After the foundation is laid using conventional method , these GFRG panels are being erected on the foundation with the help of cranes. A special locking system is being used to grip the ribs of the panel on top. Glass fibres are spread evenly onto the mix by means of a screening and rolling process. Then, special aluminium plugs are inserted on top of the finished first layer with 20mm gaps in between to form the hollow cavities in the panel. Now the second pouring of the mix is done along with cutting glass fibres with tamping to form the ribs of the hollow panel. In the third stage of the process, the first stage is repeated to complete the top layer of the panel after setting which takes 25 minutes the plugs are withdrawn and the casting table is rotated and in its vertical position, the panel is taken out for drying by means of a special forklift.
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Therefore, all walls are constructed from the foundation or plinth beam till the terrace. Most suitability the same floor plan has to be replicated for all floors in multi-story buildings.
Buildings can be designed up to ten stories in low seismic zones, using GFRG panels and to lesser height in high seismic zones , without conventional columns and beams.
In this building system, the foundation is conventional, while the entire structural elements in the superstructure are constructed using GFRG panels. Limit states design procedures are used for the design of GFRG buildings, considering the ultimate limit state for strength design, as well as serviceability requirements.
Earthquake resistant design is carried out in compliance with the requirements of international codes in India IS Part 1 : , where the response reduction factor R is taken as 3. The GFG building construction is not the same as a conventional system. It requires a special type of equipment, tools, and tackles such as appropriate crane for loading, unloading and erecting the panels, lifting jaws and spreader bars for lifting the panels and reset the prop later for supporting wall panels after erection.
The design and construction of important structural elements are summarized in the following sections. The foundation is designed base on the safe bearing capacity of soil and soil profile at the particular site and the number of storeys of the structure.
This ensures the connection of the superstructure with the foundation, spread over the entire wall length over the network of plinth beams. If the foundation is deep, properly designed reinforced concrete pedestals can be used to support RC plinth beams, with small isolated footings. The in-plane bending capacity of the walls depends on its length, the reinforcement provided, as well as the level of axial load and lateral shear. The values of Mud and in-plane shear strength increase with the length of the wall.
Longer shear walls tend to attract larger lateral loads and will form vertical shear cracks in the middle region, causing a further redistribution of forces, and possible further vertical shear cracking.
Design interaction curves are developed for various lengths of GFRG panels from1. The cavities in the GFRG wall panels shall be filled, wherever structurally required, with concrete of grade not less than M20, using an aggregate of size less than 12mm. For up to 3 storeyed high low rise GFRG building there is no need structural requirement to infill all cavities with reinforced concrete, although it is desirable to fill all cavities with PPC or Cement quarry dust, in view of public perception of safety against intrusion, and also facilitate nailing, drilling, fastening of non-structural components etc.
Reinforcing bars may be provided where required, but in no case, more than three adjoining cavities shall remain unreinforced. Single bar reinforcement of suitable diameter not less than 8mm , may be used in such low-rise buildings. This will keep the panel in balance and help to locate the center of gravity of the wall panel.
Once the panel is brought in position, the plumb and level are to be checked. These props can be removed once the panels are in-filled with concrete and gain sufficient lateral stability. The first pour of concrete is to be of a maximum mm high from the base of cavities.
After 2 hrs for allowing an initial set of 1st pour of concrete, 2nd pour of concrete up to window sill level shall be done. Simultaneously, the cavities which are not structurally required to be in-filled with concrete shall be in-filled with lean concrete or quarry dust mixed with cement dry in stages.
All the electrical conduits and plumbing lines can be laid through cavities now. It is mandatory to provide RC embedded lintels over openings for doors and windows, exceeding 1. This tie beam shall be done on top of walls, all around just below roof slabs. All the top flanges of panels shall be cut open and the reinforcement cage is to be inserted. This can be concreted after providing appropriate support. The steps can be constructed with either concrete or bricks.
The total built-up area of this building is sq. This model house apartment houses four flats two for the Economically Weaker Section of carpet area of sqft each and two for the Lower Income Group of carpet area of sqft each , which can be replicated for mass housing, horizontally and vertically. The entire building was completed in 30 days. The use of prefabricated lightweight GFRG panels for the entire building system facilitated a substantial reduction in building self-weight, construction time and workforce requirement.
So far, more than buildings are constructed in India, most of them are individual residential buildings. These panels can be used not only for residential buildings but also for industrial and institutional buildings. This building system gains popularity in a few Asian counties also like in Oman, China, Saudi Arabia, etc. Buildings from a few Asian countries are shown in Fig. This building system has many advantages over the conventional building.
GFRG building has significant potential to providing rapid affordable mass housing. This is an eco-friendly and sustainable building system, making use of recycled industrial waste gypsum or natural gypsum and minimizing the use of cement, steel, sand, water and labor input. This technology is now gaining acceptance in India and other Asian countries. Read More:.
GFRG CONSTRUCTION FAQ'S
Therefore, all walls are constructed from the foundation or plinth beam till the terrace. Most suitability the same floor plan has to be replicated for all floors in multi-story buildings. Buildings can be designed up to ten stories in low seismic zones, using GFRG panels and to lesser height in high seismic zones , without conventional columns and beams. In this building system, the foundation is conventional, while the entire structural elements in the superstructure are constructed using GFRG panels. Limit states design procedures are used for the design of GFRG buildings, considering the ultimate limit state for strength design, as well as serviceability requirements. Earthquake resistant design is carried out in compliance with the requirements of international codes in India IS Part 1 : , where the response reduction factor R is taken as 3.
GFRG – Glass Fibre Reinforced Gypsum Panel Building
GFRC is used for exterior projects as it is similar to concrete in strength and durability with only a fraction of the weight. GFRG is a reinforced gypsum product having high strength with lighter weight for interior projects. Glass Fiber Reinforced Gypsum GFRG consists of high strength resistant glass fibers bonded with high density gypsum cement to produce panels that traditionally were done with plaster castings. The GFRG is lighter in weight, superior in strength and much easier to install than the traditional plaster castings.
Everything You Need to Know About GFRG Panels
Glass fiber reinforced gypsum GFRG wall a new composite wall product is made of gypsum plaster reinforced with glass fiber. The glass fibers are random distributed inside the panal skin and ribs in the manufacturing process. Panels are hollow and manufactured in mm thick by 12 metre length and 3 metre width and are cut in the sophisticated wall cutting plant to suit the customers requirement. The wall panels can be reinforced with concrete during construction as per requirement of the structure. Gypsum based wall putty and wall plaster from FRBL are high quality surface coating products. The unique calcining process of Gypsum prevents over heating and maintains uniform quality of the putty and plaster base. Suitable additives are added to base in a state of art automatic mixing plant for the manufacture of wall putty and wall plaster.