not more than
2mm.

Positions for cross-sectional

dimension check
12020
1000
500
580
3050

500 520
5750
580
1075
500

Flexural test sample

Routine test sample plates
Positions for crosssectional dimension check

Fig.3 Positions of sampling

520mm

Compression test
specimen520250

Ribs

250mm

Water content test by

drying oven and Water
absorption test specimen
250300

5 80mm
300mm
250mm

Fig.4 Detailed dimensions of test specimens

520 500

10.2.2. Sampling for Flexural Tests

The flexural strength of a panel largely depends on the quality, quantity and distribution
of the glass-fibers in the panel. The flexural strength test may be conducted over a much
longer interval and when any variation (such as quality, quantity or distribution) in
glass-fibre takes place in the manufacturing process. One set of flexural tests consisting
of three test specimens shall be conducted on one cluster of panels. Panels are grouped
as one cluster if they are:
1). Made in the same six-month period of time when nothing changes in the
manufacturing process; or
2). Made with a same batch of glass fiber. When an old batch of glass-fibre is used up
and a new batch of glass-fibre is used for production, the panels made with new
batch of glass fiber are considered as a new cluster. Any other change that is made
to the glass fiber such as change of supply source, change of brand, change of
quantity or quality of glass fiber, change of fiber strand length and means of
distributing fiber, etc. shall make a different cluster of panel.
The three test specimens shall be cut from three different panels selected randomly from
the same cluster. Specimen shall be cut at least one meter away from the vertical sides of
the panel and shall be cut in such a way as shown in Fig.3 and Fig.5.
ribs
125

Test specimen

250

1000

250

250
125

2850 or 3050

Fig. 5 Plan view of flexural test specimen

Criteria of Compliance
The batch or cluster of panels is deemed to satisfy the performance requirements of Clause
7 if all the test specimens selected in accordance with Clause 10.2 pass all the tests
described in Clause 10.4. Otherwise it is considered to be non-compliant.
Panels that do not comply with the requirements for partition grade must not be used for
building purposes and shall be destroyed. Panels that do not satisfy the general grade or
water resistant grade may be downgraded to partition grade if they pass the specification
for partition grade.
It is generally recommended that the samples be representative of the quality of all the
panels in the same batch or cluster. In other words, the whole patch or cluster of panel fails
the quality check and cannot be used if the samples fail any of the tests of Clause 10.4.
However, if it is judged that the failed sample does not represent the quality of the whole
batch of panel, and the manufacturer intends to use some or any panel in that batch

or cluster, then all the tests in Clause 10.4 shall be repeated to that batch or cluster such that
the quality of the panels are proved. An acceptable way of repeated tests is that the number
of test panels is doubled and all the repeated tests pass the performance requirements.
Only the panels that pass all the quality checks can be marked as quality checked.
Test Methods
Laboratories that undertake the tests shall generally satisfy AS ISO/IEC17025-1999:
General Requirements for the Competence of Testing and Calibration Laboratories. Test
equipment and devices shall satisfy the relevant requirements and be calibrated regularly to
a local or international standard.

Appearance Inspection
Every finished panel shall be visually inspected in accordance with Clause 7.1.

Measurement of Dimensions and Flatness

The overall and cross-sectional dimensions as well as flatness shall be measured from
the selected test panel (selected in accordance with Clause 10.2.1) to satisfy Clause 7.2
in any part of the panel.
Apparatus
The tools used for measurements shall satisfy the following requirements:1). The overall panel dimensions of length, height and thickness shall be measured
to accuracy within 1.0mm; and
2). The other dimensions shall be measured to within 0.5mm.
Measurement

The length of the panel shall be measured at the positions of 1d, 2e and 3f; and the
height of the panel shall be measured at the positions of a4, b5 and c6, as shown in
Fig.6a. The thickness of the panel shall be measured at the 12 positions of 1 to 6 and a
to f.
As shown in Fig.3, the cross-sectional dimensions shall be measured at six different
positions of a, b, c, 4, 5, and 6, as shown in Fig.6a. Six separate measurements shall be
taken at each of the above six positions, as shown in Fig.6b.
The flatness shall be checked at the positions of a2a22, a22b2, b2b22, b22c2, a4, b5 and
c6.

a
1
2
3

a1
a2
a3

b
a11

b1

a22

b2

a33

b3

4
1000

c
b11
b22
b33

5
5000

c1

500

350

1000

1000

c2

or

c3

1000

1000

550

500

6
5000

1000

(a) Positions of overall dimension measurements

(b) Cross-sectional measurement points

Fig.6 Dimensional measurements

Measurement of Water Content

The water content shall be tested for the selected panels against Clause 7.3. Sampling
of the test specimen shall be made in accordance with Clause 10.2.1. Do not treat the
edges and surfaces of the specimens nor damage the specimens.
This test measures the loss of water of the specimen after drying in a standard oven. It
is combined with the measurement of density and water absorption tests. Should the
samples after conditioning take up moisture then the panel was over cooked (calcined)
in the dryer and fails the test.
10.4.3.1 Apparatus

Air circulating oven: The net space available inside the drying oven shall not be less
than 200300360. The oven shall have a temperature control at 402C and a
humidity control at 502%.
Balance or scale: with a capacity of 5kg and an accuracy of 0.5g.

Test Procedure

1). Weigh each original specimen and record their weights;

2). Condition the specimen (or specimens) to constant weights, within 0.1% of the
dried weight, at a temperature of 402C, in an atmosphere having a relative
humidity of 502%. This can be done by drying the specimen for 24 hours initially
and weighing the specimen; then drying for another 4 hours each time and weighing
the specimen until the difference of the two consecutive weights of the specimen is
with 0.1% of the dried weight; and
3). Weigh the dried weight w of each specimen to within 0.5g.
Calculation of Results

The weight loss of the individual specimen in percent with respect to its dried weight
w is the water content of the specimen.

Measurement of Density
Density of the panel shall be measured from the specimens immediately after the water
content tests and before water absorption tests. Care shall be taken to prevent damaging
the specimens in the measurement so that it does not affect the water absorption test.
Apparatus

Right-angle ruler: with an accuracy of within 1 mm.

Test procedure

Take the following measurements from each specimen:The four dimensions as shown in Fig.7 measured to within 1mm, where H1 and H2
are the lengths of the two vertical sides, respectively, and B1 and B2 are the
horizontal dimensions that is perpendicular to the vertical side measured with a
right-angle ruler.
B1
Rib
H1

H2

B1

Fig.7 Dimensions for density measurement

Calculation of results

The density (weight per surface area) of a specimen is calculated by

w

H1 + H 2 B1 +
B2 2 2
where w is the weight of the specimen measured at step 3 of 10.4.3.2 and
dimensions H1, H2, B1 and B2 are shown in Fig.7.

10.4.5. Measurement of Water Absorption Rate

The specimens tested for density is immediately used for water absorption rate.
Apparatus

Balance: same as 10.4.3.1.

Water bath or container: enough room to immerse the three specimens and keep them
separated and elevated from the bottom of the bath with minimum spaces of
25mm.
Test procedure

1). Immerse the specimens flat in a bath of water at a constant temperature of

210.5C with a head of 25 mm of water over the top of the sample. The sample
should be positioned in the water bath elevated one inch above its base;
2). Remove the specimens from the bath after 24 hours of immersion, wipe excess
water from the surfaces and edges of the specimens and weigh immediately to
within 0.5g.
Calculation of results

The percentage of weight gain with respect to the dried weight of each specimen
calculated is the water absorption rate.

Measurement of Vertical Load-bearing Capacity

The test specimen as sampled in accordance with Clause 10.2.1 is shown in Fig.8 and
the test set up is shown in Fig.9, where a universal compression test machine shall be
used.
520

120 Typ.

13

20

Fig.8 Cross-section of compression test specimen

Compression
load

Platen of
compression
machine

Specimen
250

Thin layer of quicksetting plaster to

ensure a firm
contact with platen

Fig.9 Compression test set up (Elevation)

Apparatus

Universal compression machine: the test machine shall be calibrated

Test procedure

1). Measurement of Dimension the width B of the test specimen is measured at the
waist of the specimen as shown in Fig.9. The measurement shall be taken on both
the front face and the back face of the specimen and an average value used;
2). Placing of Specimen the test specimen shall be placed at the centre of the platen
on the test machine. Under no circumstance should any part of the specimen be
placed outside the perimeter of the platen of the test machine;
3). Capping-the top and bottom faces of the test specimen shall be capped with a thin
layer of quick-setting plaster (such as dental paste) to ensure firm and uniform
contact with the platen. The strength of the applied plaster shall not be lower than
that of the test specimen at the time of testing;
4). Loading Apply the compression load gradually in a rate not greater than 10kN per
minute until it reaches the peak load and then drops at least 20% off the peak load.
The maximum applied load (peak load) F indicated by the testing machine shall be
recorded.
Calculation of results

The unit strength of a specimen is reported as p =

in a unit of kN/m, where F is

B
the peak load, in kilo newtons, and B is the width in meter at the waist of the specimen.

Flexural Bending Test

The flexural test set up is shown in Fig.10.

L/3

L/3

L/3

Load F
from
loading jack
Main Steel beam
Pin support
Secondary
Steel beam

Roller
support

Test specimen
Pin support

Displacement
measurement
L=2500mm

Fig.10 Flexural test set up

124
Roller
support

Apparatus

As the specimen is one meter wide, it is important for the load and reaction force from
the supports to be distributed evenly along the width of the specimen. The point load
from a load jack is applied to a main distribution beam that then distributes the load
equally to two secondary distribution beams. The load is finally transmitted from the
secondary distribution beams to the top face of the test specimen as an evenly
distributed line load.
The minimum ultimate flexural strength of the main distribution beam shall be 10kNm.
The secondary distribution beam shall be 1000mm long with a minimum flexural
11
2
rigidity EI of 510 N/mm .
To ensure a good contact and even distribution of load, a thin layer of quick-setting
plaster (such as dental paste) shall be applied between the bottom face of the
secondary beams and the contact surface of the specimen.
The specimen shall be supported firmly with one pin support and one roller support as
illustrated in Fig.11. The pin support is composed of two steel plates of 1000mm
long100mm wide minimum10mm thick and a 1m long steel roller bar with a
minimum diameter of 30mm. The steel bar is fixed to the bottom plate (such as by
welding) and the top plate just sit on top of the bar to ensure free rotation. The roller
support shown in Fig.11(b) is similar to the pin support except that some smaller steel
roller bars of about 10mm diameter and 1000mm long are provided underneath the
bottom steel plate to ensure both free rotation and longitudinal movement.
The loading jack shall have a minimum load capacity of 20kN. The displacement
transducer shall have a minimum travel distance of 100mm.
The measurement or data acquisition involves both the applied load measured from the
load cell and displacement from the displacement transducer at the mid-span. The
accuracy of measurements shall be within 0.1kN for load and 0.5mm for displacement.
For tests in China, guidelines for the test apparatus and methodology shall follow GB
50152-92: National standard for tests of concrete structures.
Test procedure

1). Mark the positions of support line (centre line position of the roller bar) on the
bottom of the specimen, and load line (centre line position of the secondary
distribution beam) on the top of the test specimen;
2). Set up the pin and roller supports;
3). Apply a thin layer of quick-setting plaster on top of the supporting steel plates and
then place the test specimen on top of the two supports. Waite a few minutes for the
plaster to set;
4). Apply a layer quick-setting plaster on top of the test specimen at the position of the
secondary distribution beams and place the secondary distribution beams in
position. Allow the plaster to set;
5). Set up the rest of the loading system (main distribution beam and its support, etc.)
and loading jack;
6). Place the displacement transducer under the test specimen at the mid-span. A piece
of small plate (about 20mm20mm2mmthick) shall be glued onto the tip of the
transducer to prevent it from going into a crack if the crack happens to occur at the
position of the displacement measurement point;

7). Load the jack under displacement control in a strain rate of not greater than
5mm/minute until the load passes the peak and drops at least 50% off its peak load; 8).
In the mean time of applying loading, record the test data at sufficient number of test
points to produce a load vs. displacement curve (as illustrated in Fig.12). An automatic
data acquisition system is recommended that can record the complete test curve
automatically. If manual record is used, one data point (a pair of load and displacement
readings) shall be taken at a displacement increment of not more than 1.5mm.
Calculation of results

The maximum moment capacity of a specimen is given by

M u = 1 wL2 + 1 (F + S) L
8
6
Where
2
w = the unit weight of the panel which is typically 0.4kN/m ;
F = the first peak load from the load vs. displacement curve as explained in more
detail below, in kN;
S = the weight of the load distribution system including the main and secondary
distribution beams, in kN; and
L = the span which is 2.5m.
The first peak load is the applied load at which the first major crack occurs (usually
accompanied with a clear sound of breaking). Two typical cases to identify the first
peak load are illustrated in Fig.12. This first peak load may not be the maximum load
as shown in Fig.12(b).

Total load F(kN)

First peak

5
4
3
2
1
0
0

10

20
Mid-span deflection

30

40

F(kN)

(a)

8
7
6

First peak

Total

load

5
3
2

1
0

10

20

30

40

50

60

70

Mid-span deflection
(b)
Fig.12. Typical out-of-plane bending test results

Alternative Flexural Bending Test

When the test frame and equipment required for the test as described in Section 10.4.7 are
not available, the test provided in this section can be used as an alternative for the flexural
bending test. The test set up is shown in Fig.13. Blocks of weight are used as load in this
test instead of a loading jack.

Total weight F
One column of
weight. Minimum 7
columns along span

Gap between columns

minimum 50
Layer 2
Layer 1

Test specimen

120
Roller
support

Pin support
L=2500mm

Fig.13 Alternative flexural test set up

Apparatus

The supporting systems of the test specimen and the displacement measurement
transducer are the same as that described in Section 10.4.7.
All the weight blocks shall have an equal size and weight and be calibrated to an
accuracy of within 1.0% of the weight. The maximum weight of each block is
generally required to be less than 10kg in order to have enough number of blocks to
provide an even distribution of load on top of the specimen (in an area of 25001000),
unless it can be shown that the heavier blocks will not adversely affect the even
distribution of load. The size of the blocks shall also be restricted such that at least 7
columns of weight with a minimum gap of 50mm between columns can be distributed
evenly along the span of the specimen, as shown in Fig.13.
For tests in China, guidelines for the weights can be found in GB 50152-92.
Test procedure

1). Mark the positions of support line (centre line position of the roller bar) on the
bottom of the specimen;
2). Set up the pin and roller supports;
3). Apply a thin layer of quick-setting plaster on top of the supporting steel plates and
then place the test specimen on top of the two supports. Waite a few minutes for the
plaster to set;
4). Place the displacement transducer under the test specimen at the mid-span. A piece
of small plate (about 20mm20mm2mmthick) shall be glued onto the tip of the
transducer to prevent it from going into a crack if the crack happens to occur at the
position of the displacement measurement point;
5). Put the weight blocks row by row, column by column and layer by layer on to the
specimen as shown in Fig.13, starting from the mid span of the specimen and
ensuring the even distribution of weights on the whole surface area of 25001000;
6). In the mean time of applying loading, record the test data at sufficient number of
test points to produce a load vs. displacement curve (as illustrated in Fig.12). One

data point (a pair of load and displacement readings) shall be taken at a

displacement increment of not more than 1.5mm.
Calculation of results

The maximum moment capacity of a specimen is given by

2

Mu = 1 (w + f)L
8
Where
2
w = the unit weight of the panel which is typically 0.4kN/m ;
f = F/L, F in kN is the first peak load (total weight) from the load vs. displacement
curve as explained in Section 10.4.7.3; and
L = the span which is 2.5m.
The first peak load may not occur exactly at a time when a whole layer of load is applied.
In that case, the load distribution at failure is not uniform and the maximum moment shall
be calculated based on the actual distribution of the load.
Durability Test
Wetting and drying test
0

Put the panels through 20 cycles of wetting and drying at room temperature of 30 C.
Each cycle consist of 24 hours of wetting followed by 24 hours of drying.
Measure the average compressive strength at the end of 20 cycles.
Salt spray test

Embed a 12mm dia,250mm reinforcing rod in the concrete filled in cavity. After 7 days
curing, hung the same in a salt spray chamber for 2 weeks.
Observe any apparent damage to the panel and to the reinforcement.
Fire Resistance test
The fire resistance test on GFRG panel (Rapidwall) shall be conducted using a blow torch
(burning kerosene as fuel). The blue flame temperature shall be measured and shall be in
0
0
the range of 700 C to 1000 C. The blower tip of the blow torch shall be kept at a
distance of about 50 mm from one face of the building panel (size 300 x 300 x 124 mm)
so that the blue flame shall directly hit the panel continuously. The panel shall be exposed
to such a state for continuation duration of 4 hours. The other face of the panel shall be
pasted with a thermocouple to monitor the temperature continuously.
0

Record the temperatures ( C) at 30 minutes interval during the test period of 4 hours for
the hollow GFRG panel and the GFRG panel filled with M20 concrete the results.
At the end of the test, no damage or cracks should be observed beyond the spot where he
flame was directly hitting the face of the panel.

CUTTING, HANDLING, STORAGE AND DELIVERY

This part of specification is only applicable within the factory before delivering to end-users. For the
transport and storage of panel outside the factory, reference shall be made to specification for
transport, storage and installation.
Cutting
Cutting shall be made with specific machine and impact tools such as hammer shall not be used for
cutting or removing part of the panel. All cutting shall be made in accordance with the drawings and
requirements provided by the client. Generally the following requirements are applicable: 1). Tolerance to be 1mm;
2). Openings to be partially cut in the factory, leaving about 100mm at the corner to be cut after
installation of the panel;
3). Damage to corners shall be limited to within 10mm10mm; and
4). Metal closure studs (C channels) are fitted to the edges of a panel immediately after
cutting.
Handling
Handling of panel shall be made with specific machinery. Movement of panel shall be reasonably
slow and care shall be taken to prevent undue sagging, cracking or damage to the panel especially at
the sides, edges and corners. The damaged panel or part of the panel must not be used and shall be
removed and destroyed. The RBS Friction Lifting Jaws must not be used in the factory as every rib in
the GFRG panel can be clamped only once.
Stacking
GFRG panels shall be neatly stacked to avoid panel distortion, damage or moisture ingress. This can
be achieved by stacking vertically on support extending the full length of the panel or a firm, clean
and flat surface not susceptible to moisture. It shall also be kept free of any dirt, oil or other foreign
matter.
When vertically stacked in open air, panels shall be protected from collapse caused by strong wind. A
good practice is stacking panels inside a Stillage with its stabiliser legs extended.
Protection from Weather
All panels shall be kept dry preferably by being stored inside a building and under cover. Where it is
necessary to store the panels outside, it shall be stacked off the ground in accordance.
Delivery
GFRG panels are usually packed and loaded on specifically designed stillage and delivered by
suitable trucks. Extreme care must be taken in loading, transportation and unloading to ensure the
safety and protection of the panels from damage due to collision or collapse of the panels. Care
shall be exercised to avoid exceeding the maximum allowable height of vehicles applicable to a
specific road in a specific area. All general grade panels shall be protected from rain with a plastic
membrane. Protection from rain for water resistant grade panels is generally not required.

Chapter5

StructuralTestsResults
Conductedby
IITMADRAS

STUDIES ON THE BEHAVIOR OF GLASS FIBER REINFORCED

GYPSUM WALL PANELS

Glass fiber reinforced gypsum (GFRG) wall panel is made essentially of gypsum
plaster reinforced with glass fibers. The panels are hollow and can be used as load
bearing walls. The hollow cores inside the walls can be filled with in-situ plain or
reinforced concrete.
This paper presents guidelines for the use of GFRG wall panel as a lateral load
resisting component in buildings based on a numerical analysis procedure to
arrive at its capacity estimation under axial compression, compression with inplane bending and shear. Variation of buckling load of unfilled GFRG wall panels
for various widths is reported. The axial load carrying capacity of 1.02 m wide
and 2.85 m high wall panel, obtained from the numerical analysis and the test
results are comparable for this load case. While assessing the axial load capacity
for design under compression, a minimum possible eccentricity (causing out-ofplane bending) is accounted for. An engineering model is proposed to assess the
strength of unfilled and concrete filled GFRG wall panels in multi-storied
building system subjected to lateral load such as earthquake.
Introduction
In a high seismic intensity zone, resistance of buildings to earthquakes is often ensured
by adopting structural systems where seismic actions are assigned to structural walls (shear
walls), designed for horizontal forces and gravity loads while columns and beams are designed
only for gravity loads. Structural walls provide a nearly optimum means of achieving the
important objectives, viz., strength, stiffness and ductility. Buildings braced by structural walls
_______________________________________________________

Ph D Research Scholar, 2 Professor, Structural Engineering Division,

Department of Civil Engineering, Indian Institute of Technology Madras, Chennai 600 036, India.

are invariably stiffer than framed structures, reducing the possibility of excessive deformations
under small earthquakes. The necessary strength to avoid structural damage under moderate
earthquakes can be achieved by properly detailed longitudinal and transverse reinforcement.
Special detailing measures need to be adopted to achieve, dependable ductile response under
major earthquakes (Paulay and Priestley, 1992).
Glass fiber reinforced gypsum (GFRG) wall, a new composite wall product known as

Rapidwall /Gypcrete in the industry, is made essentially of gypsum plaster, reinforced with
chopped glass fibers. The glass fibers about 300 350 mm long are randomly distributed inside
2
the panel skins and ribs in the manufacturing process. The fiber content is 0.8 kg/m . The 120
mm thick panels are hollow and can be filled with in-situ plain or reinforced concrete to increase
the strength. A typical cross section of the panel is illustrated in the Fig. 1.

Length

94mm

Thickness = 120mm

250mm

20mm thick web

Gypsum Plaster
13mm thick flange

230mm
Reinforcement by chopped glass fibers

Figure 1. Cross section of GFRG wall panel

Wu and Dare (2004) have carried out axial and shear load tests on GFRG wall panels of
standard 2.85 m height. The width of panel specimens was 1.02 m for axial load tests, 1.52 m
and 2.02 m for shear load tests. They have reported that under axial load, unfilled GFRG wall
panels failed due to plaster crushing, irrespective of the eccentricity of axial load. The concrete
filled specimens all failed due to buckling and flexural tensile breaking of the GFRG walls. The
failure load was governed by the eccentricity and support conditions. The compressive strength
of unfilled wall panels was governed by the plaster strength and that of concrete filled panels was
governed by out-of-plane buckling. The axial load carrying capacity of concrete filled wall
panels was only affected by the axial load eccentricity and support conditions. The failure mode
for shear load specimens of concrete filled walls was due to the longitudinal tearing of the GFRG
panels, which is very different from the failure mode of a traditional RC wall. As a result, the
shear strength is governed by the strength of the GFRG panels and was not affected by the

strength of the concrete infill. Typical shear failure modes for unfilled panels and concrete filled
panels are shown in the Fig. 2.

(a) Unfilled panel

Diagonal cracks

(b) Unfilled panel

End crushing

(c) Concrete filled panel

Vertical cracking

Figure 2. Typical failure modes for GFRG wall panels subjected to shear
(Wu and Dare, 2004)
Wu (2004) has reported that there are two types of shear failure modes in a building
constructed with GFRG walls. The first mode is the shear failure of the panel itself, and the
second is shear sliding at the interface of a wall and the floor slab. The continuity of longitudinal
reinforcement at the horizontal joint may affect the shear strength of both the failure modes.
Mechanical properties of the GFRG panel, as reported by Wu and Dare (2004) are shown
in Table 1. Axial load capacity of wall panels against buckling are estimated and shown in the
Table 2 and the in-plane lateral load buckling capacity is shown in Table 5. It is found that the
Poissons ratio of the wall panel is approximately equal to 0.2 from experimental results. The
modulus of elasticity of the panel considered is 3000 MPa.
Estimation of GFRG Wall Panel Capacities
In the present study an attempt is made to estimate for design purposes the capacities of
GFRG wall panels under (i) Axial loads, (ii) Axial load with out-of-plane bending (iii) Out-ofPlane bending capacity (iv) Axial load and in-plane bending moment and (v) Capacity of wall
panel due to shear load.

Table 1. Mechanical Properties of GFRG Building Panel (Wu and Dare 2004)
Mechanical Property
Unit Weight
Uni-axial Compressive
Strength
Uni-axial Tensile Strength
Elastic Modulus
Coefficient of Thermal
Expansion
Water Absorption
Thermal Resistance
Sound transmission
coefficient
Fire Resistance Level

Characteristic Value
2
40 kg/m
160 kN/m
35 kN/m
3000 6000 MPa

Remarks
Unfilled Single leaf GFRG
Panel.

12 x 10-6 mm/mm/ 0C

< 5%
2

0.36 m K/W
28
45
>3h

By weight after 24 h
of immersion
Unfilled Panel
Unfilled panel
Concrete filled panel
For Structural adequacy

Axial Load Capacity

While assessing the axial load carrying capacity of the wall panels a minimum
eccentricity causing out of plane bending is accounted for. As per standards such as IS 456
(2000), the design of reinforced concrete walls should take into account the actual eccentricity of
the vertical force subjected to a minimum value of 0.05 times the wall thickness t (6 mm for t =
120 mm). According to masonry design codes such as IS 1905 (1987), the design of a wall shall
consider appropriate eccentricity, which in no case shall be taken to be less than t/24 (5 mm for t
= 120 mm).
In the case of wall panels supporting floor slabs from one side, the eccentricity to be
considered should be more than the minimum values indicated above. It is recommended that a
value of minimum eccentricity equal to t/6 (20mm for t = 120 mm) shall be considered
conservatively. Additional value of eccentricity may be considered when the out of plane
bending is explicitly involved.
The characteristic values of axial compressive strength of GFRG wall panels are obtained
from the compression test results on 2.85 m full height panel subjected to eccentric loading. In
general, it is conservative to assume pinned-pinned condition as shown in Fig. 3. It may be noted
that for design purposes, the characteristic values should be divided by partial safety factor 1.7.
Finite element analysis of the wall panel, using plate-shell elements to model both flanges
and webs, was carried using the SAP 2000 NL software. These numerical analysis results are
compared in Table 2 with the experimental results reported by Wu and Dare (2004). It is seen
that the numerical results are comparable with the experimental results for the 1.02 m panel. The
axial load carrying capacity of the unfilled GFRG panels of widths 1.52 m and 2.02 m, estimated
by finite element analysis are also shown in the Table 2.

Table 2. Axial Load Carrying Capacity of Unfilled GFRG Wall Panels

Width of

Numerical analysis Results (kN)

Experimental Results** (kN)

Panel (m)

e=0

e = 20 mm

e=0

e = 20 mm

158.1
230.1
300.0

132.4 166.7

119.6 166.7

e = 6mm
(Minimum)
168.7
252.4
319.6

1.02
173.7
1.52
245.3
2.02
328.7
e = Eccentricity
** Wu and Dare (2004)

P
e

2850 mm

Figure 3. Experimental set- up for Pinned-Pinned panels

The same finite element model was used to estimate the elastic critical buckling load of
the wall panel, and the results are listed in Table 3 for different widths of the wall panel. These
results indicate values much higher than those shown in Table 2, confirming that buckling is not
a likely mode of failure, as evidenced by the testing (which showed crushing of plaster).
Table 3. Buckling Load Values When the Wall is Subjected to only Axial Load
Width of GFRG Wall Panel (m)
1.02
1.52
2.02

Buckling Load Pcr (kN)

622
926
1233

Out-of-Plane Bending Capacity

The out- of-plane flexural strength of 120 mm thick GFRG wall panel without filling is
shown in Table 4. From the test results, it is found that filling without reinforcement does not
improve the out-of-plane moment capacity of the panel.
Table 4. Out-of-plane flexural capacity of Unfilled / Concrete filled Panel without Steel
Reinforcement
Property
Out-of-plane moment
capacity (kNm / m)

Ribs parallel to span

Ribs perpendicular to span

2.1

0.88

In-Plane Bending Capacity

GFRG wall panels can be used as load bearing walls in multi storied buildings capable of
resisting fairly large lateral load. Each wall can act as a shear wall resisting vertical load, inplane bending and shear. Invariably, such a wall shall be infilled with reinforced concrete. The
following simplified procedure may be used to calculate the ultimate in-plane flexural strength of
concrete filled GFRG wall panel.
6) Assess

the stress distribution along the cross section of the wall panel based on linear
elastic assumption.
P M y
(1)
A
I

2. Based on the stress distribution from the Eq. 1, there are two different cases to be
considered.
(a). The whole cross section is under compression or there is no tensile stress in the cross
section ( 0) compare the maximum value of in the cross section with the
compressive strength of wall panels given in Table 1. If the calculated stress is less than
the design compressive strength of the wall, the design is safe otherwise redesign is
required.
(b) If tension exists in the cross section ( < 0) go to step 3.
The unfilled and concrete filled GFRG wall panel without continuous reinforcement in
the cores is not able to transmit tension between floors, therefore case (b) is not
applicable to unfilled or concrete filled GFRG wall panel without continuous longitudinal
reinforcement.

xii)

When tension exists in the cross section, the flexural strength can be calculated
using the following assumption.

8) The contribution of the panel to ultimate strength in tension and compression is

neglected and the system is treated as filled concrete with concrete effective only in
compression and the reinforcement bars in tension.

9) Tension reinforcement (full length bars) are assumed to act as unbonded bars with
constant stress, limited to 90 MPa in the entire tension zone (assuming lack of bond
between the infilled concrete and the wall panel).
The assumed stress distribution across the cross section of a GFRG wall panel is shown
in Fig.4. From the test results, it has been found that there is practically no bond between
concrete and GFRG wall panel. It is assumed that all reinforcing bars are subjected to same
stress and that this stress is limited to the following value based on the studies in prestressed
concrete section with unbonded tendons.
Pu
Mu

0.42xu
0.5D

Dxu xu
D

Cu= 0.36f ckbxu

xi

Figure 4. Stress Distribution across the GFRG Wall Panels under Axial Load and in-plane
Bending Moment.
Tensile stress in steel rod,
0.85 fck
fst 70
A
100

in N/mm

st

(2)

bd
p

Equating forces:
P 0.36 f bx f
u

th

ck

n
st

sti i1

(3)

where Asti is the area of the i bar located at a distance xi from the
centre. Equating moments,
n

M u fst

Asti D / 2 xi 0.36 fck xu D / 2 0.42xu

i1

where xi is considered to be positive if it is on the tension side of the mid depth.

(4)

From the Eqs. 3 and 4, the value of xu and Asti can be determined by trial and error.
Alternatively, Pu Mu interaction curves may be generated for a given panel with infill concrete
(fck) and given area of steel per cavity (Ast). Such an interaction diagram (using non-dimensional
coordinates) has been generated and is shown in Fig. 5. The value of p/fck can be obtained from
this diagram and the suitable bar reinforcement can be identified. It may be noted that minimum
eccentricity requirement should be satisfied.
0.50
0.45
0.40
0.35

Pu /f ck bD

0.30
0.25

p/fck = 0.005

0.20

p/fck = 0.01

0.15
0.10
0.05

p/fck = 0.015
p/fck = 0.02

0.00
0

0.01

0.02

0.03
M u /f ck bD

0.04

0.05

0.06

Figure 5. Interaction diagram for panel subjected to axial load Pu and in-plane bending
moment, Mu
Shear Capacity of Panels
Wu and Dare (2004) have reported that in all of the shear load tests on unfilled panels,
there were visible 45 shear cracks, developed before the peak load was reached, as shown in
Fig.2(a), and shear strength varies from 19.1 kN/m to 24.5 kN/m. Using strength of materials
approach, the capacity of unfilled panels under shear load can be assessed as follows.
b
Capacity of unfilled panel under shear load =

cos

where b = Width of wall panel,

= Inclination of crack with respect to horizontal
axis, tf = Thickness of flange of the wall panel,
t = Permissible tensile strength of wall panel.
This capacity works out to 39 kN/m for a GFRG panel of 1.02 m width.

Buckling Capacity under In-Plane Shear Load

The possibility of buckling failure under shear loading was investigated in the
present study through numerical analysis using SAP 2000 NL. The results obtained are
shown in Table 5, corresponding to three widths of wall panel. The values of lateral load
obtained (262 to 596 kN) are significantly higher than the capacities reported by Wu and
Dare (2004). Hence it is clear that buckling mode of failure is unlikely to occur not only
under axial load but also under shear loading for the unfilled GFRG wall panels.
Table 5. In-Plane Buckling Capacity due to shear Load alone
Width of Wall Panel (m)
1.02
1.52
2.02

Buckling Lateral Load Vcr (kN)

262
425
596

Conclusions
Axial load carrying capacity of unfilled GFRG wall panels, of various widths
when subjected to eccentric loads, is estimated using numerical analysis. The lateral load
carrying capacity of panels is also estimated. A simplified procedure has been suggested
for assessing in-plane flexural strength of concrete filled wall panels. For a given force
demand, reinforcement required for a concrete filled GFRG wall panels can be obtained
using interaction diagram that has been developed. Using simple approach, the capacity
of unfilled panels under shear load is estimated. It is also established by comparing the
results of finite element buckling analysis with the available experimental results, that
failure of the GFRG wall panel does not occur due to buckling, on account of in-plane
axial and shear loads, as the critical loads are much higher than the actual capacities.
References
IS: 456-2000, Plain and Reinforced concrete - Code of Practice, Bureau of Indian Standards, New
Delhi, India.
IS: 1905-1987, Code of Practice for Structural use of Unreinforced Masonry, Bureau of Indian
Standards, New Delhi, India.
Paulay T., and Priestley M.J.N., 1992. Seismic Design of Reinforced Concrete and Masonry
Buildings,
John Wiley & Sons, New York, USA.
SAP 2000 NL. Structural Analysis Program (Static and Dynamic Finite Element Analysis of
Structures),
Computers and Structures Inc., Berkeley, CA, USA.
Wu, Y.F. and Dare, M. P., 2004. Axial and Shear Behavior of Glass Fiber Reinforced Gypsum Wall
Panels: Tests. Journal of Composites for Construction, ASCE, 8 (6): 569-578.
Wu, Y. F., 2004. The effect of longitudinal reinforcement on the cyclic shear behavior of glass fiber
reinforced gypsum wall panels: Tests. Engineering Structures, ELSEVIER, 26
(11):1633-1646.

Conclusion
Rapidwall Panel provides a new method of building construction in fast track,
fully utilising the benefits of prefabricated, light weight large panels with modular
cavities and time tested, conventional cast-in-situ constructional use of concrete and steel
reinforcement. By this process, man power, cost and time of construction is reduced. The
use of scarce natural resources like river sand, water and agricultural land is significantly
reduced. Rapidwall panels have reduced embodied energy and require less energy for
thermo-regulation of interiors.
Rapidwall buildings thereby reduce burdening of the environment and help to reduce
global warming. Rapidwall use also protect the lives and properties of people as these
buildings will be resistant to natural disasters like earthquakes, cyclone, fire etc. This
will also contribute to achieve the goal of much needed social inclusive
development due to its various benefits and advantages with affordability for low income
segments also. Fast delivery of mass dwelling/ housing is very critical for reducing huge
urban housing shortage in India. Rapidwall panels will help to achieve the above multiple
goals.