GFRG/ Rapid wall is load bearing pre-fabricated walling panel. This is suitable for rapid mass scale building construction was originally developed and used since 1990 in Australia. Currently, in India GFRG Wall Panels are manufactured at FACT-RCF Building Products Limited (FRBL) at Ambalamedu, Kochi, Kerala. These presentation contains all in one information about GFRG Panel like uses of GFRG Panels, manufacturing of GFRG Panels at FRBL, stepwise construction of GFRG building and finally a comparison of GFRG building and a conventional building.

1. Prepared By :-
M.Saad Attarwala
Glass Fiber Reinforced Gypsum
Panel

2. What is GFRG Wall Panel?
• GFRG Wall also called Rapidwall is an energy
efficient green building material with huge potential
for use as load bearing and non load bearing wall
panels.
• GFRG wall is manufactured using Phosphogypsum
as a core material, which is generated as a by
product of phosphoric acid plant.
Glass Fiber Reinforced Gypsum Wall Panels

3. • GFRG wall is load bearing pre-fabricated walling panel. This is suitable for rapid
mass scale building construction was originally developed and used since 1990 in
Australia.
• It can be used for both internal and external walls.
• GFRG wall is suitable for hybrid Construction in multi- storey buildings.
• GFRG wall is manufactured at FACT-RCF Building Products Limited (FRBL),
Kochi, Kerala.

4. Raw Materials used for manufacturing GFRG Panels
 Phosphogypsum
 Glass Fiber Rovings
 Water
 White Cement
 D 50 (retarder)
 BS 94 (water repellent)

5. Manufacturing Process of GFRG Panels

6. Raw Gypsum is collected from the Gypsum deposition at Phosphoric acid plant

7. Raw Gypsum is Crushed in the storage shed

8. Raw Gypsum is than feeded to Calciner for Calcination process

9. In Calciner Raw Gypsum is heated at 180 oC to 200 oC with the efficiency of 15
tons/hr.

10. Calcined Gypsum (Plaster) is than stored in a Silo which has a capacity to
store 300 tons of plaster

11. From Silo, plaster is mixed with water, white cement and chemicals (D50 and
BS94) in a mixer

12. Now, the first layer of slurry is spread over the table.

13. First layer of Glass Fiber is spread over the slurry

14. Than aluminum plugs are inserted for forming hollow cavities in the panel.
After this, the process of spreading slurry (1 layer) and glass fibers (2 layers) is
repeated.

15. After 20 minutes the plugs are removed and than the panel is kept as it is for
20 minutes.

16. Than the panels are lifted by Acrobat and taken to drying process

17. Now, the panels are dried in a dryer at 200 oC. The dryer can dry 6 panels at
the same time.

18. After drying, panels are stored at storage area which has a capacity to store
500 panels

19. Now, as per the clients requirement the panels are cut at the cutting area and
loaded in the trucks.

20. Before
• Optimum moisture
content Test
• Density Test
• Cube Test
(Compression)
• Water absorption
During
• Initial Gilmore Test
• Final Gilmore Test
After
• Axial Compression
Test
• Water Absorption Test
• Density Test
• Flexural Test
Laboratory Tests

21. USE OF THE GFRG PANELS
• As lightweight load bearing wall in building (single or double storey
construction) upto two storey construction: the panel may be used with or
without non-structural core filling such as insulation, sand polyurethane or
lightweight concrete.
• As high capacity vertical and shear load bearing structural walling in multi-
storey construction.
• As partition infill wall in multi-storey framed building: Panel may also be
filled suitably.
• As Horizontal floor/ roof slabs with reinforced concrete micro beams
• As pitched (sloped) roofing
• As cladding for industrial building
• As compound wall

22. Stages for constructing GFRG Building

23. Upto plinth level the construction is done as per conventional building (GFRG
Panels does not require any special foundation)

24. Than, the panels are lifted with cranes and special hooks and are placed in the
proper position

25. Once the panels are placed properly, the cutting of doors, windows, sanitary
fitting, etc. is done

26. Reinforcement bars are inserted where the infillment is to be done

27. Concrete Pouring is done. Concrete is poured in different levels of 1 m each at
the interval of 1 hour.

28. Now, the panels are placed for the slab

29. Reinforcement done for slab. Triangular micro beam reinforcement is done
and placed as per structural design. Than the concreting is done.

30. Finally, the water proofing is done on the roof.

31. Strength of GFRG Panels
1 Compressive Strength
i. Empty Panel
ii. Concrete Infill
73.10 Kg/cm2
180.70 Kg/cm2
2 Flexural Strength
i. Empty Panel
ii. Concrete Infill
21.25 Kg/cm2
20.80 Kg/cm2
3 Net Density 1140 Kg/m3
4 Earthquake Resistance Upto Ritcher Scale
8
5 Fire Resistance (rating 700oC to
1000oC)
4 hrs

32. Comparison of GFRG Wall Building vs Conventional
Building (for 1500 Sq. ft)
Materials/ items GFRG Wall Building Conventional Building Saving in %
Cement 16 tons 32.55 tons 50.8
Steel 1800 kg 2779 kg 35.2
River sand 20 cum 83.37 cum 76
Granite metal 38cum 52.46 cum 27.56
Water 50000ltr 2000000tr 75
Built Area 143 sqm 154.45sqm 8
Labor 389 mandays 1200 mandays 67.59
Construction Time 21 days 120days 82%
Total Wgt. Of Superstructure 170 tons 490 tons 65
Construction Cost Rs 13.25 Lakhs Rs 18.27 lakhs 27.47%

33.  Why GFRG Wall Panel?
• Light weighted GFRG Wall Panel has high compressive strength, shearing
strength, flexural strength and ductility compared to brick masonry wall.
• It has very high level of resistance to fire, heat, water, termites, rot and corrosion
which far more than brick masonry wall.
• Concrete infill with vertical reinforcement rods enhances its vertical and lateral
load capabilities. GFRG wall buildings are resistant to earthquakes, cyclones and
fire.
• CO2 reduction is about 2.9 tons per panel.
 Limitation of Use:
• Can not be used for wall with circular or higher curvature.
• 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.

34. Thank You