The glass fibre-reinforced gypsum (GFRG) panel, also known as the Rapid wall, is the latest building construction feature that was developed by the GFRG Building System Australia to rapidly construct large numbers of homes in a short amount of time.
GFRG panels: What are they?
Panels made of glass fibre-reinforced gypsum, often known as GFRG Panels, are a new architectural component that is utilised for the rapid construction of large numbers of homes in a relatively short amount of time. The key features and applications of the GFRG panels include the following:
- These panels are white in colour and have a glossy finish all over their bodies.
- They are a green construction material that is efficient in terms of energy usage and have a huge potential for use as load-bearing and non-load-bearing wall panels.
- They can be used in the building of either exterior or interior walls because of their versatility. In conjunction with Reinforced Cement Concrete (RCC), they are also a viable option for usage as a composite material in the capacity of an intermediate floor slab or roof slab.
- GFRG panels are used to construct not only the walls but also the floors, sunshades, boundaries, and roofs in addition to the walls themselves.
see also about: load bearing structure
GFRG panels: Classification
Water resistant grade
When it comes to the building of exterior walls in damp locations where water resistance is of the utmost significance, water-resistant grade types of GFRG panels are employed. In addition, this particular kind of GFRG panel can serve as floor or wall formwork for the placement of concrete.
General grade
In dry environments, General Grade GFRG panels are used for a variety of purposes, including structural as well as non-structural uses. When it comes to the building of interior or exterior walls, the majority of the time, these kinds of panels are not appropriate to use. They should not be used for the building of the wall or floor formwork either since this is not advised.
Partition grade
The installation of non-structural interior partition walls with GFRG panels is where GFRG panels shine the brightest. Only dry environments are advised to use this particular kind of GFRG panel.
known about: isolated footings
GFRG panels: Building applications in construction
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see also: about the plinth beam
For load bearing walls
Load-bearing structures in buildings are a typical use for GFRG panels, making this one of the most prevalent uses for these materials. The compressive strength of the GFRG panels is improved by filling the spaces inside the panels with concrete, which also increases the panels’ tensile strength. In addition, the capacity of the panel to withstand lateral stresses is improved when reinforcing bars are included in the construction of the panel. Consequently, using such load-bearing structures in the construction of multistoried buildings is the most appropriate choice that can be made.
In the construction of buildings with one or two stories, the cavities can be filled with a different kind of structural material, such as quarry dust combined with 5% cement. On the other hand, the filling process is advised to be carried out at every joint or opening site, as well as every third or fourth cavity. The use of concrete type M20 is strongly recommended for the filling process. In addition to that, it has to be strengthened with one reinforcing bar that is 8 millimetres in diameter.
Horizontal floor and roof slabs
In conjunction with reinforced concrete constructions, GFRG panels can also be used as an intermediary floor or slab. By integrating it with reinforced concrete micro beams, the strength of such GFRG slabs can be greatly increased, resulting in a more robust structure. To produce microbeams that are embedded, the top flange of the corresponding cavity is cut and removed in such a manner that a minimum of 25 millimetres of the flange is left protruding from both ends. This is done so that the microbeams are produced.
GFRG panels that will be used for the floor and slab are trimmed to the necessary dimensions and then notated. To begin, concrete is poured into the wall joints, voids, and any horizontal RCC tie beams that are present. After that, a hardwood plank with a width ranging from 300 to 450 millimetres is placed between the walls of the room to serve as a room divider. This plank receives support from the implanted micro beams. At this point, the roof panels are going to be hoisted up by the crane so that they can float completely horizontally.
A space of at least 40 millimetres is left between each GFRG roof panel and the wall once it has been mounted on the wall appropriately. This is done to produce a monolithic RCC frame inside the fast wall and allow vertical rods to be installed constantly from floor to floor.
Partition walls
GFRG panels can also be utilised as partition-in-fill walls in single or multiple-story structures. It is possible to use suitable filler material in the cavities of GFRG panels. These panels can also be used for cladding in industrial buildings or sports facilities, in addition to their usage as partition walls, which are commonplace for such panels. Similarly, you can construct compound walls or security barriers with them.
GFRG panels: Manufacturing and transportation
- The sludge that is produced as a byproduct of heating calcined raw gypsum is used in the semi-automatic machine that is used for the production of GFRG panels.
- A mixer is used to combine calcined raw gypsum (plaster), water, white cement, and certain additives such as D50 (a retarder) and BS94 (a water repellant).
- After that, many layers of slurries are spread out across a table, and in between each layer, glass fibres and metal plugs are placed (for creating hollow cavities).
- After about half an hour, the metal plugs are removed, and the panels are then placed in a drier.
- Trucks or trailers are used to move GFRG panels with ease from the manufacturer to the construction site. To prevent any damage from occurring while the panels are being transported, they must be secured in a vertical position using stillages.
GFRG panels: Construction of homes using GFRG panels
Work Begins on the Excavation and Foundation
The process of laying the foundation is identical to the process of excavating the dirt. The first thing to do is lay the foundation. Strip footing, isolated footing, and raft footing are the three forms of foundation that are used the vast majority of the time.
In the event of multistory structures or when the soil is deemed to be of poor quality, raft footing is often employed as the foundation. In most cases, the footing for tiny dwellings consists of an isolated slab. After the foundation has been placed, the required chemicals are sprayed on it to waterproof it. This process takes place after the foundation has been laid.
The installation of the GFRG panels
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To construct the plinth beams, the casting of reinforced concrete is first placed down. After that, the starting bars are secured within the concrete casting in preparation for the installation of the GFRG panels.
The building site receives the panels once they have been brought from the production facility. They are attached to the starting bars in the places and dimensions that have been allotted to them following the measurements. After they have been set in place, waterproofing is applied to the joints to secure them.
The process of pouring concrete
After the GFRG panels have been fastened in place, they have to be kept there until the concrete mixture is poured on top of them. The support bars are what provide the structural integrity to these panels. After that, the concrete mixture is poured into each and every cavity of the panels beginning at the top.
The installation of the slabs
After the walls have been completed, the panels are then laid out as slabs and set on top. The slab receives a concrete screed and a reinforcing cage for the embedded beams by pouring concrete mix onto the slab. The construction procedure is completed with the application of finishing and plastering once the roof slab has been concreted.
GFRG panels: Advantages
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Construction takes less time
Using GFRG panels, conventional structures with G+1 that would typically take between six and eight months to construct can be finished in only one month using these panels.
Economical
The use of GFRG cuts down the use of cement by nearly half, steel by 35%, and sand by a staggering 76%.
Fire resistant
In the case of a fire, GFRG panels expel 15–20% of the moisture that is contained within their own weight, which significantly lowers the surface temperature and the amount of damage caused by the fire.
Defiant against earthquakes
It has been discovered that GFRG panels are effective in preventing damage caused by earthquakes that occur in the fifth seismic zone. This is because the panels can be converted into shear barriers.
Having a lower temperature than a standard structure
Panels made of GFRG can reduce the temperature inside of your structure by up to 4 degrees Fahrenheit when compared to standard construction materials.
Strength and endurance under pressure
Panels made of GFRG have strength and durability that is five times more than that of materials used in traditional construction. Gypsum is well-known for its strength and provides great dimensional stability and durability. In addition, it has a long history of use.
Water resistant
During the manufacturing process of GFRG panels, certain chemicals are added to the mixture, which renders the panels resistant to the corrosive effects of water.
More carpet area
When opposed to traditional walls, which have a thickness of 9 inches, the walls of a structure constructed with GFRG panels have a thickness of just 5 inches, which allows for a larger carpeted area to be accessible.
GFRG panels: Limitations
- The panels must be handled with the utmost care, and specialised equipment is necessary to transfer them.
- These panels are not suitable for use on walls that have a circular or more complex curve.
- To prevent abrasion, the panels need to be placed in an orderly manner.
- In residential construction, the clear span can be no more than 5 metres.
FAQs
Are GFRG panels better?
GFRG panels are frequently used in the construction of shear walls, which is crucial for tall structures. Gypsum is renowned for its longevity and provides excellent dimensional stability and strength. It is stated that GFRG panels are five times stronger and more durable than typical building materials.
Is GFRG housing safe?
The building is resistant to natural calamities such as earthquakes, cyclones, and fire. The construction provides excellent sound isolation. The GFRG-based construction system is energy-efficient, sturdy, and long-lasting.
How are GFRG panels made?
GFRG panels are produced in a semi-automatic facility utilising the slurry formed by heating calcined raw gypsum. In a mixer, calcined raw gypsum (plaster) is combined with water, white cement, and additives such as D50 (retarder) and BS94 (water repellent).
How resilient is GFRC?
The flexural strength of GFRC can reach up to 4000 psi, and its strength-to-weight ratio is quite high.