Compendium of Prospective Emerging Technologies for Mass Housing

Compendium
of Prospective Emerging
Technologies for Mass Housing
Third Edition

Building Materials & Technology Promotion Council

Ministry of Housing & Urban Affairs
Government of India

The Executive Director The Joint Secretary & Mission Director (Housing for All)
Building Materials & Technology Promotion Council Ministry of Housing & Urban Affairs, Government of India,
Core-5A, 1st Floor, India Habitat Centre Room No.116, G-Wing, Nirman Bhawan,
Lodhi Road, New Delhi New Delhi-110011
Tel: 011-24636705; Fax: 011-24642849 Tel: 011-23061419; Fax: 011-23061420
E-mail: info@bmtpc.org E-mail: jshfa-mhupa@gov.in
Website: http://www.bmtpc.org Website: http://mhua.gov.in
Compendium of Prospective
Emerging Technologies
for Mass Housing
Third Edition

September 2018

Building Materials & Technology Promotion Council

Ministry of Housing & Urban Affairs
Government of India
 Compendium of Prospective Emerging Technologies for Mass Housing

HARDEEP S PURI
Minister of State (I/C)
Housing and Urban Affairs
Government of India

Message
Under the leadership of the Hon’ble Prime Minister, India has embarked on the most
comprehensive, planned programme of urbanisation undertaken anywhere in the world.
This massive push involving huge projects will be green and resilient, according the highest
priority to environmental concerns.

Conventional construction systems are typically slow paced, energy intensive, dependent on
natural resources and have a large carbon footprint. They use low levels of mechanization
and have high dependence on manual labour. The advent of new construction technologies
in India has been gaining usage but the pace needs to be accelerated. A concerted effort
is required to create mass awareness to enhance technology transition from conventional
to new technologies.

Hon’ble Prime Minister of India has emphasized the need to accelerate the adoption of
new construction technologies to improve the pace and quality of construction under the
Pradhan Mantri Awas Yojana (U) in order to address the challenges of rapid urban growth
and its attendant requirements. Nearly 1 crore houses are to be constructed by 2022.
Construction of houses at this scale offers an opportunity for using new and alternative
technologies from across the globe which may trigger a major transition through introduction
of cutting-edge building materials, technologies and processes.

Building Materials and Technology Promotion Council (BMTPC) has been identifying,
evaluating and certifying new technologies for mass housing. The first edition of a
Compendium of eight prospective emerging technologies brought out at the time of launching
of the Mission by the Hon’ble Prime Minister of India on 25 June 2015. The second edition
of Compendium comprising of 16 technologies was published in March 2017. I am happy
to know that BMTPC has now further evaluated and certified eight more new emerging
technologies for mass housing.

The Compendium will be a useful resource for State Governments and other Authorities
dealing with construction of mass housing.

I wish BMTPC all success in their efforts.

New Delhi
26 September 2018 (Hardeep S Puri)
 Compendium of Prospective Emerging Technologies for Mass Housing

DURGA SHANKER MISHRA

Secretary
Ministry of Housing & Urban Affairs
Government of India

Message
Pradhan Mantri Awas Yojana (Urban), a flagship Mission of Government of India, reaching
halfway stage and most of the States/UTs have completed their demand survey. The demand
is around 1 crore houses across the country. I am glad to inform that over 55 lakh houses
have been sanctioned till mid-September. States/UTs are fully geared up to implement the
scheme and achieve their targets by 2022.

2. Construction of 1 crore houses by 2022 with conventional ‘brick and mortar’

construction approach is not an easily achievable target. Not only these traditional
construction methods are slow paced but also have issues related to quality, maintenance
and environment. Realizing this, Government of India has been constantly endeavoring to
expedite the use of fast track innovative technologies for construction of houses. Evaluation
and certification is one of the most critical steps in the acceptance and mainstreaming of
these technologies.

3. Building Materials & Technology Promotion Council (BMTPC), an autonomous

organization under this Ministry has been given the mandate of certification of innovative
materials & technologies under its Performance Appraisal Certification Scheme (PACS).

4. In order to disseminate knowledge and technical information on new technologies,

BMTPC prepared first compendium on eight such technologies in 2015 and updated it with
sixteen technologies in 2017.

5. I am glad to learn that during last one year, more technologies have been identified
and certified by BMTPC which have been included in this 2nd updated version. Now, 24
technologies are available to State Government agencies and other stakeholders for use
in their housing projects. CPWD has issued Schedule of Rates (SoRs) for 11 of these
technologies.

6. I appreciate the efforts made by the Council in preparing this compendium and
hope that it will prove to be a useful resource for policy makers, technocrats and other
concerned stake holders.

(Durga Shanker Mishra)

 Compendium of Prospective Emerging Technologies for Mass Housing

AMRIT ABHIJAT
Joint Secretary & Mission Director (Housing for All)
Ministry of Housing & Urban Affairs
Government of India

Message
The “Housing for All by 2022” mission is now in advanced stage of implementation in urban
areas, wherein out of 10 million estimated housing shortage in the Country, 5.5 million
houses have been sanctioned, 0.88 million houses have been completed & 2.2 million
houses are in various stages of construction. States & UTs are making concerted efforts
to achieve its respective targets & greater focus is now being laid on early grounding &
completion of the sanctioned housing projects.

Facing the issues with conventional construction system such as slow paced in-situ
construction, and being resource, energy & labor intensive, various States/UTs have started
using emerging technologies in housing projects, while some are in the process of exploring
the same. The “Compendium of prospective emerging technologies for mass housing”,
containing eight emerging technologies in its first edition was released by the Ministry
during launch of the mission in June, 2015. Subsequently, 2nd edition of compendium with
16 technologies was released in April, 2017. The compendium containing technologies
as identified, evaluated & certified by Building Materials & Technology Promotion Council
(BMTPC), has primarily facilitated the States/UTs in adoption of new technologies. The
inclusion of these technologies in generic form in National Building Code (NBC), 2016
& selected technologies in the Schedule of Rates of CPWD, has further boosted the
confidence of States/ UTs in these technologies.

It is heartening to note that BMTPC has now included eight more emerging technologies
in the third edition of the Compendium, & with this the present edition encompasses the
technical details of 24 technologies. The eight newly added technologies have been
evaluated & certified by BMTPC in last one & half year under its Performance Appraisal
Certification Scheme (PACS). I also appreciate the efforts of BMTPC in providing technical
help to States in selection & finalization of new technologies & conducting sensitization
programmes in various States.

I am sure the States will be further benefited in its upcoming projects of Mass housing with
more number of technological options available with present edition of the compendium.

(Amrit Abhijat)
 Compendium of Prospective Emerging Technologies for Mass Housing

Foreword
With the launch of Pradhan Mantri Awas Yojana (PMAY) - Urban & Rural, which envisions to provide pucca house to
each household of India by 2022, a year when India will be celebrating its 75th year of Independence, it is incumbent
on part of academic, research & other organizations involved in construction to bring innovation & thus paradigm
shift in the prevailing construction practices so as to fast-track delivery of houses without compromising structural
& functional performance. With this objective in mind, BMTPC initiated identifying, evaluating & certifying new
emerging construction systems from all across the globe which can help in replacing the conventional cast-in-situ
RCC construction. The first set of such 8 technologies were published in form of compendium in 2015 and its second
edition with 16 new construction systems was published in April 2017. Since 2017, more number of technologies are
knocking the door of Indian construction industry and it is heartening to mention here that with the concerted efforts
put up by BMTPC, now, we have a set of 24 such new emerging technologies which can bring in speed, safety,
sustainability in the construction sector and same are being published in this document as third edition.

The next biggest challenge is to mainstream these new systems in the construction sector and, therefore, there is need
to create an enabling eco-system to facilitate use of these new systems. Under PMAY(U) mission, Ministry of Housing
& Urban Affairs (MoHUA) has setup a Technology Sub-Mission which aims to encourage the use of sustainable & safe
practices across states with the help of IITs/NITs/SPAs and other institutes of repute. It has always been BMTPC’s
endeavor to handhold State Governments so as to mainstream new technologies in the construction sector and with
its dedicated efforts, there are around 9 lakhs houses being constructed by State Governments under PMAY(U) and
other Sate Schemes using new construction technologies certified by BMTPC. There has always been questions
regarding standards and schedule of rates of any innovative technologies and treated as impediment in promotion
of any new product/system. Realizing the need, CPWD and BIS was roped in by the Ministry and as on date CPWD
has published in DSR 2016, Schedule of Rates of almost all such technologies. There have been a few circulars from
CPWD & Ministry which recommends mandatorily use of such systems and encourage turnkey approach instead of
item rate contract for use of new technologies. Bureau of Indian Standards (BIS) has also included these systems
in their recently published NBC-2016. Apart from this, MoHUA along with BMTPC is also constantly interacting with
Defence, Railways & PSUs involved into construction such as NBCC, DDA etc. to make use of these emerging
technologies in their own housing projects. The response has been very good. In fact, almost all states are coming
forward to embrace these technologies for their upcoming social mass housing projects.

As of now, the only impediment in usage of these systems has been cost but given economies of scale, the cost comes
comparable with conventional construction cost and there are host of additional benefits such as low maintenance, low
life-cycle cost, better durability, improved thermal & acoustical performance, better hazard resistance, low wastages,
less pollution & above all green & sustainable development, which are often neglected while drawing comparisons.
I have been the great proponent of life-cycle cost and it is strongly recommended that whenever an innovation is
being introduced in construction sector, instead of initial cost, the life-cycle cost need to be ascertained. With the
tools available, the life-cycle assessment (LCA) can easily be done. The emerging technologies included in the
Compendium have low life-cycle cost and thereby resource-efficient and environmentally-responsible.

The technical contributions made by BMTPC officers namely Shri S.K. Gupta, Shri C.N. Jha, Shri Pankaj Gupta,
Shri A.K. Tiwari, Shri Y.D. Munjal & Shri Dalip Kumar in bringing this compendium are deeply appreciated and
acknowledged. Through this publication, I sincerely hope that the all stakeholders involved into construction including
state agencies will repose faith in the technologies and make use of the information available in right earnest and
start using these innovative systems in their future housing projects so as to fulfil the dream of Govt. of India of
providing housing to all without vitiating the environment & stressing the natural resources.

Date: September 12, 2018 (Dr. Shailesh Kr. Agrawal)

Place: New Delhi Executive Director, BMTPC
 Compendium of Prospective Emerging Technologies for Mass Housing

Contents

Background...................................................................................................................................................... 1

Formwork Systems - Engineered Formwork Systems.............................................................................. 5

1 Monolithic Concrete Construction System
– using Plastic - Aluminium Formwork.......................................................................................................... 7
– using Aluminium Formwork...................................................................................................................... 10
2. Modular Tunnel Form.................................................................................................................................. 13

Formwork Systems - Stay-in-Place Formwork Systems......................................................................... 19

3. Insulating Concrete Forms ......................................................................................................................... 21
4. Monolithic Insulated Concrete System........................................................................................................ 21
5. Structural Stay-in-place formwork system................................................................................................... 28
6. Lost-in-place formwork system- Plaswall Panel system............................................................................. 34
7. Lost-in-place formwork system- Plasmolite Wall Panels............................................................................. 40
8. Sismo Building Technology ....................................................................................................................... 45

Precast Sandwich Panel Systems - EPS based Systems................................................................. 53

9. Advanced Building System – Emmedue .................................................................................................... 55
10. Rapid Panels .............................................................................................................................................. 61
11. Reinforced EPS Core Panel System........................................................................................................... 69
12. QuickBuild 3D Panels ................................................................................................................................ 75
13. Concrewall Panel System .......................................................................................................................... 80

Precast Sandwich Panel Systems - Other Systems.......................................................................... 87

14. Glass Fibre Reinforced Gypsum Panel System.......................................................................................... 89
15. Prefabricated Fibre Reinforced Sandwich Panels....................................................................................... 94
16. Rising EPS (Beads) Cement Panels ........................................................................................................ 104

Light Gauge Steel Structural Systems........................................................................................ 113

17. Light Gauge Steel Framed Structure (LGSF)............................................................................................ 115
18. Light Gauge Steel Framed Structure with Infill Concrete Panel Technology . .......................................... 121

Steel Structural Systems................................................................................................................... 127

19. Factory Made Fast Track Modular Building System . ............................................................................... 129
20. Speed Floor System . ............................................................................................................................... 132

Precast Concrete Construction Systems................................................................................... 137

21. SRPL Building System (Waffle-Crete) . .................................................................................................... 139
22. Precast Large Concrete Panel System .................................................................................................... 146
23. Industrialized 3-S system using RCC precast with or without shear walls, columns, beams,
Cellular Light Weight Concrete Slabs/Semi-Precast Solid Slab................................................................ 153
24. Walltec Hollowcore Concrete Panel ......................................................................................................... 156

APPENDICES...............................................................................................................................................161-186
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Background

The Pradhan Mantri Awas Yojana (Urban) launched on 25th day of June 2015, set the target of delivering approxi-
mately 10 million houses by 2022 and subsequently Pradhan Mantri Awas Yojna (Rural) launched on 1st day of April
2016 envisages 10 million houses in next three years. In order to achieve this gigantic task, the natural question
comes to mind whether we have sufficient quantity of such building materials which do not impact the mother earth
adversely and further do we have existing construction practices in vogue which can help fast delivery of houses?
The answer to both the question is negative as if we look at the traditional building materials e.g. brick, cement,
steel, aggregates, sand etc., they are either based on natural resources which are finite in nature or energy inten-
sive or emit greenhouse gases during production. Thus, the entire proposition of using these materials as usual
will not be sustainable and environment friendly. Further, the construction technologies being practiced in India, is
cast-in-situ RCC beam-column construction which is primarily slow track methodology and is subjected to time &
cost overruns. Also, these constructions are labour intensive, which further hamper fast delivery, as there is acute
paucity of unskilled labour force in cities. Therefore, it is prudent to take a paradigm shift from brick & stick approach
and look for alternate systems which overcome these limitations. There have been number of such construction
systems available elsewhere in the world which are in use since decades successfully. Nevertheless, these systems
ought to be promoted and adapted in Indian conditions. BMTPC have been identifying, evaluating and certifying
these systems and also in order to showcase these technologies, demonstration housing projects are being ex-
ecuted in different states. Our endeavor has been to bring innovation, speed, safety & sustainability in the existing
construction methodology without compromising structural & functional performance. Also, BMTPC has been con-
ducting handholding programmes across India, in partnering with states, so as to educate practicing engineers &
architects, students, policy makers, contractors and artisans about these technologies.

In order to give further impetus to these technologies, Ministry of Housing & Urban Affairs has assertively pursued
CPWD, BIS and state departments to come out with notifications, circulars, SORs, specifications etc. which will
authorize state governments to use these new construction technologies in housing projects. The various OMs of
the Ministry and CPWD, and DSR items are included in Appendices. CPWD has included New Technology Items
in Delhi Schedule of Rates (DSR) 2016 Volume-2 namely (a) Light Gauge Steel Framed System (Item No. 26.41 to
26.45), (b) Expanded Polystyrene Core Panel System (Item No. 26.46 to 26.47), and (c) Aluminum Formwork for
Monolithic Construction (Item No. 26.48) and their detailed analysis is given in Delhi Analysis of Rates (DAR) 2016
(Volume-2). Further, CPWD, through Correction Slips, has also included (a) EPS cement sandwich light weight solid
core panels (Item No.26.49), (b) Non asbestos fibre reinforced aerated cement sandwich wall/roof/floor light weight
solid core panels (Item No.26.50), (c) GFRG Panel System (Item No.s 26.51 to 26.61), (d) Speed Floor System
(Item No.26.62 to 26.64), (e) Factory Made Fast Track Modular Building System (Item No.26.65 to 26.66), and (d)
Prefab Technology (Item No.5.50 to 5.57) along with their Analysis of Rates.

Further, in the recently published National Building Code 2016 by BIS, provisions have been updated to ensure
utilization of number of new/alternative building materials and technologies so as to provide for innovation in the
field of building construction. Updated provisions on new alternate technologies for speedier construction have
also been included in Part-5 BUILDING MATERIALS; Part-6 STRUCTURAL DESIGN: Section 7 Prefabrication and
Systems Building and Mixed/Composite Construction, 7A Prefabricated Concrete, 7B Systems Building and Mixed/
Composite Construction; and Part-7 CONSTRUCTION MANAGEMENT, PRACTICES AND SAFETY.

This third edition of compendium contains following 24 innovative construction systems, developed within the coun-
try & from aboard. These systems are recommended for use by the public and private agencies based on their
technical suitability and certification.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

FORMWORK SYSTEMS - Engineered Formwork Systems

1 Monolithic Concrete Construction System
– using Plastic - Aluminium Formwork
– using Aluminium Formwork
2. Modular Tunnel Form

FORMWORK SYSTEMS - Stay-in-Place Formwork Systems

3. Insulating Concrete Forms
4. Monolithic Insulated Concrete System
5. Structural Stay-in-place formwork system
6. Lost-in-place formwork system- Plaswall Panel system
7. Lost-in-place formwork system- Plasmolite Wall Panels
8. Sismo Building Technology

PRECAST SANDWICH PANEL SYSTEMS - EPS based Systems

9. Advanced Building System – Emmedue
10. Rapid Panels
11. Reinforced EPS Core Panel System
12. QuickBuild 3D Panels
13. Concrewall Panel System

PRECAST SANDWICH PANEL SYSTEMS - Other Systems

14. Glass Fibre Reinforced Gypsum Panel System
15. Prefabricated Fibre Reinforced Sandwich Panels
16. Rising EPS (Beads) Cement Panels

LIGHT GAUGE STEEL STRUCTURAL SYSTEMS

17. Light Gauge Steel Framed Structure (LGSF)
18. Light Gauge Steel Framed Structure with Infill Concrete Panel Technology

STEEL STRUCTURAL SYSTEMS

19. Factory Made Fast Track Modular Building System
20. Speed Floor System

PRECAST CONCRETE CONSTRUCTION SYSTEMS

21. SRPL Building System (Waffle-Crete)
22. Precast Large Concrete Panel System
23. Industrialized 3-S system using RCC precast with or without shear walls, columns, beams, Cellular Light
Weight Concrete Slabs/Semi-Precast Solid Slab
24. Walltec Hollowcore Concrete Panel

One of the crucial components of technology transfer cycle is demonstration construction and therefore, in order to
demonstrate these new systems in the field, BMTPC with the support of Ministry of Housing & Urban Affairs, Govt.
of India has initiated several Demonstration housing projects as pilot projects in different states wherein around 40
houses are being constructed. The land is provided by the state govt. free of cost whereas the houses are con-
structed along with onsite infrastructure by BMTPC as per the Operational Guidelines of Demonstration Housing
Projects issued by the Ministry of Housing & Urban Affairs in April 2018. During the construction, the professionals,
students, artisans, policy makers & residents of the area are sensitized & educated about these new technologies.
Two projects at Nellore, AP using GFRG panel systems and at Bhubaneshwar, Odisha using EPS Core Panel sys-
tem have already been completed. The other projects at Bihar Sharif, Bihar (using structural stay-in-place formwork
system), Lucknow, UP (using double walled EPS Core Panel system), Hyderabad, Telangana (using light gauge
steel structural system & structural stay-in-place formwork system) are in advanced stages of completion.

The details of the technologies evaluated and recommended, as contained in this Compendium, will help user
agencies in getting informed choice of different innovative construction practices, which could be utilized for mass
housing scheme.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

BMTPC operates Performance Appraisal Certification Scheme (Gazette Notification No. I-16011/5/99 H-II in the
Gazette of India No. 49 dated December 4, 1999). The emerging technologies for mass housing appearing in the
Compendium have been evaluated and certified through Performance Appraisal Certification Scheme (PACS) of
BMTPC.

The PACS is a third party assurance system based on laboratory and field tests of the required performance criteria
of the any system / building materials on which there is no Indian Standard. The broad parameters, based on which
the evaluation is done inter-alia include:
• Structural performance against vertical & lateral loads
• Fire resistance
• Protection against rain & moisture.
• Thermal & accoustic behaviour
• Ease of fixing services
• Quality assurance
• Durability / Service Life

The process flow chart for PACS is given in figure-1. Whereas PACS takes care of verifying technical suitability of
the system; other parameters are required to be addressed for proper selection of technology for particular place.
A multi attribute evaluation system developed by BMTPC to provide a technical framework for selection of any new
technology is given in Figure-2. It may be used by agencies for selection of any technology/construction system.

Figure-1: Performance Appraisal Certification System – Process Chart

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4
Primary Attributes
Attributes

Secondary Mandatory Preferential

Attributes Attributes Attributes

Strength & Stability Performance & Functional

Constructability Economic Viability Maintenance Sustainability Finish Quality
Requirements Code Compliances Requirements

Simplicity in
Load Bearing Design Compatibility Frequency of
Fire Resistance execution & Cost Eco-friendliness Internal Finish
Strength & Flexibility maintenance
Versatility

Stability against Compliance with Restriction on Speed of Type of

Foundation Type Embodied Energy External Finish
Dynamic Forces codes & regulations no. of floors construction Maintenance

Performance of Service Ease of

Skilled Labour Economies of scale
joints Life/Durability Maintenance

Tertiary Attributes
Thermal & Accoustic
Equipment Lead Time
Performance
Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

End user Construction

Efficiency of design
friendliness Safety

Supply Chain
Weather Tightness
Reliability

Prevention of Water Technology

and Moisture
Penetration Transfer Possibility

Figure-2: Multi-Attribute Evaluation System for New Technologies

Page 1 of 1
Formwork Systems
Engineered Formwork Systems
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Monolithic Concrete Construction System

– using Plastic - Aluminium Formwork
(Suitable for Low Rise to High Rise Structures)

ABOUT THE TECHNOLOGY

The technology intents to replace the conventional steel/plywood shuttering (formwork) system with customised
engineered formwork which is manufactuered in the factory set up under controlled conditions. In this system,
in place of traditional RCC framed construction of columns and beams and infill walls; all floors, slabs, columns,
beams, walls, stairs, together with door and window openings are cast-in-place monolithically using appropriate
grade of concrete in one operation. The specially custom designed modular formwork made up of Aluminium/
Plastic/Aluminium-Plastic Composite is used for the purpose which facilitates easy handling with minimum labour &
without use of any equipment. Being modular formwork system, it enable fast construction of multiple/mass modular
units.

Basic Material Requirements

Formwork system

Formwork system is manufactured by various firms in India and abroad and shall have to be designed as per
loading requirements of the structure. It must have adequate stiffness to
weight ratio, yielding minimum deflection during concreting & operation.
The panel formwork should fix precisely, securely and require no bracing.
Being recent advancement in technology, IS 14687 : 1999 Guidelines for
falsework for concrete does not cover requirements of special type of
formwork system, however, it is being covered in NBC - 2016.

Concrete

Shall be of appropriate grade based on environment condition (exposure)

as per IS 456:2000.

Reinforcement

Shall conform to IS 1786:2008.

Details of Formwork

The formwork made of Aluminium Extruded Section conforming to IS

733:1983 and PVC of Grade PVC 67G ER01 is in accordance with IS
10151:1982. It consists of different sections including starter of MS Angle,
top frame of aluminium channels, wall panels, slab panels & truss.

The formwork is designed based on the structural requirements of building

units. A quality control system is required to be followed in manufacturing
of formwork components.

Under Performance Appraisal Certification Scheme, the present formwork

system manufactured by M/s Sintex Industries, Ahmedabad, has been
evaluated and certified by BMTPC (PAC No. 1006-A/2011).

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Structural Requirements of the Construction

The Monolithic RCC construction is considered as shear wall system. The maximum spacing between cross wall
shall be limited to 1.5 times the floor height if supported on two edges and 2.0 times the floor height, when supported
on all four edges.

The walls are designed primarily for vertical loading and also for in-plane lateral load (shear) and out of plane
(bending) due to wind load and earthquake forces as per relevant Indian Standard Code IS 875(Pt.3):2015 and
IS1893(Pt.1):2016 respectively. For out of plane loading, the walls can be assumed to be supported by floor slabs
/ diaphragm and cross walls and continuity can be assumed, wherever applicable.

The structural design of plain & RCC shall be as per IS 456:2000

while IS 13920:2016 is referred for ductile detailing of reinforced
concrete structure. Thickness of wall below plinth level should be
minimum 200 mm with double layer reinforcement.

Guidelines on Monolithic Concrete Construction prepared by

BMTPC may be referred for material requirements & design aspects
of this system.

Durability

Since concrete is main constituent material in this system, durability

of the structure can be achieved by using proper ingredient, grade
of concrete as per IS 456:2000 and mix design in accordance with
IS 10262:2009.

Thickness of the wall is generally 100 mm with the centrally placed

reinforcement. Therefore, adequate cover is likely to be maintained,
for higher durability.

Thermal Behaviour of Structure

100 mm thick RCC walls and slab has thermal transmittance (U)
value as 3.59 W/m2K) (as per IS 3792:1978). As, it is more than the
normal plastered brick masonry walls (thermal transmittance (U)
2.13 W/m2K), it is advised that implementing agency shall ensure
proper planning for heat insulation and air ventilation in the housing
units through proper orientation, shedding etc. (see IS 3792:1978
for guidance).

Acoustic

Average sound reduction for 100 mm concrete is ≥ 45db

(IS 1950:1962), which is considered as reasonable acoustic
insulation.

Ease of fixing services

All electric and plumbing fixtures, service lines have to be pre-

planned and placed appropriately before pouring concrete in RC
walls & slabs. Post construction alternations are not desirable.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Economy OF SCALE

Economies of scale depend upon the volume of work and number

of repetition of the formwork. To achieve economy, minimum 100
repetitions are desirable.

For very small project of less than 500 units, this system may not
prove to be economical. However, now with number of formwork
manufacturers available, the project with less number units may also
be feasible.

Other features

1) Pre designed formwork acts as assembly line production and enables rapid construction of multiple/mass scale
units of repetitive type.
2) Varying work cycle is possible, however, for speed and economy, 3 to 4 days cycle is desirable.
3) It is flexible in design and can form any architectural or structural configuration, such as stairs, windows, etc.

LimitationS

1) A lead time of about 3 months is required for initiation of work, as the formwork are custom designed,
manufactured and prototype approved before manufacturing required number of sets of formwork.
2) Capital cost to initiate construction is high and may require regular flow of funds.
3) Post construction alterations are difficult.
4) All the service lines are to be pre-planned in advance.
4) Not much saving in construction in one storey structure.

Major Completed/under completion Projects

1) 5008 houses at Kanjhawala Narela, Delhi for DSIIDC.

2) 512 houses in Bawana, Delhi for DSIIDC.
3) 3000 houses in Ahmedabad for Ahmedabad Municipal Corporation.
4) 3000 houses in Lucknow for Lucknow Development Authority
5) 4,52,656 houses under PMAY (U) in various parts of Andhra Pradesh
6) 4,586 houses under PMAY(U) in Naya Raipur, Chhattisgarh
7) 30,000 houses under PMAY(U) in Maharashtra

Standards/Guidelines Referred

IS 456 : 2000 Code of Practice for plain and reinforced concrete (Fourth Revision)
IS 733 : 1983 Wrought Aluminium and Aluminium Alloy Bars, Rods and Sections (for General
Engineering Purposes)
IS 875 (Pt.3) : 2015 Code of Practice for Design Loads (Other than Earthquake) for Buildings and Structures
- Part 3 : Wind Loads
IS 1786 : 2008 High strength deformed steel bars and wires for concrete reinforcement-
IS 1893 (Pt.1) : 2016 Criteria for Earthquake Resistant Design of Structures - Part 1 : General Provisions and
Buildings (Sixth Revision)
IS 1950 : 1962 Code of practice for sound insulation of non-industrial buildings (Reaffirmed 2010)
IS 3792 : 1978 Guide for heat insulation of non-industrial buildings (Reaffirmed 2013)
IS 10151 : 1982 Polyvinyl Chloride (PVC) and its Copolymers for its Safe Use in Contact with Foodstuffs,
Pharmaceuticals and Drinking Water
IS 10262 : 2009 Concrete Mix Proportioning - Guidelines (First Revision) (Reaffirmed 2014)
IS 13920 : 2016 Ductile detailing of reinforced concrete structures subjected to seismic forces - Code of
practice (First Revision)
IS 14687 : 1999 Falsework for Concrete Structures - Guidelines (Reaffirmed 2014)
BMTPC Guidelines : 2011 Guidelines on Monolithic Concrete Construction
PAC No. 1006-A/2011 Performance Appraisal Certificate issued by BMTPC on Formwork for Monolithic
Construction

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Monolithic Concrete Construction System

– using Aluminium Formwork
(Suitable for Low Rise to High Rise Structures)

ABOUT THE TECHNOLOGY

The technology intents to replace the conventional steel/plywood shuttering (formwork) system with customised
engineered formwork which is manufactuered in the factory set up under controlled conditions. In this system,
in place of traditional RCC framed construction of columns and beams and infill walls; all floors, slabs, columns,
beams, walls, stairs, together with door and window openings are cast-in-place monolithically using appropriate
grade of concrete in one operation. The specially custom designed modular formwork made up of Aluminium/
Plastic/Aluminium-Plastic Composite is used for the purpose which facilitates easy handling with minimum labour &
without use of any equipment. Being modular formwork system, it enable fast construction of multiple/mass modular
units.

Basic Material Requirements

Formwork system

Formwork system is propriety system and designed as per loading requirements of the structure. It has adequate
stiffness to weight ratio, yielding minimum deflection under concrete loading. The panel should fix precisely,
securely and require no bracing. Being recent advancement in technology, IS 14687 : 1999 Guidelines for falsework
for concrete does not cover requirements of special type of formwork system.

Concrete

Shall be of appropriate grade based on environment condition as per IS

456:2000

Reinforcement

Shall conform to IS 1786:2008

Details of Formwork

The formwork systems used are made of light weight Aluminium.

The recommended concrete forms generally use robotics welding system
for manufacturing. A soft alloy weld wire is utilized in the concrete form weld
process. Fixing of the formwork is done using tie, pin & wedges system.
Does not require very skilled labour to do the job.
The formwork can be designed based on requirements of dwelling unit
and the project. A repetition of about 1000 cycle is claimed (This, however,
needs, verification).

Structural Requirements of the Construction

The Monolithic RCC construction is considered as shear wall system. The

maximum spacing between cross wall shall be limited to 1.5 times the
floor height if supported on two edges and 2.0 times the floor height, when
supported on all four edges.

The walls are designed primarily for loading and also for in-plane lateral

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

load (shear) and out of plane (bending) due to wind load and earthquake forces as per relevant Indian Standard
Code IS 875(Pt.3):2015 and IS1893(Pt.1):2016 respectively. For out of plane loading, the plate can be assumed to
be supported by floor slabs / diaphragm and cross walls and continuity can be assumed, wherever applicable.

The structural design of plain & RCC shall be as per IS 456:2000 while IS 13920:2016 is referred for ductile detailing
of reinforced concrete structure. Thickness of wall below plinth level should be minimum 200 mm with double layers
reinforcement.

Guidelines on Monolithic Concrete Construction prepared by BMTPC may be referred for material requirements &
design aspects of this system.

Durability

Since concrete is main constituent material in this system, durability of the structure can be achieved by using
proper ingredient, grade of concrete as per IS 456:2000 and mix design in accordance with IS 10262:2009.

Thickness of the wall is generally 100 mm with the centrally

placed reinforcement. Therefore, adequate cover is likely to be
maintained, as a result high durability is achieved.

Thermal Behaviour of Structure

100 mm thick RCC walls and slab has thermal transmittance (U)
value as 3.59 W/m2K) (as per IS 3792:1978). As, it is more than
the normal plastered brick masonry walls (thermal transmittance
(U) 2.13 W/m2K), it is advised that implementing agency shall
ensure proper planning for heat insulation and air ventilation in
the housing units through proper orientation, shedding etc. (see
IS 3792:1978 for guidance).

Acoustic

Average sound reduction for 100 mm concrete is ≥ 45db (IS

1950:1962), which refers reasonable acoustic insulation.

Ease of fixing services

All electric and plumbing fixtures, lines have to be pre-planned

and placed appropriately before pouring concrete in RC walls &
slabs. Post construction alternation is not desirable.

Economy OF SCALE

Economies of scale depend upon the volume of work and number

of repetition of the formwork. To achieve economy, minimum 100
repetitions are desirable.

For very small project of less than 500 units, this system may not
prove to be economical. However, now with number of formwork
manufacturers available, the project with less number units may
also be feasible.

For very small project of less than 500 units, this system may not
prove to be economical.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Other features

1) Pre designed formwork acts as assembly line production and enables rapid construction of multiple/mass scale
units of repetitive type.
2) Varying work cycle is possible, however, for speed and economy 3-4 days cycle are desirable.
3) It is flexible in design and can form any architectural or structural configuration, such as stairs, windows, etc.

LimitationS

1) A lead time of about 3 months is required for initiation of work, as the formwork are custom designed,
manufactured and prototype approved before manufacturing required number of sets of formwork.
2) Capital cost to initiate construction is high and may require regular flow of funds.
3) Post construction alterations are difficult.
4) All the service lines are to be pre-planned in advance.
4) Not much saving in construction in one storey structure.

Major Completed ProjectS

1) Houses in Bangalore for Karnataka Slum Development Board.

2) Houses in Mysore for Karnataka Slum Development Board.
3) 2,112 houses under PMAY(U) in Tamil Nadu
4) 34,928 houses under PMAY(U) in Gujarat
5) 1,136 houses under PMAY(U) in Puducherry
6) Houses in Bangalore for Bangalore Development Authority & several other projects in major cities of India,
among many others...

Standards/Guidelines Referred

IS 456 : 2000 Code of Practice for plain and reinforced concrete (Fourth Revision)
IS 733 : 1983 Wrought Aluminium and Aluminium Alloy Bars, Rods and Sections (for General
Engineering Purposes)
IS 875 (Pt.3) : 2015 Code of Practice for Design Loads (Other than Earthquake) for Buildings and Structures
- Part 3 : Wind Loads
IS 1786 : 2008 High strength deformed steel bars and wires for concrete reinforcement-
IS 1893 (Pt.1) : 2016 Criteria for Earthquake Resistant Design of Structures - Part 1 : General Provisions and
Buildings (Sixth Revision)
IS 1950 : 1962 Code of practice for sound insulation of non-industrial buildings (Reaffirmed 2010)
IS 3792 : 1978 Guide for heat insulation of non-industrial buildings (Reaffirmed 2013)
IS 10151 : 1982 Polyvinyl Chloride (PVC) and its Copolymers for its Safe Use in Contact with Foodstuffs,
Pharmaceuticals and Drinking Water
IS 10262 : 2009 Concrete Mix Proportioning - Guidelines (Reaffirmed 2014)
IS 13920 : 2016 Ductile detailing of reinforced concrete structures subjected to seismic forces - Code
of practice
IS 14687 : 1999 Guidelines for Falsework for Concrete Structures (Reaffirmed 2014)
BMTPC Guidelines : 2011 Guidelines on Monolithic Concrete Construction
PAC No. 1006-A/2011 Performance Appraisal Certificate issued by BMTPC on Formwork for Monolithic
Construction

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Modular Tunnelform
(Suitable for Low Rise to High Rise Structures)

ABOUT THE TECHNOLOGY

Tunnel formwork is customized engineering formwork

replacing conventional steel/plywood shuttering system. It is a
mechanized system for cellular structures. It is based on two
half shells which are placed together to form a room or cell.
Several cells make an apartment. With tunnel forms, walls
and slab are cast in a single day. The structure is divided into
phases. Each phase consists of a section of the structure
that will be cast in one day. The phasing is determined by
the program and the amount of floor area that can be poured
in one day. The formwork is set up for the day’s pour in the
morning. The reinforcement and services are positioned and
concrete is poured in the afternoon. Once reinforcement is
placed, concrete for walls and slabs shall be poured in one
single operation. The formwork is stripped the early morning
next day and positioned for the subsequent phases.

The formwork is manufactured in a fully automated plant. Presently, it is imported from France and there is no plant
in India.

The on-site implementation of 24 hour cycle is divided into following operations.

1. Stripping of the formwork from the previous day.

2. Positioning of the formwork for the current day’s phase, with the installation of mechanical, electrical and
plumbing services.
3. Installation of reinforcement in the walls and slabs.
4. Concreting and if necessary, the heating equipment.

TYPES OF FORMWORK SYSTEM

TMPH Modular Tunnelform

Tunnel forms are room size formworks that allow walls and floors to be caste in a single pour. With multiple forms,
the entire floor of a building can be done in a single pour. Tunnel forms require sufficient space exterior to the
building for the entire form to be slipped out and lifted up to the next level.

This Tunnelform consists of inverted L-shaped half tunnels (one vertical panel and one horizontal panel) joined
together to create a tunnel. Articulated struts brace the horizontal and vertical panels. These struts enable the
adjustment of the horizontal level of the slab and simplify the stripping of the formwork. The vertical panel is equipped
with adjustable jacking devices and a triangular stability system. Both devices are on wheels.

A range of spans is possible by altering the additional horizontal infill panel’s dimensions. Due to the distribution of
the horizontal beams on the vertical plank, the formwork also cast staggers and offsets in the layout of the walls as
well as differing wall thicknesses. The half-tunnels shall be equipped with back panels to cast prependicular shear
walls or corridor walls. Assembly and levelling devices ensure that the frormwork surfaces are completely plumbed
and levelled.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Standard Characteristics

Standard dimensions: TMPH & Modular

Unit width : 2.40 m to 6.00 m
Type 1 horizontal panel : 1.20 m to 1.60 m
Type 2 horizontal panel: 1.80 m to 2.40 m
Type 3 horizontal panel: 2.40 m to 3.00 m
The span can be adjusted by fitting an additional panel measur-
ing between 0.05 and 0.60 m
Package length: Up to 12.50 m in length as a function of the
hoisting facilities and availability
Basic length: 1.25 m
Average weight: 90 Kg/m2
Handling: Lifting triangle or sling
Transportation: 180 m2 per truckload.

Wallforms

Wallforms are temporary moulds in which concrete is poured in

order to build a structure. Once the concrete is poured into the
formwork and has set, the formwork is stripped to expose perfect
finished concrete. These forms constitute a system approach for
construction and are particularly suited to build structural walls,
columns, bridge piers, culverts etc. This system adopts well to
daily work-phase of both repetitive and non-repetitive tasks. The
equipment used each day is productive and is reused in subse-
quent phases. The four daily operations which outlines the daily
production cycle for wall form equipment are identical to those for
Tunnel form equipment with the exception that it is solely used for
casting concrete walls. The slabs are cast as a secondary phase.
The existing equipment can be adapted on a day-to-day basis by
the addition of standard elements and corner-wall formwork to
take into account different wall configurations on site. All safety
and stability devices shall be fully integrated into the standard
version of Wallform equipment.

B 8000 Wallforms

These Wallforms are tools specially designed to be used on spe-

cific buildings and structures. This vertical wallform panel is a
multi-purpose formwork system. This system has been designed
and developed to ensure that it is simple and quick to assemble
and position the following:

• A full range of standard dimensioned components

• Multiple combination of panels for simple adoption to
specific configurations
• Basic standard equipment incorporates complete safety,
circulation and stability equipment
• Caliper–device opposing Wallform packages are craned
into position in one lift.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Standard characteristics

Standard dimensions:
Standard height: 2.80 m
Upper extension: 0.50 m
Lower extension: 1.00 m-1.50 m
Average weight: 135 Kg/m2
Assembly: 0.80 H/m2 of formwork
Use: 0.15 to 0.30 H/m2 of formwork, depending on complexity
Wind stability: by prop
Access: inner ladder accessed via hatch
Superposition: up to 22.5 m with specific engineering performed to determine hoisting and stability characteristics
Transportation: 24 wall forms per container/ truckload

Angle Formwork
Inner and outer angle configurations are designed to attach to 1.25 m wall forms to obtain a 160 mm wall. Spacers
shall be installed for producing wall thicknesses.

Back Panel
The back panel allows pouring of cross walls, other walls, walls and slab in one operation.

Slab Stop End and Wall stop

These can be adjusted to fit the lengths of wall and slabs. These remain fixed to the form during all handling opera-
tions.

Kicker Form
In order to guide the walls of the upper floor precisely above the walls of the floor below, a kicker form is fixed to the
tunnel form before pouring the concrete. Slab and starting walls are then poured during the same phase.

Box Out
During each phase, window box out, door box out and slab box out are mounted on the tunnel using a magnetized
system.

MATERIAL REQUIREMENTS

i. Hot dip galvanized steel sheet – 3 mm thick shall conform to IS 277:2003

ii. Steel for Angle section – 80 mm x 80 mm x 6 mm shall conform to IS 2062:2011
iii. Cold rolled U-sections – 60 mm x 30 mm shall conform to IS 2062:2011.

Mechanical properties:

Yield stress : ≥ 23.5 daN/mm2

Breaking load : ≥ 36 daN/mm2
Elongation : ≥ 20%
Steel for spacer pins – Apart from the requirements given above, the steel used for the manufacture of the spacer
pins, the gripping mechanisms, anchoring points for the rear stabilizing and adjusting mechanisms shall guaran-
tee a KCV resilience at –20ºC of at least 28J.

CHARACTERISTICS OF THE SYSTEM

• Maximum span between walls shall be 5.60 m without accessory units and 7.00 m with accessory units.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

• Height of the formwork – The forms are designed for floor to ceiling height of 2.51 m minimum with the
possibility to increase this by action of the leg jacks or with the use of movable panels in the event of extra
heights.
• Appearances of the faces after form removal – The surfaces obtained allow direct application of finishing
paint or wallpaper after sanding off the fins at the joints connecting the units and smoothing with paint filler.
• Working rhythm using the system – Under average temperature conditions, with the use of ordinary cement,
the normal rhythm is two days per cycle with one day and two nights for drying and setting of the concrete.
• Time period required for execution of the process – The time required for execution shall vary according to
the cell plan. For a type cell consisting of two formed wall surfaces and a floor surface, the average time
is less than one & one half hours per square meter of building. This time includes the form removal, oiling,
displacement of the units, formwork and adjustment.

UTILIZATION OF THE FORMWORK SYSTEM

At each stage, utilization of the system requires the following successive operations:

i. The placing of the vertical wall reinforcement of the floor and possibly the door frames provided for in the
erection drawing;
ii. Dismantling of the movable form units of the preceding storey. This shall be carried out in two stages:
a) Loosening of the normal units (half-shells), by removal of the spacers passing through the walls, by
unlocking the tunnel keys and disassembly of the sections. This work is executed in principle by two
non-specializes maneuvers.
b) Striking and removal of the forms. This shall be carried out by using the special dolly and two ma-
neuvers in the tunnel and by two other maneuvers at the new location (usually on the storey above).
This suite of operations shall be carried out by bringing the dolly under the half-shell to be removed
and then working the different jacks for the striking operation itself. The leg jacks are lifted first, then
a slight deformation of the half-shell is provoked by working the diagonal bracing jacks (shortening).
This deformation is sufficient to strip the form progressively. It drops down automatically onto the
dolly. The dolly half-shell assembly shall then be rolled across the service platform where the form
is cleaned and oiled with a sprayer, then picked up with a crane and hoisted to its new location site,
the dolly remaining in place. The half-shell design makes it possible to remove the whole side of a
tunnel, then to prop the slab near the key before removing the other half, permitting if necessary, a
faster rotation of the equipment.

iii) Reassembly of the units on the floor above. This assembly consists of the following operations:
a) A half-shell shall be positioned on its leg jacks and knee brace, and adjustment shall be squared by
blocking the diagonal bracing jacks, then adjustment of the height and plumb by working the leg jacks
and the knee brace jack.
b) The half-shells shall be assembled together.
c) The opposite half-shells shall be positioned, and adjacent half-shells of the ‘tunnel’ half-shells shall
also be positioned using the same procedure.
d) The half-shells shall be blocked by constituting the two faces of the wall on the ‘starters’ with the help
of the lower spacers; the upper spacers shall be tightened without being forced, only after verification
of the general adjustment; positioning of the butt end forms of the walls and floors.
e) The key-locks solidifying the opposite half-shells shall be positioned and blocked. If necessary, a
light action on the knee brace and diagonal bracing jacks shall be used to bring the locking units into
line.
f) The starter forms shall be positioned and blockouts, if necessary for anticipated door and window
frames.
g) The overall adjustment and finish making–up shall be verified, if necessary, after lifting of the knee
braces.
h) The suspended floor shall be reinforced and concrete shall be poured in the walls and slab.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

iv) The service platform shall be removed and this platform shall be installed on the storey above.
APPLICATIONS

Designed to cast concrete load-bearing walls and slabs in a single monolithic pour, tunnel forms are suited for the
construction of following structures:
• Multiple residential dwellings
• Housing projects
• Garden apartments
• Town homes
• Condomiums
• Hotels etc.

SPECIAL FEATURES

Behavior in earthquake
Formwork shall be designed to meet the requirement of permanent structures using specified Indian Standards for
material used. The design should take into account the conditions of materials to be actually used for the formwork,
environment, site condition loads on formwork and combination of loads shall be taken in accordance with the
clause 7.3 of IS 14687:1999.

Behavior under high winds

The design for wind loads shall be in accordance with the provisions given in IS 875 (Part 3):2015 and IS
14687:1999.

Productive
The equipment used each day is productive and is reused in subsequent phases.

Day-to-day basis
The existing equipment can be adapted on a day-to-day basis by the addition of standard elements and corner-
wall formwork to take into account different wall configurations on site.

LIMITATIONS
• The floor spans executed with movable forms shall not be more than 5.60 m, unless accessory units are
used.
• The thickness of vertical in-situ walls shall not be more than 120 mm, unless justified by special provisions.

MAJOR WORKS COMPLETED USING THE FORMWORK

• Apartments by M/s Runwal Group at Mumbai in 2000
• Apartments complexes by M/s B G Shirke Construction Technology Pvt. Ltd., Pune at Navi Mumbai, and
Tirupati in 2001
• Apartments by M/s L&T South City Projects Ltd., at Chennai in 2008
• Slum Rehabilitation by M/s Pawar Patkar Construction Pvt. Ltd., at Nasik in 2014

CERTIFICATION

Performance Appraisal Certificate No. 1018-S/2015 issued to M/s Outinord Formworks Pvt. Ltd., Pune by
BMTPC.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

STANDARDS/REFERENCES

Agreement No. 2569 relating to New Materials and Non-traditional Construction Processes between Cashiers of the C.S.T.B, Paris, France
and Outinord, Company, S.A.

Case studies of the projects carried out by various agencies throughout the world including India using Outinord Formwork.

Design of the Formwork submitted by the manufacturer

Quality Management Manual and Maintenance Manual followed by the manufacturer

Application of accelerated curing to Apartment Formwork System – Advisory Note from British Cement Corporation

IS 277 : 2003 Specifications for plain and corrugated galvanized steel sheets (sixth revision)

IS 456 : 2000 Code of practice for plain and reinforced concrete (fourth revision)

IS 875 (Part 3) : 2015 Code of Practice for Design Loads (Other than Earthquake) for Buildings and Structures - Part 3 : Wind Loads

IS 2062 : 1999 Hot rolled medium and high tensile structural steel

IS 14687 : 1999 Falsework for concrete structures

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Formwork Systems
Stay-in-Place Formwork Systems
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Insulating Concrete Forms (ICF) &

Monolithic Insulated Concrete Systems (MICS)
(Suitabvle for Low Rise Structures)

About the technology

Insulating Concrete Forms (ICF) & Monolithic Insulated Concrete Systems (MICS) comprise of panels of two walls of
Expandable Polystyrene (EPS) separated by a nominal distance of 150mm by hard plastic ties. These are assembled
on site to hold reinforced concrete. The forms are open ended hollow polystyrene blocks which fit tightly together to
form a shuttering system. Concrete is poured into the hollow space to form a continuous wall. When cured, this wall
supports the structural loads from floors and roofs, and the shuttering provides thermal insulation. Reinforcing steel
shall be as required from design. Upper and lower surfaces of the polystyrene panels are castellated and the vertical
mating surfaces are tongue-and-groove to form a tight fit when joined together. The rigid formwork does not require
supporting false work. The inner surfaces have tapered grooves running vertically and have offset on opposite faces
to ensure uniform concrete thickness. They also form locks for end stops. The outer surfaces are grooved vertically
at 50mm centers to aid cutting and trimming.

Fig. 1 Plan View

CLASSIFICATION AND TYPES OF FORMS

Standard Forms – These form bulk of the forms and have 50mm EPS panels on both sides with 8 nos. hard plastic
ties holding the panels. Dimensions of these forms are 1000 x 250 x 250mm. (See Fig. 2)

Half Height Forms – Together with the lintel, these form the top layer of all gaps in the wall and hold the required
steel reinforcement. Dimensions of these forms are 1000 x 150 x 250mm. (See Fig. 3)

Lintel Forms – In combination with Half Height forms, these form the top layer of all wall gaps and hold the concrete
thus preventing thermal leaks. Dimensions of these forms are 1000 x 125 x 250mm. (See Fig. 4)

Floor Edge Forms – These form the top most layer, where the wall ends and floor begins. This envelopes the floor
slab and thus prevents thermal bridging. Dimensions of these forms are 1000 x 375/125 x 250mm. (See Fig. 5)

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Corner Forms – These constitute 90º corner of the building. The two sides are 50mm EPS panels held together
with 8 nos. hard ties. Dimensions of these forms are 750/500 x 250 x 250mm. (See Fig. 6)

End Forms – These create wall ending by fitting in inside the Standard or Corner form and provide a smooth and
thermal bridge ending to the wall. Dimensions of these forms are 150 x 125 x 50mm. (See Fig. 7)

Fig. 2 Standard Fig. 3 Half Height Fig. 4 Lintel

Fig. 5 Floor Edge Fig. 6 Corner Fig. 7 End

RAW MATERIALS

• Expanded Polystyrene (EPS): Self-extinguishing type EPS shall conform to IS 4671: 1984 having density not
less than 25 kg/m3 and valid Restriction of Hazardous Substance (ROHS) test certification.
• Polyurethane (PU) Foam Adhesive: Shall have Skin Formation of 8 min, Density 25 kg/m³, Sound insulation
58 dB, Insulation factor 35 mW/mK, Shrinkage< 2%, Fire rating B3, Insulation factor 35 mW/m.K and Water
absorption of 1 % volume
• Plasticizer: Slump retaining super plasticizer for self-compacting plastic concrete (CEMWET SP-3000) shall
conform to IS 9103:1999
• Hard Plastic Tie: Shall be made with High density polyethylene and shall be as per manufacturer’s specifica-
tions.
• Cast-in-place concrete: The ingredients, grade of concrete & slump for walls, floors and roofs shall be used as
per IS 456:2000.

Structural

The Insulating Concrete Forms (ICF) & Monolithic Insulated Concrete Systems (MICS) may be designed using
the appropriate design software. The buildings constructed with EPS shall be studied and designed as reinforced
concrete structure since the parameters required for their design are the same as needed for traditional reinforced
concrete. In the calculation model, the building shall be designed in accordance with IS 456:2000, as applicable, as
structure composed of load bearing walls with a box-like structure.

The system is intended for use where architectural drawings are available and satisfy the various requirements.
The system shall be designed to provide the required performance against the loads to be taken into account in
accordance with IS 875 (Parts 1,2,4&5):1987 and the data given by manufacturer for various panels. It shall also
provide the required bearing resistance for earthquake and wind forces as per IS 875 (Part 3):2015 and IS 1893
(Part 1):2016, wherever applicable.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Foundation shall be specifically designed in accordance with provision given in IS 1904:1986. The design concept
is same as that of the conventional building design. The safe bearing capacity and soil properties (soil investiga-
tion report)) shall be provided from the site after soil investigations. Foundation shall be designed based on the
soil investigation report. Both single and double panels should have starter bars from either foundation or ground
floor slab. All foundations should be designed by experienced engineer with appropriate reference. In addition, any
other requirement regarding safety against earthquake need to be ensured by the designer as per prevailing codal
requirements.

Typical construction

Construction process

The construction of most Insulating Concrete Forms (ICF) & Monolithic Insulated Concrete Systems (MICS) build-
ings is fundamentally a process of stacking lightweight blocks together in a similar manner to building bricks, laying
reinforcement where necessary and pouring concrete into the voids of the block work. It does not call for the same
skill set as solid brick or brick veneer construction.

Footings
The footings for Insulating Concrete Forms (ICF) & Monolithic Insulated Concrete Systems (MICS) buildings are
usually reinforced concrete rafts or strips that are flat and even enough to enable stacking of the form blocks, with
reinforcement starter bars set ready to connect with the concrete when poured into the formwork.

Load bearing walls

Any Insulated Concrete System/Forms wall can be designed to be load bearing.

Joints and connections

Joints and connections with other building elements are kept to a minimum, especially when the flooring or roofing
elements are also made from Insulated Concrete System/Forms.

Fixings
The foam block work or formwork forms a poor basis for any fixings. Light loads are generally carried by the lining or
facing materials, such as plasterboard, and heavier loads can be carried by supporting points drilled into the concrete
that forms the inner material of the Insulated Concrete System/Forms.

Openings
Major openings for doors, windows, etc., need to be set out in the formwork as it is relatively difficult to make changes
later, owing to the fundamentally monolithic nature of the structural elements. Once openings have been made, they
can accommodate window and door frames of any type. A typical kind of fixing uses timber blocks set into the ends
of the form blocks around the opening.
Electrical conduit and plumbing is generally run in chasing in the depth of the form blocks.

Finishes
Finishes are dependent on the materials used to face the Insulated Concrete System/Forms units. Typically, the
main finish is a render or render-equivalent covering or paint. Any additional cladding can be added to the Insulating
Concrete Forms (ICF) & Monolithic Insulated Concrete Systems (MICS) walls subject to making appropriate sup-
ports for it, although many sheet finishes, such as plasterboard, can be glued directly to the surface of the formwork.
External renders require a base or skim coat embedded with fibreglass mesh, followed by a second coat and then
a texture coating, finally finished with an ‘armour coat’.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

BASE: Insulated Concrete System/Forms can be built on footings similar to conventional masonry footings, slabs-
on-grade or piles or can also be built on step footings & shallow foundation systems.

FORMWORK: Walls built by assembly of interlocking, moulded hollow forms.

REBARS: Fixing reinforcement steel bars with hard TRESTLES: Fixed for plumb straight walls & support during
ties inside formwork as per calculated structural re- concrete pour
quirement.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

SCAFFOLD: Platform on trestles for access & assembly of high walls

PROPPING: Fixing framework as props around Doorways & window frames.

CONDUITS & PIPES: Inside chased lines

INSULATED WALLS: External walls

CONCRETE: High slump concrete poured inside formwork

42

SPECIAL FEATURES

• Cost Effective - Saves 70% or more in energy equipment & consumption bills for maintaining cooling tempera-
tures
• Quicker - Commissioned in nearly half the normal time period, with less manpower & no heavy machines
• Resource Conserving - No water for curing, hence time & labour also saved at site
• Load bearing external walls - With minimized need for columns or beams

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

• Minimal on site waste - Modular form work enables any wall height or design complexity with ease,
• 100% insulation - With zero thermal leaks (R-Value = 19, higher than any other new or traditional construc-
tions
• Durable - Monolithic structure for highest degree of fire & disaster resistance 3 hours of fire rating, can withstand
earthquakes of Magnitude +7
• Sound Insulation - Up to 60 Db
• Maintenance free - Fibre glass mesh reinforced, crack resistant plaster on walls
• Heat resistant external roof - With interlocking insulation tiles of uniformly high R-Value
• Code Compliance - System designed to meet International Standards & Building Codes

ADVANTAGES

• Not just Walls: But multiple building steps with one product
• Form system -- light weight, interlocking
• Wall structure -- strong, load bearing, disaster proof
• Insulation -- thermal & acoustic, on both sides
• Air barrier -- no drafts with monolithic insulation
• Vapour barrier -- moisture & condensation kept out
• Smooth, straight surface -- less finishing time for Interior/exterior Render

USES AND LIMITATIONS of ICF/MICS

Insulating Concrete Forms (ICF) & Monolithic Insulated Concrete Systems (MICS) may be used as a load bearing
and non-load bearing internal or external walls to build residential and other buildings. This construction technology
may be used for wide variety of buildings including apartments, villas, low-rise buildings, commercial complexes,
hotels, industrial buildings, etc.

Limitations

1. Door and window position can’t be changed after pouring of concrete

2. Forms are not reusable as compared to conventional materials

Executed Project

S. No. Name of Project Location Period of Supply

1. Construction of Farmhouse of approx. 110 sqm area Manesar (Haryana) January 2015
2. Construction of G+3 showroom of total area of approx. Indore (MP) Mar-April 2015
1600 sqm
3. Construction of G+1 Hillside Cottage of approx. 250 Theog, Shimla (H P) June – Aug., 2015
sqm area
4. Construction of G+5 Multi storey residence of total area New Delhi Nov. – April 2016
900 sqm
5. Construction of G+1 Office & godown of 590 sqm area Greater Noida (UP) 2014-15
each
6. Construction of a single storey Prototype house VDOS Colony, Kham- 2016
mam (Telangana)

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Certification

i) Under Performance Appraisal Certification Scheme, the present formwork system with patent name ‘Insulating
Concrete Forms’ vide Performance Appraisal Certificate No. 1029 -S/2018 issued to M/S RELIABLE INSUPACKS
(P) LTD, Greater Noida by BMTPC.

ii) Under Performance Appraisal Certification Scheme, the present formwork system with patent name ‘Monolithic
Insulated Concrete System’ vide Performance Appraisal Certificate No. 1036-S/2018 is awarded to M/s Maiwir
Ecotech Pvt. Ltd., Khammam (Telangana) by BMTPC.

Standards

Following Standards are referred:

IS 383:2016 Specifications for coarse and fine aggregate for concrete (Third Revision)
IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 875 (Parts 1,2,4&5):1987 Code of Practice for Design Loads (Other than Earthquake) for Buildings &
IS 875 (Part 3):2015 Structures (Parts 1,2,4&5 – Reaffirmed 2013)
IS 1346:1991 Code of practice for waterproofing of roofs with bitumen felts (Reaffirmed 2016)
IS 1542:1992 Specifications for sand for plaster (Reaffirmed 2014)
IS 1786:2008 Specifications for high strength deformed steel bars and wires for concrete
reinforcement (Reaffirmed 2013)
IS 1893 (Part 1):2016 Criteria for Earthquake Resistant Design of Structure - Part 1 : General Provisions
and Buildings (Sixth Revision)
IS 1904: 1986 Code of practice for design and construction of foundations in soils: General
requirements (Reaffirmed 2015)

IS 3346:1980 Method of determination of thermal conductivity for thermal insulation materials

IS 4326:2013 Code of Practice for Earthquake Resistant Design and Construction of Buildings
(Third Revision)
IS 4671:1984 Specifications for expanded polystyrene for thermal insulation purposes
IS 4759:1996 Hot Dip Zinc Coating on Structural Steel Products
IS 8112:2013 Specifications for 43 grade Ordinary Portland Cement (Second Revision)
IS 9103:1999 Specifications for concrete admixtures (Reaffirmed 2013)
ISO 9705:1983 Fire tests for evaluating contribution of wall & ceiling interior finish to room fire
growth
ACI 318:2014 Building code requirements for structural concrete, structural design for flat wall ICF
systems
ASTM C 578:2015 Standard specifications for rigid, cellular polystyrene thermal insulation
ASTM E 119:2014 Standard test methods for fire tests of building construction and materials
ASTM E 2634:2011 Standard specifications for flat wall ICF systems

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Structural Stay-in-Place Formwork System

(Coffor Technology)
(Suitable for Low Rise to Medium Rise)

About the technology

It is a patented structural stay in place formwork system known as ‘Coffor’ to build load bearing monolithic concrete
wall structures based on shear wall concept.

The formwork system comprises of two filtering grids made of rib mesh reinforced by ‘C’ channel vertical stiffeners.
The grids are connected by rebar which act as horizontal stiffeners and connector which act as a shear link. The
grids on both faces act as sacrificial formwork in which concrete is poured in-situ.

After the erection of formwork panels in alignment, corners, edges of doors and windows frame are closed with
rebar positioning & concrete of required grade is poured in the panels. The concreting may be done with a pump,
bucket or with a shovel loader. The inside and outside walls are finished with cement plaster of suitable grade.

The panels are prefabricated according to a structural plan (based on client’s architectural plans) designed by
structural engineers.

Product assembly Components in Coffor Panel:

The various parts of Coffor panel are explained briefly below:

Part – 1: C-Chanel
– These are vertical stiffeners, work as vertical steel in Reinforced Concrete
wall
– It is made up of 0.6 mm thick galvanized sheet. The 180 GSM to 275
GSM zinc coating is used based on geological location to prevent rusting
of steel.
– Area of profile is 60.6 mm2 (i.e > 8 mm dia bar)
– Placed at every 200 mm distance along the width

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Part – 2: Rebar
– Rebar’s are horizontal stiffeners at every 200 mm or 100 mm centre to
centre
– It is 5 mm dia MS bars and work as distribution bar.
– Made up of Fe 415 Grade steel

Part – 3: Connector
– Connects C profile & Rebar.
– It is made up of 1.6 thick Cold Rolled Cold Annealed (CRCA) plates of
120 gm/m2 zinc coated sheet to prevent rusting
– Works as shear link to connect steel on both face of form work.
– Also helps to avoid bulging of formwork during concrete pouring.

Part – 4: Rib Mesh

– Rib meshes are filtering grids.
– They are made up of 0.42 mm thick high galvanized sheet with 180
GSM to 275 GSM zinc coating used as per geological location to
prevent rusting of steel
– It works as reinforcement to plaster to prevent crack generated due to
contraction and expansion.
– Also provide good bonding to plaster.

Size and Types of Panels

Panels are normally produced in sizes as given below (See Fig. 2):
Width (W): 300mm, 500mm, 700mm, 900mm & 1100mm
Height (H): 500mm to 5000mm in multiples of 100 mm.
Thickness (T): 100mm, 140mm, 160mm, 200mm & 250mm.
However, customized sizes also be made available on demand.

Panel T A B W H
Type mm mm mm mm mm
C10 100 200 100, 200 300, Min.
C14 140 200 100, 200 500, 500
C16 160 200 100, 200 700, then
C20 200 200 100, 200 900, in multiples
C25 250 200 100, 200 1100 of 100

Fig.2
Types of panels are given below:

i. Standard single panels – These panels shall be used for slab shuttering but may also be used as shuttering
option for RCC wall having thickness of more than 350mm. (Fig. 3)
ii. Double panels – Double panels shall have inbuilt steel and not require extra reinforcement. In double panels,
the grids shall be connected by articulated rebar loops and connectors that fold.
These panels are of two types:
(a) Standard double panels shall be of fixed size and need to be cut on site for openings etc.
(b) Customized double panels from the factory shall have required cutting for openings as per drawing
and there is no need for cutting on site.
(c) These panels create a monolithic structure as it allows pouring of walls and slab together.
These panels shall be used for load bearing walls, retaining walls and shear walls. (Fig. 4)

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

iii. Insulated Double panel – These panels shall have an integrated insulation on the exterior side. The insulated
material shall be of polystyrene or polyurethane of required thickness as per design.(Fig. 5)
iv. Fiber Cement Double panel – These panels shall have its interior face as fibre cement board which has smooth
surface and avoid plastering of walls. (Fig. 6). These panels may be used for water retaining structures.

Fig.3 Standard Single Panel Fig.4 Standard Double Panel

Fig.5 Insulated Panel Fig.6 Fiber Cement Panel

Basic steps to construct with Coffor panels

Foundation
Strip Footing or normal column and beam structure up to Plinth level based on soil condition.
In case of Strip footing, Coffor panels will start from foundation and on the top of strip concrete raft which increase
speed to come out from the ground.

Installation of Panel:

Layout and Blocking

- The alignment shall be traced with chalk on the two sides. Boards/battens shall be nailed on the ground to
indicate the positioning of one face of the panels.

Positioning the Panel

- The Structural formwork panels shall be fitted over projecting vertical reinforcing rods. Each panel shall be
held vertically with wood pieces (boards/battens) or metal pieces (L-sections/tubes). The minimum length of
these bracing elements shall not be less than 1.80m. The panels shall preferably be positioned beginning
from the angles and from the doors. Whenever length of the wall does not correspond to a multiple of width
of the panels, the last panel shall be cut with a rotary saw to adjust to length of the wall. The horizontal

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

battens shall be installed on a single side. The verticality shall

be checked using a plumb line or level.
- Shuttering of Slab: after completion of Coffor panel installation
of the wall, slab shuttering will start either with use of Coffor
single panels or normal conventional shuttering for RCC or any
other slab.
- Plumbing and Electrification: After installation of slab shuttering,
electrical and plumbing conduits can be placed in between
panels. For installing the electrical box, panels can be cut with
small grinder machine.
- Panel alignment & slab steel needs to be checked & ensured prior to concreting.
- Concrete Pouring: The placing of concrete of specified grade is done in wall and slab in one go with either
with Boom placer, stationary pump or manually. As all concreting is done in one go, a monolithic reinforced
concrete structure is created.

Structural Requirements of the Construction

The design strategy is to utilize concrete and formwork steel to the ultimate and to provide standard solutions for
minimum reinforcement to be used, wherever required, depending on the application and will be determined by
structural calculations performed according to the IS 456:2000. In seismic prone areas requiring seismic resistant
construction, relevant provisions of IS 875 (Part 1, 2, 4 & 5):1987, IS 875 (Part 3):2015, IS 1893 (Part 1):2016, IS
4326:2013 and IS 13920:2016 shall apply.

Design analysis of the Structural formwork walls, panels, floor slabs etc. shall be done using Staad Pro Software or
equivalent. The Optimal result is obtained when walls shall be designed as braced construction elements whose
horizontal loads are supported by other bracing elements belonging to the same construction e.g. shear walls. The
panels with concrete shall act as “lightly reinforced RCC walls” as per clause 32 of IS 456:2000 and as “prefabricated
concrete load bearing walls” as per IS 15916:2010 & IS 15917:2010 & amp; IS 15971:2010.

Structural design and analysis of the formwork shall be based on relevant Indian and International standards. The
panel construction assembly shall be used for free standing walls when designed and anchored as cantilever walls.
Panels shall be reinforced and tied at vertical joints to maintain alignment. Additional reinforcement and cement
plaster shall be provided as required by the design.

The technology is intended for use where Architectural drawings are available. The Architect and Engineer designer
team of the concerned developer/owner (client) is responsible for the drawings and overall building design to
comply with the various regulatory requirements applicable to the area.

Foundation shall be specifically designed in accordance with provisions given in IS 1904:2005. All foundations
should be designed by structural engineer with appropriate reference.

Durability

Since concrete is main constituent material in this system,

durability of the structure can be achieved by using proper
ingredients, grade of concrete as per IS 456:2000 and mix
design in accordance with IS 10262:2009.
Thickness of the wall is minimum 120 mm thick, with 100
mm concrete thickness & 10-12 mm plaster on both sides.

Thermal Behaviour of Structure

100 mm thick RCC walls and slab has thermal transmittance

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

(U) value as 3.59 W/m2K) (as per IS 3792:1978). As this system uses 10-12 mm plaster on both sides of the walling
unit, the thermal transmittance value is going to be slightly lower than 100 mm thick RCC wall. Further, in G+3/G+4
building units, the panel thickness used is generally 140 mm, which will have still lower thermal transmittance value.
However, it is more than the normal plastered 9” brick masonry walls (thermal transmittance (U) 2.13 W/m2K),
hence it is advised to ensure proper planning for heat insulation and air ventilation in the housing units through
proper orientation, shedding etc. (see IS 3792:1978 for guidance).

Acoustic

Average sound reduction for 100 mm concrete is ≥ 45db (IS 1950:1962), which is reasonable acoustic insulation.

Ease of services

All electric and plumbing fixtures, lines have to be pre-planned and placed appropriately before pouring concrete in
RC walls & slabs. Post construction alteration is not desirable.

Main Advantages of the System

- Creates good quality monolithic earthquake resistant structure.

- Ensures significant reduction in construction time, labour requirement, overheads, etc.
- Easy to use system with no need for heavy machinery, Cranes, etc.
- Simplifies the construction process
- No need of skilled labor, the labor can easily be trained in a short span of time
- Maintenance free building as the outer surface having mesh provides good bonding to plaster and helps to
prevent cracks, water seepage, etc.

The application of the System & its limitations

This sacrificial Formwork System is used for load bearing walls/ retaining walls/shear walls for residential buildings
upto G+4 storey, Industrial buildings, Underground Tanks, Water retaining, structures, Storm water drains, Compound
walls etc. and as shuttering material for slabs. The limitations of the system are;
hh For construction of high rise buildings beyond G+ 4 storeys, extra steel in walls shall be required.
hh Post construction alterations are difficult.
hh All the service lines are to be pre-planned in advance.

Execution of Projects

hh Coffor France SNC, France for construction of various projects, with total built-up area of approx 17839 sqmt
during 2008 -15
hh Coffor France SNC, France for construction of Swimming pools, with total built-up area of approx 22770
sqmt during 2008-15
hh West Coast Contractors Pvt. Ltd., Vadodra, Gujarat for construction of P+4 apartments, with total built-up
area of approx 1596 sqmt during 2012-13
hh Sandeep Shah & Associates, Surendranagar, Gujarat for construction of G+4 structure, with total built-up
area of approx 1251 sqmt, during 2013-14
hh Lubi Pump Pvt. Ltd., Ahmedabad, Gujarat for construction of Retaining wall, with total built-up area of approx
1400 sqmt during 2013-14
hh The demonstration housing project under PMAY as being executed by BMTPC with 36 DUs (G+2) at
Biharsharif, Bihar & 16 DUs (G+3) at Hyderabad, Telangana. The proof checking of design for both the
projects is available with BMTPC.

The projects other than demonstration housing projects, are as per the details provided by PAC holder.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

CERTIFICATION

Under Performance Appraisal Certification Scheme, Structural Stay-in-place Formwork System has been evaluated
and certified by BMTPC PAC No.: 1035-S/2018 is awarded to M/s Coffor Construction Technology Pvt. Ltd.,
Vadodra (Gujarat).

standards & references

IS 456:2000 Code of Practice for plain & reinforced concrete (Reaffirmed 2016)
IS 15916:2010 Code of practice for Building design and erection using prefabricated concrete
IS 15917:2010 Code of practice for Building design and erection using mixed/composite construction (Reaffirmed 2014)
IS 875 (Part 1):1987 Code of practice for design loads (other than earthquake)for buildings and structures part 1 dead loads -
unit weights of building material and stored materials (incorporating IS:1911-1967) (Reaffirmed 2013)
IS 875 (Parts 2,4&5):1987 Code of practice for design loads (other than earthquake) for buildings and structurres: Imposed Loads,
IS 875 (Part 3):2015 Wind Loads, Snow Loads and Special loads & combinations
IS 1893 (Part 1):2016 Criteria for Earthquake resistance design of structure
IS 10262:2009 Concrete mix proportioning - Guidelines (Reaffirmed 2014)
IS 13920:2016 Code of practice for Ductile detailing of reinforced concrete structures subjected to seismic force
IS 4759:1996 Hot Dip Zinc coating on structural steel products.
Technical Assessment No. 16/10-607 of Coffor Structural Formwork by CSTB, Paris, France
Structural Evaluation of Prefabricated Concrete Wall System made of Coffor Steel panels comprising tests of Lateral load, Flexural strength
and Axial load of the Panels by IIT Bombay
Project Report of Flexural, Compression, Shear & Deflection tests by Geo Test House, Vadodra
Quality Assurance Procedure Manual
Operating Manual giving details of Installation and Execution of the panels

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Lost-in-Place Formwork System – Plaswall Panel System

(For Structural Applications)
(Suitable for Low Rise to Medium Rise Structures)

About the technology

Plaswall Panel System is a lost in place formwork, where two fiber cement boards (FCB) of 6mm thickness each
and HIMI spacers (High Impact Molded Inserts) bonded between two sheets of FCB (in- situ) are erected to produce
straight-to-finish panels. A monolithic structure is then created by filling the entire structure with M20 or higher grade
of concrete as per the design. Additional load capacity can be obtained by providing extra reinforcing bars and/or
by increasing grade of the concrete.

At present, the firm imports the fibre cement board (FCB) manufactured by Hume Cemboard Industries, Malaysia
for use in the construction of structures.

An Isometric View of the Plaswall is shown in Fig. 1 below:

STARTER BARS FOR NEXT FLOOR
SHEAR CONNECTOR BAR EXT.
FROM VERT.REINF.
SHEAR CONNECTOR BAR EXT.
FROM VERT.REINF.

HOTIZONTAL REINF.BAR

SPACER
FCB BOARD

STARTER BARS FROM FOUNDATION

Fig. 1 Isometric View

Size of Panels

Panels are normally produced in sizes and

dimensions as below:

Length: 2400mm/3000 mm
Width: 1200 mm
Thickness: 87 mm, 112 mm, 137 mm, 162
mm & 230 mm including two
fiber cement boards of 6mm
thickness each and infill of
concrete of 75mm, 100mm,
125mm, 150mm and 218mm.

The dimensional sketches are shown in Fig. 2

Fig. 2 Dimensional sketches

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Raw Materials

• Fibre cement board shall be 100% asbestos free and conform to Type A, Category 3 min. as stipulated in IS
14862:2000.
• Recycled plastic spacers made of High Impact Molded Inserts shall conform to the specifications of the
manufacturer.
• PU Adhesive Glue shall conform to the specifications of the manufacturer.
• Putty shall conform to IS 419:1967.
• Cement, sand, aggregate and reinforcement steel shall be as per the relevant Indian Standards.

Uses AND LIMITATIONS

Uses:
Plaswall panels may be used upto G+3 storey residential and commercial buildings, villas, apartments, factories
and malls, etc.

Limitations:
• Nails should be inserted in walls by first making a hole by drilling and fixing a plastic sleeves or rawl plugs.
• Chisel shall not be used to chase directly on the wall for providing additional services. Instead 100 mm
grinder machine shall be used to cut out exact portion of wall and then rendering of the wall with mortar and
putty.
• If wall tiles are to be changed, walls shall not be hacked for fixing new tiles. Instead, a cementitious tile
adhesive should be for fixing new tiles.
• Post construction alternations are difficult. All the service lines are to be pre-planned in advance.

Design Parameters

• All concreting work shall be done in accordance with IS 456:2000 with regard to workmanship and materials.
M20 or higher grade of concrete as per the design shall be used for construction and mix should be prepared
in accordance with Clause 9.2 of IS 456:2000.
• The Reinforcement shall be placed according to the specifications, depending on the application and shall
be determined by structural calculations performed according to the IS 456:2000.
• The lateral forces as applicable shall be taken into account based on relevant Indian Standards.

Panel Fabrication

Fibre cement edge recessing

After cutting fibre cement sheets to the desired dimensions, the edge of the sheets shall be recessed using recessing
machine.

Panel Lamination
• Plastic pallets and jigs shall be arranged perpendicular to each other
• Fibre sheet shall be laid in alignment with respect to pallet and jig setup
• Marking of spacer with use of specific stencil positions shall be done on the sheet
• Glue @ 250gm min. is the standard consumption. Reusable bottom angles shall be laid as per alignment of
walls where panels are to be installed.
• Desired number of plastic spacers (32 nos. of spacers for panel of size 1200 mm x 2400 mm) shall be placed
on the top of the fibre sheet, where glue is applied and kept in linear manner for 4 to 5 hours.
• Glue shall be applied on upper faces of spacers and upper sheet is laid perfectly in line with lower sheet.
(Fig. 3 & 4)
• Ten number of panels shall be fabricated on each side of jig and stacked on pallets. (Fig. 5)
• These panels then shall be cut as per the specified dimensions and sizes such as rectangular, square,
curves etc.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Fig. 3 Fig. 4 Fig. 5

Joint Splicing
Joints between two panels shall be fixed by using FCB strips 50 mm wide inside the panel with help of glue, screws
and tacking pins. (Fig. 6).

Fig. 6 Splicing

Construction, Installation and Jointing Procedure of Plaswall

Foundation

The foundation type as raft, strip, isolated footing shall be decided based on bearing capacity of the soil, site
condition, etc. However, the provision for starter bars for walls shall be ensured in all foundation scenarios. Typical
sketch for starter bars from foundation are given below (Fig.7).

Fig. 7 Typical Strip footing

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Panel Installation

Installation
The panel shall be lifted slightly and then placed along the bottom angles. The panel shall be plumbed at edge and
face sides with provision of shims, if needed.
• The panel shall be screwed both sides at bottom at 250 mm center to center, while glue is applied & tacky.
If glue is not available, spacing shall be kept at 200mm center to center.
• Support the temporarily angle installed on other side of panel to hold it in position for concreting (Fig. 8)
• Corner connection details shall be followed as shown in Fig. 9.

Fig. 8 Diagonal bracing Fig. 9 Corner connection

T-Section
• After installing the primary walls, mark the place where corner will be constructed.
• The joiner stud shall be placed and marked by pencil to have a vertical line reference.
• The joiner stud shall be moved up by 60mm from slab to bottom of joiner stud. The stud hole shall be marked
by pencil.
• The marked slots shall be cut by 100mm angle grinder with dry type diamond blade.
• Reinforced dowels shall be prepared, inserted & tied just after screwing the joiner stud corner connection.
(Fig.9)
• In case, the holes intersect with panel stud of the primary wall, the portion of primary stud shall be cut
to accommodate the marked holes for T-connection. One 12mm vertical bar shall be provided as
replacement.
• In case of cross-connection, horizontal bars shall be provided.

Nib End Wall Detail

• For nib, end cap shall be provided.
• Glue shall be applied on end cap stud which shall be inserted to correct position and screwed. (Fig. 10)

Fig. 10 Nib End Wall Detail Fig. 11 Door & Window Jambs

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Door & Window Jambs Installation

• Light gauge door & window jambs shall be provided for the panels
• Door jambs shall be installed along with the panel. (Fig. 11)
• Window jambs shall be installed (not fixed) to accommodate concrete at window sills. This will eliminate
honey-comb and ease pouring of concrete.
• The window sill shall be overflowed by concrete and then push down window frame. The lintel panel shall be
screwed to press down the window frame. Spacing of screws shall be the same.

Embedment of Services
After installation of the panels, electrical and plumbing pipes shall be inserted into the panel as per the drawings.

Concreting
After placing of reinforcement and services in the panel, designed grade/mix of concrete shall be poured manually
or by Pumping system. The concrete shall be poured from top of the wall or by cutting slit and attaching chute in
the panel.

Joint Treatment
After walls are completely filled and mix dried, joint treatment shall be done using fibre mesh tape and putty. (See
Figs. 12 & 13)

Fig.12 Yellow Putty with Fibre mesh tape Fig.13 Joint Treatment

Construction of Slab

Once construction of panels is completed, slab construction shall be done as per the structural drawings with wall
reinforcement and connection with slab reinforcement.

Key Features of “Plaswall” Load Bearing System

• It is significantly faster than conventional technology.

• Brick work & plastering is eliminated
• Curing of concrete is not required & hence considerable water is saved
• Inlaid plumbing & electrical lines, superior quality finish.
• Better Acoustic Insulation
• Termite & Algae Resistant.
• Applicable in Humid conditions.
• HIMI is manufactured from 100% recycled plastics.
• Fire Resistance: PLASWALL™ is non-combustible and has fire resistance for one hour as determined by
ASTM E 119 tests. Its excellent thermal insulation acts as a thermal shield. A 112mm thick wall will withstand
fire for 2 hours 20 minutes and a 162mm thick wall has fire resistance for 3 hours.
• Acoustic Insulation: Its inbuilt sound reduction properties make it excellent for sound absorption and noise
isolation. Concrete walls carry sounds, thus hampering privacy.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Major Projects Executed

• Construction of Row Houses (Area= 675 sq.mts) at Boisar.

• Sales Gallery at Vaisind for Tata Housing, Mumbai.
• Construction of Villas at Cupertino, Bangalore for M/s Concorde Group, Bangalore
• Construction of 4 Villas at Goa ( Area= 1085 sq.mts) for M/s Naiknaware Developers, Pune.
• Construction of 113 no .of Villas (G+1 configuration) at Sawantwadi, Maharashtra( Area= 6200 sq.mts) for
M/s Ranco Reality, Mumbai
• Construction of Villas & School at Ooty for M/s Ground Reality, Bangalore

Certification

Performance Appraisal Certificate No. 1034-S/2018 issued to M/s FTS Buildtech Pvt. Ltd., Mumbai by BMTPC.
(Download from website (www.bmtpc.org.).

List of Standards and Codes Used In Assessment

Standards: These Standards are referred for carrying out a particular test only and do not specify the requirement
for the whole product as such.

IS 383:2016 Specifications for coarse and fine aggregates (Third Revision)

IS 419:1967 Specifications for putty.
IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 516:1959 Method of test for strength of concrete (Reaffirmed 2013)
IS 2380 (Part 14):1977 Methods of test for wood particle board and other Ligno cellulosic materials – screw & nail
withdrawal test (Reaffirmed 2013)
IS 3809:1979 Fire Resistance Test for Structures
IS 8112:2013 Specifications for 43 grade Ordinary Portland Cement
IS 13920:2016 Ductile detailing of reinforced concrete structures subjected to seismic forces - code of practice
IS 14862:2000 Specifications for Fibre Cement Flat Sheets (Reaffirmed 2015)
ASTM C 518-02 Standard test method for steady state thermal transmission properties by means of heat flow
meter apparatus
ASTM C779 Standard test method for abrasion resistance of horizontal concrete surfaces
ASTM C873 Standard test method for compression strength of concrete cylinders
ASTM C900 Standard test method for pullout strength of hardened concrete
ASTM 322:09 Standard test method for thermal conductivity
ASTM E119 Standard test method for fire tests of building construction and materials
ASTM E 152-58 Non-combustibility test for materials and heat emissions from building materials
ASTM E413 Classification of rating of sound insulation and field transmission class
ASTM E2179 Standard test method for lab measurement of effectiveness of floor coverings
BS 476 (Part4):1970 Fire tests on building materials and structures—Method of test to determine classification of
surface spread of flame

References:
1. Evaluation of Structural Design of G+2 storey 30m x 40m Villa Project at Cupertino, Bangalore using Plaswall Technology by IIT
Bombay.
2. Design of a G+2 storey with Roof Deck Residential Villa Project at Djibouti, Africa by Senior Consultant Engineer
3. BBA Agreement Certificate No. 16/5380 pertaining to Greenspan Permanent Shuttering Systems on which Plaswall Technology
is based
4. Report on Thermal Transmission Properties of Plaswall (Load bearing walls) by calculation method by Material Lab, Dubai, UAE
5. Small –Scale Fire Resistance Test on a 110mm thick panel by Firelab, Glenstantia, South Africa
6. Tests performed on Plaswall Panel for Fire Resistance at the Forest Products Research & Development Institute Fire Testing
Laboratory, Philippines as per ASTM E152-58.
7. Tests performed on samples of spacers i.e. High Impact Moulded Inserts (HIMI) of size 125mm collected by the IO for carrying out
the following tests by Central Institute of Plastics Engineering and Technology (CIPET), Ahmedabad
8. Tests Performed on samples of Fibre Cement Board and Panels by Indian Institute of Technology Bombay, Mumbai.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Lost-in-Place Formwork System – Plasmolite

Wall Panel
(Suitable for Non Load Bearing Structures)

About the technology

Plasmolite Panels are lost in place formwork system comprising of two fibre cement boards (FCB) of 6 mm thickness
and High Impact Molded Inserts (HIMI) bonded between two sheets which also acts as spacers. The panel is
erected to produce straight to finish walls which are filled with light weight foam concrete. The system may be
integrated with conventional column and beam and also with pre-engineered buildings. The panels may be used as
non load bearing walls for external and internal applications.

The firm imports the fibre cement board (FCB) manufactured by Hume Cemboard Industries, Malaysia for use in
the technology. An Isometric View of the Plasmolite panel is shown in Fig. 1 below;

Fig. 1 Isometric View of Plasmolite Panel

Size of Panels

Size: Panels are normally produced in sizes and dimensions as given below:
Length: 2400/3000 mm
Width: 1200 mm
Thickness: 87 mm, 112 mm, 137 mm, 162 mm & 230 mm including two fibre cement boards of 6mm
thickness each.

Typical dimensional diagrams are shown in Fig. 2.

Fig.2 Dimensional Diagrams

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Raw Materials

• Fibre cement board shall be 100% asbestos free and conform to Type A, Category 3 min. as stipulated in IS
14862:2000.
• Recycled plastic spacers made of High Impact Molded Inserts shall conform to the specifications of the
manufacturer.
• PU Adhesive Glue shall conform to the specifications of the manufacturer.
• Foaming agent shall conform to the specifications of the manufacturer.
• Putty shall conform to IS 419:1967.
• Cement, sand, aggregate and reinforcement steel shall be as per the relevant Indian Standards.

Uses AND LIMITATIONS

Uses: Plasmolite Panels may be used as partition walls for external and internal applications for residential and
commercial buildings, schools, hospitals, factories and malls etc.

Limitations:
• Nails/screws should not be inserted directly on the walls by using hammer. Instead, a hole shall be drilled by
using drilling machine and then plastic sleeves or rawl plugs be inserted for fixing the nails/screws.
• Chisel shall not be used to chase directly on the wall for providing additional services. Instead, 100 mm
grinder machine shall be used to cut out exact portion of wall and then rendering of the wall with mortar and
putty.
• If wall tiles are to be changed, walls shall not be hacked for fixing new tiles. Instead, a cementitious tile
adhesive should be for fixing new tiles.

PANEL FABRICATION

Fibre Cement Edge Recessing

After cutting fibre cement sheet to the desired dimensions, the edge of the sheet shall be recessed using recessing
machine.

Panel Lamination (Fig. 3)

• Using the panel jig, one fibre cement sheet 6mm thick shall be placed on top of jig with the smooth face
touching the jig flat form.
• Desired number of HIMI spacers shall be placed on top of fibre cement sheet and PU adhesive applied on
the stud flanges (32 pieces for full panel 1200mm x 2400mm). HIMI spacers shall be aligned using pattern
board.

Fig. 3 Marking & fixing of Spacers, formation of successive layers of panels

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

• Another 6mm thick fibre cement sheet shall be placed on top of the studs to close the first panel.
• The same process as above shall be repeated until jig is filled with panels.
• Flat plywood covers shall be laid to compress the panel for 4 to 5 hours.

Panel Installation

Dowelling
• Holes shall be drilled & dowels shall be grouted by using epoxy
resins in the holes.
• Centre to centre spacing between dowels shall be 300 mm as per
design
• Dowels shall be installed on beams, columns and slab (Fig. 4)

Installation
• The panel shall be lifted slightly and then placed along the bottom
Fig. 4 Dowelling
angles. The panel shall be plumbed at edge and face sides with
provision of shims, if needed.
• It is essential that panels be first installed starting from face of supporting column
• The panel shall be screwed both sides at bottom at 250 mm center to center, while glue is applied & Stacy.
If glue is not available, spacing shall be kept at 200mm center to center. (Figs. 5, 6 & 7)
• Support the temporarily angle installed on other side of panel to hold it in position for concreting (Fig. 8)

Fig. 5 Fig. 6

Fig. 7 Fig. 8

Joint Splicing
Joints between two panels shall be fixed by using FCB strips 50
mm wide inside the panel with help of glue, screws and tacking
pins. (Fig. 9)

Fig. 9 Tongue and Groove Systems

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Embedment of Services
After installation of panel, electrical and plumbing pipes shall be inserted into the panel as per the drawings.

Concrete mix
Plasmolite foam generator and mixer shall be used for this purpose. An elaborated mix of cement, sand/fly ash and
water shall be prepared, quantities of which vary depending upon required density and strength of foam concrete.

Pouring of Concrete
Concrete can be poured in the panel by pumping or manually directly from top or intermediate position depending
on floor to floor height and site conditions.

Fig. 10 Plasmolite set for pouring Fig. 11 Gap Filling

Joint Treatment
• After walls are completely filled and mix dried, joint treatment shall be done using fibre mesh tape and
putty.
• Mesh tape shall be sandwiched between first & second coats to have a hold over the wall. (Fig. 12)
• Wall is now ready to accept primer & paint.

Fig. 12 Yellow Putty with Fibre Mesh Tape

Design Parameters

The technology provider shall provide design data for good practices and as ready reckoner for users.Typical
design sketches for non-load bearing walls are shown in Figs. 13 & 14.

Project Executed

1. Supply, Fabrication & Installation of wall panels at Goa for construction of a high rise building for M/s JVS
Infrastructure & Environment, Goa
2. Supply, Fabrication & Installation of panels at TCS Sahyadri Park, Hinjawadi, Pune for M/s Shapoorji Pallonji,
Pune
3. Supply, Fabrication & Installation of wall panels at Dahej, Gujarat for M/s Indo Baijin Chem Pvt. Ltd., Bharuch,
Gujarat

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Fig. 13 Fig. 14

4. Supply, Fabrication & Installation of panels at Future Towers, Amanora Park Town, Pune for Amanora, Pune
5. Design, Supply & Installation of panels at residential building at Vikhroli, Mumbai for Shubam Dynamic,
Mumbai
6. Supply, fabrication & installation of wall panels at Pune for construction of IT Park for M/s Tata Consultancy
Ltd., Pune.

Advantages

• Faster construction
• Eco-friendly
• Good thermal & acoustics insulation

Certification

Performance Appraisal Certificate No. 1033-S/2018 issued to M/s FTS Buildtech Pvt. Ltd., Mumbai by BMTPC
(Download from website - www.bmtpc.org)

List of Standards, references used in Assessment

Indian Standards
IS 383:2016 Specifications for coarse and fine aggregates (Third Revision)
IS 419:1967 Specifications for putty.
IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 516:1959 Method of test for strength of concrete (Reaffirmed 2013)
IS 2380 (Part 14):1977 Methods of test for wood particle board and other Ligno cellulosic materials – screw & nail
withdrawal test (Reaffirmed 2013)
IS 3809:1979 Fire Resistance Test for Structures
IS 8112:2013 Specifications for 43 grade Ordinary Portland Cement
IS 14862:2000 Specifications for Fibre Cement Flat Sheets (Reaffirmed 2015)
ASTM C900 Standard test method for pullout strength of hardened concrete
ASTM 322:09 Standard test method for thermal conductivity
ASTM E119 Standard test method for fire tests of building construction and materials

References
1. Tests Performed on samples of Fibre Cement Board and Panels by Indian Institute of Technology Bombay, Mumbai
2. Tests Performed on Panels by Civil-Aid Technoclinic Pvt. Ltd., Bangalore
3. Test Performed on samples of spacers i.e. High Impact Moulded Inserts (HIMI) of size 125mm collected by the Inspection
Officer for carrying out the tests by Central Institute of Plastics Engineering and Technology (CIPET), Ahmedabad

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Sismo Building Technology

(Suitable for Low Rise to High Rise Structures)

ABOUT THE TECHNOLOGY

Sismo Building Technology is an insulating shuttering kit for whole building based
on a three-dimensional lattice made of galvanized steel wire. The lattice is filled
with materials of different nature to serve as formwork. The basic structure of the
Sismo building module is steel wire lattice. At the exterior sides of the lattice, infill
panels are inserted, which transform the lattice into a closed structure that can
be filled with concrete. The type of infill panels used depends on the purpose of
the wall: load bearing or not, insulated or otherwise, etc. The steel wire also acts
as armature and anchoring for the finished material and it holds reinforcement
bars in place during concrete filling.

This technology was initially developed in Belgium and the firm in India has a
collaboration with n. v. Desmo-Home “Sismo” Ltd., Belgium.

Description of the components is as follows:

• 3D lattice (2.2 mm Ø galvanized steel wire)
• Infill panels (EPS, rock wool, mineral board)
• Structural filler (concrete)
• Finishing (plastering, natural stone, paneling etc.)

Sismo Wall One-way girder-slab floor

MODULES

Type of Modules
Depending on the internal and external material, the walls may be divided into following types:
(i) Inside & outside insulation (EPS) strips symmetrical and asymmetrical
(ii) Inside board and outside insulation (EPS) strips
(iii) Inside & outside board strips

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

(iv) Inside & outside insulation strips

(v) 2 Sismo walls decoupled and insulated
for an optimized acoustic performance.
This type is typically used as separat-
ing wall between apartment and hous-
es.
(vi) Module with insulation strips as core
material Sismo floors and roofs may be
plain, one and two-way slabs; as per re-
quirement.

DESCRIPTION OF THE COMPONENTS

Steel Lattice
The steel wire frame, lattice formwork for
the walls, are available in panels of different
dimensions as follows:
• Height: in multiples of 150 mm, with a max. of 12 m
• Length: in multiples of 100 mm, with a max. of 1.2 m
• Thickness: Max. 500 mm, depending on the type of wall /roof required

Functions of steel lattice

The steel wire lattice has the following basic functions:
(i) To resist hydraulic pressure of fresh concrete during pouring and first hours of hardening
(ii) To keep reinforcement bars in place during pouring of concrete
(iii) To ensure adhesion (and reinforcement) of finishing when using mineral based renders

Insulation strips and Interjoists

The insulation strips have following functions:
• Maintain fresh concrete during the provisional phase of pouring
• Thermal insulation in final phase
• Support of interior and exterior finishing

The strips have fixed dimensions and shall be fixed with tongue and groove: 15 mm x 20 mm for EPS strips of thick-
ness 38 mm to 118 mm and 10 mm x 15 mm (h x w) for other strips of thickness 38 mm.

The interjoists have following functions:

• Creation of ribs in order to have a one or two-way girder-slab floor
• Thermal insulation in final phase

The inter joists have fixed dimensions (length 1200 mm & width 450 mm) but may be cut in length in multiples of
100 mm and width in multiples of 150 mm. These shall be available in various thicknesses from 100 mm to 350 mm.
These shall have a ‘waffle’ structure (100 mm x 75 mm) and the groove has depth of 30 mm and a width of 10 mm.
Their shape ensures a good grip on the metal frame of the floor modules.

The details of one-way girder-slab floor are as follows:

• The center to center distance between the ribs is in multiples of 150 mm
• The width of the ribs is 150 mm or in multiples thereof.

The details of two-way girder-slab floor are as follows:

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

• The center to center distance between the ribs is in multiples of 150 mm on one side and 10cm on the oth-
erside
• The width of the ribs is 150 mm or in multiples thereof on one side and 100 mm on the other side.

MATERIAL REQUIREMENTS

Hot galvanized steel wire shall conform to the specifications as given below:
• Zinc coating shall not be less than 60 g/m2
• The dia. of the wires and rings shall be 2.2 mm ± 0.03 mm.
• Tensile strength: 680 N/mm2 min.
• Chemical composition: C = 0.020 % min., Mn = 0.150 % min,
Si = 0.250% max., P = 0.030 % max., S = 0.030 % max.
Rings: Rings shall be used to hold the panels together during installation phase.

Insulation strips and panels:

• Expanded polystyrene (EPS): shall conform to IS 4671:1984 and shall have density not less than 15 kg/m3.
• Fibre cement board (FCB) 5 mm thick: shall conform to IS 14862:2000.

Cast-in-place concrete: The ingredients, grade of concrete & slump for walls, floors and roofs shall be used as per
IS 456:2000.

APPLICATIONS

The technology shall be used for construction of structures consisting of load bearing walls, foundations, cellars,
floors and roof etc. for residential, commercial and industrial purposes.

PRODUCTION PROCESS

The production of the modules is carried out in the Sismo Production Station (SPS). The main stages of production
include:
• Unwinding of steel wire rolls
• Cutting and straightening of steel wire
• Assembly and welding of two-dimensional lattices
• Assembly and welding of three-dimensional lattices
• Cutting of insulation strips and interjoists
• Insertion of the insulation strips into three-dimensional lattice at the lateral intervals intended for this pur-
pose.

The fixing of the panels and placing of interjoists on respective walls and floors is done at site. Panels are installed
after hardening of concrete.

The production is carried out according to an internal factory production control plan.

Conformity checks are done on incoming materials and at regular stages throughout the production sequence to
ensure the fitness of the components.

Accessories
The accessories required for erection of the walls in construction site shall be as follows:

• Struts: to support the panels during installation and pouring of concrete (max. distance of 2 m between two
panels).
• Strut for stanchion: to support stanchion for guard rail and used to align and support the top of panels at floor
level during installation and pouring of concrete.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

• Hollow profiles: to support the panels during installation and pouring of concrete (max. distance of 2 m be-
tween two panels).
• U-profiles: to connect the hollow profiles with horizontal steel wire supporting the panels during pouring of
concrete.
• Stapler & Rings: to connect the panels (7 rings per linear meter, on each side of the wall, back and front).
• Lop ties and Tie twister: to secure the reinforcement bars to the metal frame.
• Cutter: to cut the steel wire at the openings (doors, ceilings etc.) after hardening of the concrete.
• Boards: (30 mm/120 mm) for proper alignment of the walls.
• Props and Shuttering boards : as support for floors to spread the concentrated loads of the vertical props.
The number of vertical props may be reducing by using load spread beams.

IMPLEMENTATION

Handling, transportation and storage of panels

• The handling of panels on site shall be done with gloves and protective glasses as they have sharp points.
• Loading and unloading of modules shall be done either manually or by machine.
• The modules shall be transported and stored sideways, standing or in a horizontal position. When stored
and transported in horizontal position, extra care should be taken to limit stress because bottom panels of a
pile horizontal staked modules have a higher risk of deformation.

Erection of Panels
• The panels shall be placed on the foundation or on the floors. They shall be held together by rings longitudi-
nally placed every 150 mm on both sides of the wall.
• In the initial phase, the panels shall be supported on one of their sides by struts specially developed for this
purpose. They shall provide lateral support to the panels till hardening of the concrete. The maximum dis-
tance between lateral supports should not exceed 2 m. It should be possible to transform the struts to scaf-
folding to allow access at the top of the casing to monitor pouring of the concrete.
• The free end of the panels (in case of openings, windows, doors or ceilings) shall be closed in the same man-
ner as the common parts to ensure holding of fresh concrete.
• The verticality of the walls shall be checked before and during casting.
• The floor modules shall be temporarily, till hardening of the concrete, be supported by shuttering panels,
beams and props. When props are used only for supporting the weight of fresh concrete, circulation and cur-
ing platform shall be used.

Placing of reinforcement
• The modulated dimensions of the lattice shall be 100 mm horizontally and 150 mm vertically and in multiples
thereof. The securing of the bars through the lattice, shall ensure a correct positioning of the reinforcement
after pouring of concrete.
• Stirrups, straight, L and U shaped bars shall be placed during mounting of the modules. The lattice should
not be combined with welded reinforcement mesh.
• The placing of vertical bars shall be done through the top of panels and shall progress together with the
mounting of the panels.
• Horizontal bars for ties, lintels etc. shall be inserted sideways and progresses together with the mounting of
the walls. It is sometimes required to remove the insulating strips used as formwork at the edge of the panels
to be able to insert the horizontal reinforcement bars and then slide them back into position.
• Length of U-shaped horizontal bars used shall be 1 m for straight length and 300 mm for bend portion, wher-
ever required.

i. Corner –connection
• U-shaped horizontal reinforced bars
• U-shaped horizontal reinforced bars in the second wall
• Common vertical reinforced bars

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

ii. T-connection
• U-shaped horizontal reinforced bars in the wall to join
• Installation of the wall in T-connection
• Horizontal reinforced bars of a wall
• Common vertical reinforced bars

iii. Beam
• Vertical stirrups
• Horizontal reinforced bars

iv. Wall-floor connection

v. Starter bars
vi. Floor

Pouring of concrete
The pouring of concrete shall be done with a pump device or a
tipper. The following requirements shall be adhered to:
• The speed of concrete filling shall be limited to 1000 mm
per hour. Concrete is filled in layers up to 500 mm and
shall be filled up to a maximum height of 6 m in a day.
• If filling is done with a pump device, suitable measures
should be taken to cut the dynamic pressure of concrete.
A flexible rubber sleeve is secured with retaining rings to
the pipe of the pump device in order to limit the pressure of
concrete by compressing the hose manually.

In order to ensure the geometrical and mechanical properties

of the finished wall, the following checks are carried out during
concrete filling:
• Control and possible correction of verticality of the wall be-
fore hardening of concrete
• Visual verification of penetration of cement concrete in
joints between the strips so that all gaps are completely
filled. Cores shall be taken through the insulation at criti-
cal positions, such as below windows and at corners, to
establish integrity of concrete.

Roofs with pitch below and over 30º shall be constructed with
open and closed lattices respectively.
Insulating strips shall be cleaned with a water jet or brushed after
pouring of concrete to remove light leakage of laitance.

Finishing
Rendering
As there are significant regional differences due to availability of
local materials and climatic conditions, the recommendations of
the manufacturer of the material should generally be followed and
good trade practice regarding installation and sealing should be
observed. Renders should contact the local supplier to ascertain
the product best suited for finishing of the modules. If plastering
with cement mortar is to be done, the thickness of plaster shall be
15-20 mm.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Imbedding of ducts
• In self-extinguishing polystyrene panel conduits path shall be made.
• When thin hard panels are used for shuttering, conduits may either be surface mounted or inserted before
the concrete is poured.
• Alternatively, polystyrene strips may be inserted allowing the conduits to be installed at a later stage.

Fixing of objects
• It is possible to fix objects up to 80 kg per fixing device in the insulation strips.
• For other cases, the fixing devices should be inserted in the concrete.

SPECIAL FEATURES

Structural Stability
The technology used is to exploit concrete to the ultimate and standard solutions for reinforcement are used,
wherever required. Reinforcement, shall be placed according to the specifications, depending on the application
and shall be determined by structural calculations performed according to the IS 456:2000. In seismic prone ar-
eas requiring seismic resistant construction, relevant provisions of IS 1893 (Part 1):2016, IS 4326:2013 and IS
13920:2016 shall apply.

Durability
The modules provide maximum strength during concrete placement. Once complete, structures reach an incredible
structural integrity. When concrete is hardened, durability of steel wire is necessary in only those applications where
the adhesion of finishing depends on it, in addition to the adhesion between concrete and insulation and between
insulation and rendering.

Behavior in earthquake
The structure can be made earthquake resistant by applying provisions of IS 1893 and IS 13920.

Fire Safety
The assembled system is a continuous monolithic concrete system, thus without fire leakage through the assem-
bled system. The required rating is achieved with proper thickness of concrete and polystyrene/other strips.

Thermal Performance
Depending on the climate, a variety of
infill materials that completely and per-
manently insulate the building without
thermal bridges, can be chosen

Behavior in wind/hurricane
A Sismo building is extremely resistant
to the complex strains and thrusts due
to the force emitted by wind, hurricanes
and cyclones.

Light weight
Sismo modules weigh between 2 & 7
kg, eliminating the need for heavy and
expensive building equipment on site.
These can easily be handled and as-
sembled manually.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Fast implementation
The time required to raise buildings using this technology is significantly shorter than any conventional building
method.

MAJOR WORKS COMPLETED/UNDER COMPLETION

Sismo Building Technology, Belgium has constructed numerous residential and utility projects mostly in Belgium,
France, Portugal, Italy, Turkey, Korea and Middle East etc. The Indian firm is constructing about 70 (G to G+2) hous-
ing units at Kashipur (Uttarakhand) by using this technology. The project is likely to be completed by 2017. Police
Barracks (2500 sqft.) has been constructed at Siliguri. A project of construction of District Magistrate Office (7000
sqft.) at Cooch Behar, West Bengal is under progress. A Demonstration Housing Project of BMTPC at Lucknow
comprising of 40 houses in G+1 configuration is under construction.

CERTIFICATION

Performance Appraisal Certificate No. 1025-S/2016 issued to M/s M K S Infosolutions Pvt. Ltd., Manesar (Harya-
na) by BMTPC.

STANDARDS/REFERENCES

European Assessment Technical Regulation

Sismo technology: Plain concrete in high rise buildings by Sismo Engineering, Belgium
Guideline for European Technical Approval of ‘Non-load bearing permanent shuttering systems based on hollow blocks or
panels of insulating materials’ by EOTA, Brussels, Belgium
Experimental Research in 92-93 & 93-94 by Sismo Engineering & CE Deptt., University of Leunen, Belgium
IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 875 (Parts 1,2, 4 & 5) :1987 Code of Practice for Design Loads (other than earthquake) for Buildings & Structures (Part
3 : 2015)
IS 1893 (Part 1):2016 Criteria for Earthquake Resistant Design of Structure
IS 4326:2013 Code of Practice for Earthquake Resistant Design and Construction of Buildings
IS 4671:1984 Specifications for expanded polystyrene for thermal insulation purposes
IS 14862:2000 Specifications for Fibre Cement Flat Sheets (Reaffirmed 2015)

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Precast Sandwich Panel Systems
EPS based Systems



 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Advanced Building System - EMMEDUE

(Suitable for Low Rise to Medium Rise Structures)

ABOUT THE TECHNOLOGY

Expanded Polystyrene (EPS) Core Panel System is based on factory made panels,
consisting of self extinguishing expanded polystyrene sheet (generally corrugated)
with minimum density of 15 Kg/m3, thickness not less than 60 mm, sandwiched
between two engineered sheet of welded wire fabric mesh, made of high strength
galvanized wire of 2.5 mm to 3 mm dia. A 3 mm to 4 mm dia galvanized steel
truss wire is pierced completely through the polystyrene core at the offset angle
for superior strength and welded to each of the outer layer sheet of steel welded
wire fabric mesh. The panels are finished at the site using minimum 30 mm thick
shotcrete of cement & coarse sand in the ratio of 1:4 applied under pressure.
(Refer sectional details as shown). The shotcrete coat encases the EPS Core with centrally placed steel welded
wire fabric mesh.

The technology (developed about 30 years back) has been successfully

used in many countries like Morocco, Algeria, South Africa, Kenya, Austria,
Malasiya, Ireland, Romania & Australia with involvement of different agencies
and brand names.

Panel Types

The Panels being manufactured are of different types depending upon the
application. The details of different types of typical panels are given below:

Single Panel for structural uses

Longitudinal wire 2.5 mm / 3.5 mm ø spaced @ 65

mm
Transverse Wire 2.5 mm ø spaced @ 65 mm
Cross Steel Wire 3.0 mm ø approx 68 nos. / m2
Polystyrene Core Density ≥15 Kg/m3,
Thickness not less than 60 mm
Finished Masonry Not less than 130 mm thick

Single Panel for Internal partition, external walls and insulation

Longitudinal wire 2.5 mm ø spaced @ 70 mm

Transverse Wire 2.5 mm ø spaced @ 70 mm

Cross Steel Wire 3.0 mm ø approx 68 nos. / m2

Polystyrene Core Density ≥ 15 Kg/m3,

Thickness 40 mm to 320 mm
Finished Masonry 90 mm to 370 mm thick

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Single Panel for horizontal structure for floor/ roof

Longitudinal wire 3.5 mm / 4.5 mm spaced @ 65

mm
Transverse Wire 2.5 mm ø spaced @ 65 mm

Cross Steel Wire 3.0 mm ø approx 68 nos. / m2

Polystyrene Core Density 15 - 25 Kg/m3

Thickness 80 mm to 160 mm
Finished Masonry 155 mm to 235 mm thick
a = EPS Nominal Thickness (variable between 80 mm to 160 mm); b = Distance between thickness steel meshes (a + 10 mm);
c = Shotcrete thickness (average ≥ 25 mm); d = Total thickness (2xc+a)

Generally used for buildings of not more than 4 storeys for floor and covering slabs with maximum span of 4 m.

Floor Panel with reinforcement at joist

Longitudinal wire 2.5 mm ø spaced @ 70 mm

Transverse Wire 2.5 mm spaced @ 70 mm

Cross Steel Wire 3.0 mm ø approx. 68nos. /m2

Polystyrene Core Density ≥ 15 kg/m3

a = thickness of core; b = thickness of concrete; c = overall thickness

Panels are used for the floor and the roof system and reinforced in the joists with concrete casting on the site. The reinforcement of the panel is
integrated during the panel assembly by additional reinforcing bars inside the joists as per the design.
Suitable upto 8m span with the live load of up to 4 kN/m2.

Double Panel

External mesh
Longitudinal wire 2.5 mm ø spaced @ 65 m

Transverse Wire 2.5 m ø spaced @ 65 mm

Cross Steel Wire 3.0 mm ø approx 68nos. /m2

Polystyrene Core Density 25 Kg/m3 thickness 50

mm to 80 mm

Finished Masonry Finished inter-plate thickness 120

mm to 200 mm

Internal mesh
Longitudinal wire 5 mm ø spaced @ 100 mm
Externally the panels are sprayed with traditional pre-mixed
Transverse Wire 5 mm ø spaced @ 260 mm cement based plaster. The space between the panels are
Polystyrene Core Density 25kg/m3 thickness 50 mm filled with concrete. It functions as insulating elements as
to 80 mm well as formwork.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Connections

Connecting the wall panel By dowels embedded in concrete with adequate anchorage length.
to the concrete substrata

Coplanar panels By overlapping one row of electro-welded mesh and tying using 16 gauge
wire.

Walls panels and ceiling By protruding the inner vertical dowels that connect the upper and lower
panels of intermediate wall panels through. Then putting corner mesh, tied with 16 gauge wire to
floors the mesh of the lower wall panels as well as to the base mesh of the ceiling
panel. Openings for doors & windows etc. are braced using flat mesh at 45o
above and below corners of the opening.
Consecutive Floors Using the same dowels utilized to connect the walls of the first floor to the
foundation.
Additional reinforcement of electro–welded mesh is provided on edges and
diagonal fringe by tying on the inner and outer face of the panels by suitable
wire.

Staircase Panel

ax
cm m
120
var.

Variable tread and riser

Electrowelded mesh
ftk > 680 N/sq.mm.

va
r<
60
0
cm
of
fre
e
sp
an Foam polystyrene
density 15 kg/cu.m.

Additional reinforcement
(lattice of ribbed bars)
fyk > 430 n/sq.mm.

Galvanized steel wire mesh:

Longitudinal wires: 2.5 mm dia

Transversal wires: 2.5 mm dia
Cross steel wire: 3.0 mm dia
Polystyrene slab density: ≥ 15 kg/m3

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

FEATURES OF PANEL SYSTEM

Load carrying capacity

Numerous lab tests, performed in different parts of the world, have highlighted the high load carrying capacities of
the panels which after compression testing with centred
load performed on a single finished panel, 2700mm high,
have shown that they withstand a maximum load of up
to 1530 kN/m ≈ 153 ton/m. The Monolithic joints of the
building system provide a high level of structural strength
to buildings.

Seismic Performance
The prototype houses tested using both artificial and
natural accelerograms with peak values over 1.0g, came
through unscathed. Buildings made using panels are
particularly lightweight, so have a low seismic mass, but
are at the same time rigid due to two sheets of reinforced
plaster that interact to create an enveloping ‘shell’ of the
whole structure.

Thermal Behaviour
The thickness and density of the panel can be customised
to deliver specific thermal insulation requirements.
Furthermore, the EPS core extends throughout the surface
which makes up the building envelope eliminating thermal
bridging.
For example, a wall with a 80 mm core and finished
thickness of about 150mm provides the same thermal
insulation as an insulated solid masonry wall of about
400mm, with obvious advantages in terms of additional
space.

Acoustic Behaviour
The panel has good acoustic behaviour, coupling with
sound-absorbing materials (such as plasterboard, cork,
coconut fibre, rock wool, etc.), further optimizes the
acoustic insulation of walls.

Sustainability and Energy Efficiency

The insulating envelope provided by polystyrene core
eliminates thermal bridges and ducts within the panel. This
brings high level of energy efficiency. The system provides
significant improvements in indoor thermal comfort by
greatly reducing energy consumption and promoting
strategies aimed at sustainable development.

Fire Resistivity
The expanded foam polystyrene used for panels is
self-extinguishing and is perfectly encased by layers of
reinforced concrete as external coat to sides of the panel
and inhibit combustion. Fire resistance has also been
verified in tests performed in various laboratories. For
instance, a wall erected using a 80 mm core single panel

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

with 150 mm thickness provides REI* 150 fire resistance,

which means that for 150 minutes, the panel can resist
fire for 150 minutes with respect to load bearing capacity,
integrity and insulation.
* R=Load bearing capacity; E=Integrity; I=Insulation

Cost Effectiveness
Compared to traditional products, panels achieve far
better results, at considerably reduced cost. The speedy
construction represent additional savings.

Rapid Installation
The system has been used in many countries worldwide.
The construction experiences using the system show
a marked reduction in construction time compared to
traditional building methods. Panels are industrialized, and
for this reason, assembly processes are optimised, labour
is significantly reduced, and construction time decreased
by roughly 40%.

Lightness, Ease of Transport and Handling

Being light weight and rigid, panels are both easy to handle
and transport even in the most adverse conditions. Prior
to an application of shortcrete, a panel weighs between
3.5kg/m2 to 5 kg/m2 which means that a single worker can easily handle a 3 m2 wall, that is, a panel as high as the
storey height.

Versatility
The building system gives full design flexibility as it offers a complete range of building elements such as load-
bearing walls, curtain walls, floors and stairs.
The panels are easy to use in the construction of any type of structure, and can be shaped to any geometric
requirement i.e. flat or curved by simple cutting the panels at site.

Compatibility with Other Existing System

It is an extremely versatile building system which is completely compatible with all other existing construction
systems; in fact, panels are even suitable for completing reinforced concrete or steel structures. In addition, panels
can be easily anchored to other construction elements, such as steel, wood, and pre-stressed concrete.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Blast Resistance
A series of tests has been carried out on a variety of panels
finished with different types of high strength concrete. These
tests were conducted using a powerful explosive, in a test
chamber optimized to produce a uniform shock waves on the
face of the panels.
The panels performed excellently withstanding explosions of
29.5 tons/m2.

Wide Choice of Finishes

Buildings constructed using panels can be completed in a
variety of finishes, or can be painted traditionally on smoothed
plaster.
The surface of the walls has the appearance of a thin sheet
of reinforced plaster that can easily accommodate all types of
wall coverings including stone tiles and rain screen cladding.

Cyclone Resistant
Laboratory tests conducted on buildings, to determine the
resistance of cyclone impact and damage caused by wind-
borne debris confirm the strength of the building system
against such loads.
Building constructed in cyclone prone area have shown very
high resistance to cyclonic wind.

REQUIREMENTS FOR SETTING UP OF PLANTS

The viability depends upon the quantum of work. Generally

requirements of 1.5 lakh sqm of panel per year for minimum
period of three years makes the plant viable.

CERTIFICATION

BMTPC under Performance Appraisal Certification Scheme has

evaluated the System by EMMEDUE SPA, Italy and issued Per-
formance Appraisal Certificate No 1010-S/2014. The systems by
any other agency may required to be verified, appropriately.

STANDARDS/References

• Manual on M2 System by EMMEDUE, S.P.A. Italy.

• Manual on Schnell Home, Schnell Wire, Italy.
• Certificate No. 06/0241, Irish Agreement Board, Ireland.
• Technical Report on Experimental Evaluation of Building System M2 by Structure Lab. Department of Engineering,
Ponitificia Universidad Catolica Del, Peru.
• Review of EVG-3D Technology for residential buildings in India, IIT Mumbai, India.
• Report on Performance Tests conducted on EMMEDUE Panel System at Hesarghalta, Bangalore Civil Aid Techno
Clinic Pvt. Ltd., Bangalore.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Rapid Panels
(Suitable for Low Rise to Medium Rise Structures)

ABOUT THE TECHNOLOGY

The Rapid Panel is a prefabricated assembly of high-strength steel wire forming a panel with a core of expanded
polystyrene (EPS). During construction, Rapid Panels are installed as walls and/or slabs. Specified mixtures of
mortar or concrete are applied to the surfaces of the panels to complete the structure.

The basic unit of the Rapid Panel is the zig-zag truss. Steel wire is bent into a zig-zag shape to form a continuous
chain of web members. This bent wire is then welded to continuous chord wires at every node to form the complete
truss. (See Figs. 1 & 2)

The Rapid panels are manufactured in a fully automated plant. This technology was initially developed in USA and
the Indian firm has a collaboration with WorldHaus, California, USA. These panels are manufactured in Mexico and
there is no plant in India at present.

Fig. 1 Rapid Panel Fig. 2 Panel System Wall

PANEL TYPES

Wall panel
Top Wire 2.65 mm Ø
Top distribution wire 1.90 mm Ø
Truss wire 2.65 mm Ø
Bottom wire 2.65 mm Ø
Bottom distribution wire: 1.90 mm Ø
C < 0.153%, P < 0.016%
Chemical Composition S < 0.015%, Mn < 0.893%,
Si % < 0.134
Galvanizing Zinc coating of 60 gm/m2 ± 5 gm/m2
Mechanical characteristics:
1.9 mm dia
Yield stress > 680 N/ mm2,
Breaking load > 687 N/mm2,
Wall Panel
Elongation > 4.8%
2.65 mm dia
Yield strength >618 N/mm2
Breaking load >632 N/mm2
Elongation > 6.1 %

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Density > 15 kg/m3, Flammability:

Non Flammable, Moisture Continent
at 50ºC: <1.1%
Polystyrene Core
Thickness: not < 50 mm
Bead size: shall be > 95% between
0.5 – 1.12 mm as per ASTM C 578
The min. grade of concrete is M20
Cast-in-place concrete and slump for walls, floors and roofs
shall be as per IS 456:2000
Shall have a minimum 28-day com-
Cement Plaster
pressive strength

Roof Panel
Top Wire 2.65 mm Ø
Top distribution wire 1.90 mm Ø
Truss wire 2.65 mm Ø
Bottom wire 5.00 mm Ø
Bottom distribution wire: 1.90 mm Ø
C < 24%, P < 0.055%
Chemical Composition
S < 0.055%, Ceq< 0.52%
Zinc coating of 60 gm/
Galvanizing
m2 ± 5 gm/m2
Mechanical characteristics:
1.9 mm dia
Yield stress > 680 N/ mm2,
Breaking load > 687 N/mm2,
Elongation > 4.8%
2.65 mm dia Roof Panel
Yield strength >618 N/mm2
Breaking load >632 N/mm2
Elongation > 6.1 %
5.00 mm dia
Yield strength 670 N/ mm2,
Breaking load 816 N/mm2,
Elongation > 14%
Density > 15 kg/m3, Flammability:
Non Flammable, Moisture Conti-
Polystyrene Core
nent at 50ºC: <1.1%
Thickness: not < 50 mm

MATERIAL REQUIREMENTS

Galvanised high strength steel wire: Fe 500 & Fe 550 as per IS 1786: 2008

Ordinary Portland Cement: 43 grade as per IS 269:2015.

Fine aggregate: 4.7 mm size for concrete as per IS 383:2016 and plaster of sand 150 micron – 2.36 mm as per IS
1542:1992

Coarse Aggregate: of 20 mm & 40 mm size as per IS 383:2016

Steel reinforcement: as per IS 1786:2008.

Gypsum Plaster board: as per IS 2095 (Part 1):2011.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Adhesive: as per ASTM C 881

Plasticizers: as per IS 9103:1999

Waterproofing compound: as per IS 2645:2003

Fibers: Polypropylene fiber mesh as per EN 14889-2:2006

Ledger Bolt: Consists of 12.7 mm diameter L-shaped bolt with washers and nuts as per ASTM A 307. It shall be
fastened to the panel wire sand plastered.

Hartco clips: Formed from 11.11mm-wide, No. 20 gauge cold-rolled steel and manufactured by Stanley Hartco or
Spenax Flex-C-Rings, No. 516 G100.

CONSTRUCTION PROCESS

The construction process of the panels is as follows:

The shop-fabricated panels consist of welded wire zig-zag trusses and a foam plastic core to which structure plaster
shall be applied on each side. The panels have vertical 75 mm deep 14 gauge (1.63 mm) wire trusses spaced at
50 mm centers with preformed 57 mm thick expanded polystyrene (EPS) foam strips between. The assembly is
held together with 14 gauge horizontal wires on each face at 50 mm centers electro welded to the truss chords. The
horizontal wires and vertical truss chords shall project 10 mm approx. beyond each foam plastic face to permit wire
embedment within cement and gypsum plaster finish applied to each face after erection on the site.

The panels are manufactured in 1.22 m widths and varying heights from 1.52 m to 3.55 m in increments of 100 mm.
The nominal thickness of the panel is 75 mm resulting in a finished wall thickness, after plastering, of 100 mm or
more.

Manufacturing Process
of Rapid Panels

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

APPLICATIONS

The panels shall be used for construction of buildings consisting of frame

structures, load bearing walls, floors and roof etc. for residential purposes
up to G+3 storey.

IMPLEMENTATION

Panel System

Raft foundation
For only ground floor and G+1 unit constructions. When the soil is strong
or when the soil is improved, this is done by using a slab/raft foundation.

Strip foundation
For only ground floor and G+1 unit constructions. When the surface soil is
in a terrain with vegetation or lime, and it is required to locate the founda-
tion in a stronger and deeper layer, this is done by using a strip footing.

Existing foundation
When a foundation already exists or when something is being constructed
over existing construction, steps given below shall be followed:
(i) Holes of 8 or 10 mm dia. of 100 mm depth every 400 mm shall be
drilled and lined up with inside of the wall.
(ii) High strength steel bars of 8 or 10 mm dia. shall be placed in every
hole leaving 400 mm of height above the foundation.
(iii) The wall panel shall be tied with bars of 8 or 10 mm dia. on the
outside of the mesh with steel wire, with a minimum of 3 ties per
bar.
Boundary Wall
Following procedure shall be followed for construction of boundary walls:
(i) Bars of 8 or 10 mm dia shall be placed on top of the foundation, alternating one on the outside of the founda-
tion and the other on the inside every 400 mm.
(ii) The bars that are placed on the inside shall be bent in such a way that they are rooted in the foundation.
(iii) The wall panel shall be located on the soil and plastered on the bordering side. They shall be placed in
groups of two or three.
(iv) The mortar layer shall be dried, and the wall panel erected while straightening the interior bars.
(v) Finally, the wall panels shall be tied to the bars on both sides perfectly and plastered on the interior.

Wall Panels
Exterior wall panels shall be set with a minimum 6 mm clearance between the concrete slab edge and the panel
reinforcement. The slab shall be attached with perimeter 63 mm-long by 3 mm thick steel hold-down connector
channels and 13 mm diameter foundation bolts placed at a distance of 1.22 m max. centers along width and at each
panel end. Panel reinforcement and connector channels shall be attached with 305 mm long, 12 gauge (2.06 mm)
wires extending approximately 45 degrees upward along each panel face from each channel end. The upper end of
the diagonal wires shall be attached to the panel reinforcement. Panels shall be joined along vertical edges with 203
mm wide strips of 14 gauge 51 square mm welded wire mesh on each face centered on the panel joint. The mesh
shall be attached to the vertical panel wire reinforcement with Hartco clips spaced 305 mm on center at the edge
wires and 610 mm on center at interior wire Panels shall also be joined on both sides with 14 gauge wire trusses).

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Interior wall panels shall be set and attached to hold-down connector

channels with 12 gauge wires in the same manner as exterior panels.
Approved powder-actuated anchors shall be used, provided they are
adequate for applicable uplift loads. A nonstructural plaster ground shall
be attached at the base of the interior panels if desired.

Roof and Floor Panels

The panels shall not be permitted to bear on wood-frame walls. Hori-
zontal diaphragms shall be permitted the same shear values as vertical
racking shear, provided the panels are fastened to each other and to
walls as described here.

Installation of Panels
The procedure for installing the panels shall be as follows:
i. The panels shall be put in place according to the building plan as
follows:
• It must be ensured that the rebar is on the bottom of the
panel.
• Each panel shall have a portion of wire mesh on the end
without polystyrene.
• The adjacent panel shall be inserted into this area thereby
locking them together. The overlapping wire mesh should
be tied together.
• The vertical rebar in the wall shall be allowed to go through
the polystyrene in the panels.
• It shall be necessary to cut some of the wire mesh to al-
low this. The rebar on the bottom of the panel shall not be
cut.
ii. The polystyrene in the areas directly over the walls shall be re-
moved.
iii. The rebar that bends into the panels shall be placed according to
the wall reinforcement and this bar shall be tied to the wire mesh
on top of the panel. The vertical rebar shall be extended as nec-
essary.
iv. The edge molds shall be placed around the perimeter of the panel
as follows:
• Each set of holes in the edge molds shall be tied tightly
to the panel
• It must be ensured that the edge molds are level and
straight.
• It must also be ensured that there is more than 50 mm clearance between the top of panels and top
of edge molds.
vi. A minimum M20 grade of concrete shall be used.

Supports and Cambers

Slabs for roofs and floors shall be made with slab panels and supported during erection with temporary beams with
props spaced at 900 mm, leaving a camber. The support beams shall be located on the bottom of the panel, always
perpendicular to the direction of the zigzag trusses in the panel.

Connections
All the connections for walls and slabs shall use the self-connection system, where the mesh on the end of the panel
shall be used to join the panels in different situations.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Door and Window

These shall be made by marking and cutting the mesh
of the wall panel with a circular saw, reciprocating
saw, or with wire cutters, and reinforcing the edges
on both sides with zigzag mesh. The zigzag mesh
should extend 300 mm from the edges of the doors
and windows. Afterwards, diagonal zigzag mesh shall
be installed on every corner of 400 mm.

Where edges and corners are reinforced, the poly-

styrene along the perimeter of the opening shall be
removed and the space is filled with mortar or con-
crete to form a rigid boundary. In the area on top of
the opening, the polystyrene shall be removed and
reinforcing steel placed to form a lintel beam.

Plumbing and Electrical Fixtures

Water pipes and electrical conduits shall be placed
within the panels as shown in the building plans by re-
moving polystyrene from the portion. For layers pipes
wire mesh shall be cut. Good practices of electrical
and plumbing services shall be adopted.

Plumb and Alignment

It shall be assured that the wall panel is plumb and
in line, and to maintain right angles between them,
tension wire and metal rulers shall be used. The poly-
styrene in the center of the panel shall be toothed on
the surface to ensure better mortar connection and
less wastage.

Finishing
i. Floor finishing
• It must be ensured that the floor area is com-
pletely clear of any debris, dust and soil etc.
• It must be ensured that the floor surface is
damp prior to finishing and it should be fully moist without any water stagnating on it.
• Cement mortar of mix 1 cement: 3 sand shall be prepared and required quantity of mortar shall be applied
to the floor to provide a smooth finish.

ii. Ceiling finishing

• A stiff mix of 1 cement: 3 sand mortar shall be prepared and applied to the ceiling, providing a level but rough
surface.
• It must be ensured that the first layer of plaster is damp prior to applying the finish layer.
• Cement mortar of mix 1 cement: 4 sand shall be prepared and required quantity of mortar shall be applied
to the ceiling to provide a smooth finish.
• The total thickness of the ceiling finish should not exceed 19 mm below the panel wire mesh.

iii. Wall finishing

• Cement mortar of mix 1 cement: 4 sand shall be prepared and 25 mm plaster shall be applied to the pre-
damp wall to give a finish surface.
• Wall plaster should be allowed to be cured for at least 7 days after placement.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Handling of Panels
These panels are composed of two layers of steel wire mesh with a layer of polystyrene in the middle. The bottom
side of each panel has rebar welded in which provides the strength that allows the panel to be used as a slab. The
wire mesh on the top and bottom are connected to each other with a ‘zig-zag truss’ of wire running between the two
meshes, welded at each joint. Good practices for handling of the panels shall be followed.

Cutting of Panels
As the panels are manufactured in a few fixed sizes, it shall be necessary to cut the panels to a smaller size. The
procedure for cutting of the panels shall be as follows:
• The length of the panel to be cut shall be measured and the measurement extended to the far-side of the
nearest cross-wire.
• Bolt cutters shall be used to cut the wires along the measured length on one side of the panel.
• Panels shall be flipped to the other side and bolt cutters used to cut the wires along the measured length on
the other side of the panel.
• Panels shall be allowed to stand on its end and bended to 90o to expose the ‘zig-zag truss’. The bolt cutter
shall be used to cut the exposed wires.

SPECIAL FEATURES

Structural Stability
IIT Madras has certified that RapidPanel Roofing slab system is found satisfactory for use in buildings, for imposed
loads (live loads) defined in IS 875 (Part 2):1987 on the basis of static tests under gravity loading.

Durability
On the basis of test conducted, the wall panel is capable of taking the min. load of 12.0 ton and no crack observed
on the surface of the wall panel

Behavior in earthquake
Load bearing wall panel system acts as a continuous shear wall system. It is analyzed as per box section and ad-
ditional vertical bars are fixed to the panels according to lateral analysis. Load bearing/shear wall panel system is
being used for structures upto G+5 in high seismic areas (zone v) having poor soil conditions to provide an economi-
cal and robust structure that meets codal seismic design requirements.

Fire Safety
For one hour fire-resistive wall assembly, the panels are covered with 29 mm thick cement plaster on both sides.
For two hour fire-resistive wall assembly, the panels are covered with 25 mm thick cement plaster followed by 12
mm thick light weight gypsum plaster or light weight cement plaster on both sides.

Thermal Performance
As per the tests conducted, the thermal transmittance U works out to 0.503 W/mK.

Shuttering
Rapid panel slab does not require conventional shuttering/formwork, as the EPS filler acts in this capacity.

Limitations of Use
• Panel lengths shall be up to 5 m, simply supported on beams or bearing walls not less than 125 mm in
width.
• Panels shall be installed with min. M20 grade of concrete and 1:3 cement plaster.
• Total dead load (including panel self-weight) shall not exceed 3.3 kN/m2
• Total imposed load (live load) shall not exceed 3.0 kN/m2.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

WORKS COMPLETED

1. (GF) house at Sarjapura, Bangalore of 200 sqm area

2. (B+G) house at Coorg, Bangalore of 300 sqm area
3. (S+2) Nirmithi Kendra at Bangalore of 120 sqm area
4. (S+2+H) flat at Bangalore of 180 sqm area
5. (S+2) flat at Bangalore of 120 sqm area
6. CSI Church at Hosur, Bangalore of 350 sqm area
7. (G+2) flat at Bangalore of 120 sqm area
8. (G+3) flat at Bhubaneswar of 200 sqm area

CERTIFICATION

Performance Appraisal Certificate No. 1026-S/2016 issued to M/s Worldhaus Construction Pvt. Ltd., Bangalore by
BMTPC.

STANDARDS/REFERENCES

• Legacy Report by ICC Evaluation Services Inc., USA

• Construction Manual by WorldHaus Construction Ltd., USA
IS 383:2016 Specifications for coarse and fine aggregates for concrete (Third Revision)
IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 875 (Part 1&2):1987 Code of Practice for Design Loads (Other than Earthquake) for buildings & structures: Part 1 Dead
Loads; Part 2 Imposed Loads (Reaffirmed 2013)
IS 1786:2008 Specifications for high strength deformed steel bars and wires for concrete reinforcement (Fourth
Revision) (Reaffirmed 2013)
IS 1893 (Part 1):2016 Criteria for earthquake resistant design of structures (Part 1) - General Provisions and Buildings
IS 1904:1986 Code of practice for design and construction of foundations in soils: General requirements
(Reaffirmed 2015)
IS 2095 (Part 1):2011 Specifications for gypsum plaster board (Part 1) - Plain gypsum plaster boards (Reaffirmed 2016)
IS 2645:2003 Specifications for integral water proofing compounds for cement, mortar and concrete
(Reaffirmed 2016)

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Reinforced EPS Core Panel System

(Suitable for Low Rise to Medium Rise Structures)

ABOUT THE TECHNOLOGY

Reinforced Expanded Polystyrene Core (EPC) Panel System is a factory produced panel system for the construc-
tion of low rise buildings upto G+3 and as filler walls in high rise RCC and steel frame buildings. In this technique, a
core of undulated polystyrene is covered with interconnected zinc coated welded wire mesh on both sided reinforce-
ment and shortcrete concrete.

The panels are finished on site by pouring concrete (double panel, floors and stairs) and spraying concrete to rea-
lise the following different elements of the system:

• Vertical Structural Walls

• Horizontal Structural elements
• Cladding elements

PANEL TYPES

The panels are of three types depending upon the application as shown below:

Single load bearing Panel

Longitudinal wires 2.5 /3.0 mm Ø @80 mm c/c

Transverse wires 2.5 /3.0 mm Ø @80 mm c/c
Connectors & cross wires 3.0 mm Ø @ 150 mm c/c
Density : ≥ 15 kg/m3
Polystyrene core
Thickness: 50 mm to 160 mm
conforming to IS 4671
Wave Depth: 15 mm
Finished Masonry Not less than 130mm thick

Single Non Load Bearing Panel

Longitudinal wires 2.5 /3.0 mm Ø @80 mm c/c
Transverse wires 2.5 /3.0 mm Ø @80 mm c/c
Connectors & cross wires 3.0 mm Ø @ 150 mm c/c
Density : ≥ 15 kg/m3
Polystyrene core Thickness: 40 mm to 280 mm
Wave Depth: 5 mm
Finished Masonry 90 to 370mm thick

Single Floor Panel

Used as floors or roofs span upto 5 m x 5m and supported by the walls in all the sides. The panels are finished on
site by 50 mm of casted concrete in upper side and 30 mm of projected plaster in the lower side.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Longitudinal wires 2.5 /3.0 mm Ø @80 mm c/c

Transverse wires 2.5 /3.0 mm Ø @75 mm c/c
Connectors & cross wires 3.0 mm Ø @ 150 mm c/c
Density : ≥ 15 kg/m3
Polystyrene core Thickness: 80 mm to 160 mm
Wave Depth: 5 mm
Finished Masonry Not less than 80mm thick

Two Pot Floor Panel

With span up to 9 m, these panels are characterized by the presence of joist. The joists are reinforced on site by the
steel bars according to the structural verification and are finished by 40 mm of casted concrete (M25) on the upper
side and 25 mm of projected plaster (M15) in the lower side.

Longitudinal wires 2.5 /3.0 mm Ø @80 mm c/c

2.5 /3.0 mm Ø @75/150 mm
Transverse wires
c/c
Connectors & cross wires 3.0 mm Ø @ 150 mm c/c
Density : ≥ 15 kg/m3
Polystyrene core Thickness: 40 mm to 280 mm
Wave Depth: 5 mm
Finished Masonry Not less than 65mm thick

MATERIAL REQUIREMENTS

Steel for both wire mesh and connectors.

Zinc Coating – The zinc covering is variable with the diameter of the wire mesh. Standard wire mesh shall be 3.0

mm dia and minimum zinc coating galvanizing shall be of 60 gm/m2.


Mechanical characteristics
Tensile strength (2.5 mm Ø) : ≮ 750 N/mm2
     :  
Tensile strength (3.0 mm Ø)
  
≮ 700 N/mm2
 
Yield strength
(2.5 mm Ø) 
:  N/mm
≮ 680 
2 
     
Yield strength (3.0 mm Ø) 
:   
≮ 600 N/mm 
2  
Elongation
    : 
> 8%  
         
 characteristics
Chemical      
% C
     : 
< 0.24   
    
%P :   
< 0.055
%S
   : Max 0.045  
 
%Ceq
     : <0.52
    
%Si
 : 0.300 – 0.600

APPLICATIONS
    
  
The panels are used 
as: 
 
i. 
load bearing walling in buildings
 
ii. 
non- load bearing wall panels
 
iii. infill
partition 
wall 
in multi storey framed buildings
iv. floor /
   roof slabs
     

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

INSTALLATION PROCEDURE

Foundations
Foundations for the EPS Core Panel system whether strip or raft are conventional. If strip foundations are used,
they should be levelled and stepped as this makes panel positioning easier.

For EPS Core panels, parallel sided timber or metal template of the width of panel shall be required to mark the
position of the wall panels on the foundation and the spacing of the starter bar holes.

Wall start-up
• Line wall positions shall be marked and profiled.
• A timber or metal template of the exact width of panel (from wire to wire) shall be used to mark the position
of the panels with chalk or pencil lines.
• On the panel, lines positions shall be marked to drill the starter bar holes. These should be in a zig zag
pattern at 600 mm centres on each side of the panels. Starter bars should be at all panel joints and on the
opposite side in mid panel plus at all wall corners and joints.
• Starter bars should be either 6 mm or 8 mm dia. 500 mm long with 100 mm drilled into the foundations and
400 mm above.
• Drill bits shall be used to give a tight fit with the starter bars.
• Once starter bars are in position, EPS Core panels shall be placed between the starter bars, starting from
a corner. Starter bars shall be wire-tied to the panel mesh and the panels to each other on the overlapping
mesh.

Wall construction
• All corners and wall joints shall be reinforced with right angled wire mesh to the full height of the walls.
LIGHTER
• To cut panels to fit for door & window openings, wire should be cut with a wire cutter or angle grinder. Mea-
FA S T E R
E A Ssure
I E and
R mark the cut lines before starting to cut.
• After the wire mesh has been cut, EPS shall be cut with a hacksaw blade or stiff blade hand saw.
• Added steel mesh reinforcement shall be required around door and window openings to ensure that no plas-
EPS Panel
ter cracks form in these areas. Mesh reinforcement strips shall be tied diagonally with wire around openings
before plastering.
^ŵĂƌƚǁĂLJƚŽƐƚĂLJĐŽŽůŝŶƐƵŵŵĞƌĂŶĚǁĂƌŵŝŶǁŝŶƚĞƌ
• Once wall panels are in place and tied together, bracing shall be required to hold them vertical before plas-
tering. This shall be done only on one side of the panels.
For load bearing walls (G+3), external wall cladding in traditional reinforced concrete
• Once the panels are plastered on one side, the wall bracing shall be removed after 24 h. Plastering on other
structures, non-load bearing partition walls, floors and roofs.
side can be done without bracing.
Faster Construction over traditional
Saving
Door andin electricity consumption
Window fittings
Saving
• in foundation
Fix cost
a metal angle due
iron or to reduced
hollow tube structural weight
sub frame into the openings before plastering. Fix and plaster these in
place and then secure the frames to the sub frame.
Bringing to India, renowned Italian building technology from Schnell
• In order to secure heavy door/window frames, the EPS where the bolts are to be fixed to the wall, shall be

Expanded polystyrene sheet assembled together with welded wire-mesh

71
EPS Panels are used in construction of
 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs


burnt or cut and this space shall be filled with
mortar or concrete to hold the bolts.

Plastering
• Plastering shall be done by machine or hand.
The indicative quantity of each material per m3
shall be:
(i) Cement: 350 kg 
(ii) Sand with mixed granulometry: 1600 kg. 
Sand should be without clay or any organic sub- 

stance and totally washed.

(iii) Water – 160 l. The quantity of water may be
different according to the natural sand moisture.
W/C = 0.52 and I/C = 4.50 shall be maintained.
• Any problem of workability should be solved
without adding water. The retraction cracks for-
mation may be avoided by adding polypropyl-
ene fibers in the mix (1kg/m3).
• In order to control the final plaster thickness,

some guides should be used. These shall be re-

moved as soon as the plaster ‘sets up’ and the
spaces are filled and are smoother before the
plaster gets dry.
• Spray application should be done in two steps
with a first layer covering the mesh applied on
both the sides of the wall and the finishing layer
as soon as the first layer gets dry. 

Plumbing and electrical fittings
• Plumbing and electrical conduits shall be be- 
hind the panel wire mesh before plastering.
• The space behind the wire mesh shall be
opened up by using a blow torch to partially 
•
melt the EPS along the lines of the conduits.
As the EPS used in the panels is fire retardant,

it will melt under the flame but not burn.
• The wire mesh shall be cut with wire clippers to
make space for DB boards, switches and plug
boxes.

Connection
The Reinforced EPS Wall system is composed by pan-
els consisting of a polystyrene sheet assembled together with welded wire mesh.

SPECIAL FEATURES

Structural Stability 
Numerous lab tests, performed in different parts of the world, have highlighted the high load resistance of the panels
which after compression testing with centred load performed on a single finished panel, 2700 mm high, have shown
that they withstand a maximum load of up to 1530 kN/m =153 ton/m. The Monolithic joints of the building system
provide a high level of structural strength to buildings.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Durability
Durability is achieved with the use of proper grade and thickness of concrete as per IS 456. Minimum 45 mm thick
plaster is recommended for structural and fire safety point of view.

Behaviour in earthquake
Buildings made using panels are particularly lightweight, so have a low seismic mass, but are at the same time rigid
due to two sheets of reinforced plaster that interact to create an enveloping shell of the whole structure.

Fire Safety
The quality of the expanded foam polystyrene used for panels is self-extinguishing and is perfectly encased by lay-
ers of reinforced concrete as external coat to sides of the panel and inhibit combustion.

Thermal Performance
The thickness and density of the panel can be customized to deliver specific thermal insulation requirements.
Furthermore, the EPS core extends throughout the surface, which makes up the building envelope eliminating

thermal bridging. For example, a wall with 80 mm core and finished thickness of about 150 mm provides the same

thermal insulation as an in-
sulated solid masonry wall of
about 400 mm, with obvious
advantages in terms of addi-
tional space

Acoustic Performance
The panel has got good
acoustic behaviour, coupling
with sound-absorbing mate-
rials (such as plasterboard,
cork, coconut fibre, rock
wool, etc.), further optimizes
  the acoustic insulation of
those walls.

Behaviour under high winds/Cyclone

Laboratory tests conducted on buildings, to determine the resistance of cyclone impact and damage caused by
wind- borne debris confirm the strength of the building system against such loads. Building constructed in cyclone
prone area have shown very high resistance to cyclonic wind.

Sustainability and Energy efficiency

The insulating envelope provided by polystyrene core eliminates thermal bridges and ducts within the panel. This
brings high level of energy efficiency. The system provides significant improvements in indoor thermal comfort by
greatly reducing energy consumption and promoting strategies aimed at sustainable development.

Cost Effectiveness
Compared to traditional products, panels achieve far better results at considerably reduced cost. The speedy con-
struction represent additional savings.

Lightness, ease of transport and handling

Being light weight and rigid, panels are both easy to handle and transport even in most adverse conditions. Prior
to an application of shotcrete, a panel weighs between 3.5 kg/m2 to 5 kg/m2 which means that a single worker can
easily handle a 3 m2 wall, i.e. a panel as high as a storey height.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

MAJOR WORKS COMPLETED

At Angul, Odisha:

Load Bearing Structures

• Construction of C, D & F type flats of 3 to 4 storey having a total of 70 flats
• Construction of G type flats of 3 storey having a total of 60 flats
• Construction of Police Quarters of 3 storey having a total of 18 flats

Partition Walls for Non-load Bearing Structures

• Construction of C & D type flats of 3 to 4 storey having a total of 38 flats

CERTIFICATION

Performance Appraisal Certificate No. 1020-S/2015 issued to M/s Jindal Steel & Power Ltd., Angul, Odisha by
BMTPC.

STANDARDS/REFERENCES

IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 4671:1984 Specifications for expanded polystyrene for thermal insulation purposes



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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

QuickBuild 3D Panels
(Suitable for Low Rise to Medium Rise Structures)

ABOUT THE TECHNOLOGY

In quick build 3 D Panel system, the panels consist of fire resistant grade insulated
polystyrene core, two engineered layers of Galvanized Steel Mesh and galvanized
steel trusses. The steel trusses are pierced through the polystyrene core and welded
to the outer layer sheets of Galvanized steel mesh.

The wall panel is placed in position and a wythe of structural plaster is applied to both
sides. The wall panel receives its strength and rigidity from the diagonal cross wires
welded to the welded-wire fabric on each side. This combination produces a truss
behavior, which provides rigidity and shear terms for a full composite behavior.

The shell of the structure is built by manually erecting the panels directly onto the
slab with reinforcement rods. Desired utilities like doors, windows and ventilators
may be pre-built while plumbing, electrical conduits may be added onsite.

These panels are used in the construction of exterior and interior load-bearing and
non-load bearing walls and floors of buildings of all types of construction.

The details of these panels are shown in figures given at the right.

PANEL TYPES

The panels being manufactured are of three types depending upon the application. The details of different types of
typical panels are given below:

Wall Panel
Longitudinal wire 2.5 mm Ø @ 50 mm
Transverse 2.5 mm Ø @ 50 mm
Steel truss wire 3.0 mm Ø pierced through the core at
offset angle @ 100 mm spacing
Chemical Composition C < 0.24%, P < 0.055%
S < 0.055%, Ceq< 0.52%
Galvanizing Zinc coating of 60 gm/
m2 ± 5 gm/m2
Mechanical
characteristics:
Yield stress > 600 N/ mm2,
Breaking load > 680 N/mm2,
Elongation > 8%
Polystyrene Core Density > 15 kg/m3
thickness 50/80/100 mm
Self-load 120 kg/m2
Load bearing 350 kN/m
Plaster ratio: 1st coat of 20 mm of 1:2:3 (1 cement: 2
In two coats sand: 3 chips) 2nd coat
of 10 mm of 1:5 (1 cement: 5 sand)

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Roof Panel

Longitudinal wire 2.5 mm Ø @ 50 mm

Transverse 2.5 mm Ø @ 50 mm
Steel truss wire 3.0 mm Ø pierced through the core at
offset angle @ 100 mm spacing
Chemical Composition C < 0.24%, P < 0.055%
S < 0.055%, Ceq< 0.52%

Galvanizing Zinc coating of 60 gm/

m2 ± 5 gm/m2
Mechanical
characteristics:
Yield stress > 600 N/ mm2,
Breaking load > 680 N/mm2,
Elongation > 8%
Polystyrene Core Density > 15 kg/m3
thickness 50/80/100 mm
Self-load 280 kg/m2
Load bearing 10 kN/m2
Plaster ratio 30mm thick: 1st coat of 20 mm of 1:2:3 (1 cement: 2
In two coats sand: 3 chips) 2nd
coat of 10 mm of 1:5 (1 cement: 5
sand)
Concrete 75 mm thick: 1:2:4 (1cement: 2 sand: 4 chips 50% of
size < 18mm + 50% of size < 10mm)

Staircase Panel
This panel consists of expanded polystyrene block shaped according to designing requirements and reinforced by
a steel mesh. The block is joined by steel wire connectors welded in electro-fusion across the polystyrene core.
These are used for the construction of flight of stairs up to a max span <6m having a live load of 4kN/m2. The
reinforcement steel bars have to be placed inside the holes before concrete casting.

Longitudinal wire 2.5 mm Ø @ 50 mm

Transverse 2.5 mm Ø @ 50 mm
Steel truss wire 3.0 mm Ø pierced through the core at
offset angle @ 100 mm spacing
Chemical Composition C < 0.24%, P < 0.055%
S < 0.055%, Ceq< 0.52%

Galvanizing Zinc coating of 60 gm/

m2 ± 5 gm/m2
Mechanical
characteristics:
Yield stress > 600 N/ mm2,
Breaking load > 680 N/mm2,
Elongation > 8%
Polystyrene Core Density > 15 kg/m3
thickness 50/80/100 mm
Self-load 280 kg/m2
Load bearing 10 kN/m2
Plaster ratio 30mm thick: 1st coat of 20 mm of 1:2:3 (1 cement: 2
In two coats sand: 3 chips) 2nd
coat of 10 mm of 1:5 (1 cement: 5
sand)
Concrete 75 mm thick: 1:2:4 (1cement: 2 sand: 4 chips 50% of
size < 18mm + 50% of size < 10mm)

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

MANUFACTURING PROCESS

QuickBuild 3D panel is manufactured from welded wire space frame integrated with a polystyrene (EPS) insulation
core sandwiched between two layers of engineered galvanized steel mesh that are held together with steel trusses.
Steel trusses are pierced through the polystyrene core and welded to the outer layer sheets of galvanized steel
mesh to form a rigid panel.

For any structure, foundation is built using conventional methods, starter bars are cast into the slab. The panels are
erected vertical in plumb and temporarily supported by way of bracing Rebar which is set between the mesh and
the polystyrene (for easy wall alignment). Splice meshes are then fixed using fasterner tool. Door & window open-
ings can be cut both before or after panel erection. Roof panels are then erected and fastened with joining mesh.
Concealed plumbing and electrical wiring can be pre-built into the panel using hot air torch. Subsequently, doors
and windows are fixed. Structural plaster is finally applied pneumatically on both sides and concreting of exterior
side of the roof panel is done. Natural Curing is done for concrete to gain strength.

FIXING OBJECTS TO WALLS

• Light weight object: 2.5 mm screws, pins or similar devices may be used.
• Heavy object (shelves, water tanks etc.): Plastic
pins with 45 mm screws or similar devices are rec-
ommended.
• Very heavy object: During erection, metal pins may
be inserted in plaster pallets. Alternatively, threaded
pins fastened with epoxy resin may be used.

SPECIAL FEATURES

The panel receives its outer place strength and rigidity by

truss action. Outer shortcrete layers are the chaired mem-
bers.

Structural Stability
The monolithic structure of the panel in conjunction with
concrete enables a structure built with it to withstand earth-
quakes, hurricanes and high winds.
For load bearing structure of G+3 or higher in seismic prone
areas, analysis report from recognized Institute is recom-
mended for its safety against earthquake forces.

Durability
• Concrete of adequate grade and cover as per IS
456:2000 provides required durability to this struc-
ture.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

• Exterior coating may be applied to pro-

vide additional protection to the rein-
forcement against corrosion in aggres-
sive environment.

Behavior in earthquake
Buildings made using panels are particularly
lightweight, so have a low seismic mass, but
are at the same time rigid due to two sheets
of reinforced plaster that interact to create an
enveloping shell of the whole structure.

Water Tightness
Externally the walls shall be protected by an
approved render applied to minimum 35 mm
sprayed 25 MPa concrete. DPC/radar barrier
shall be installed at ground level to prevent
rising damp. DPC shall also be used around
window sills and a sealant shall be applied
around window or door frames.

Thermal Performance
QuikBuild panels are an efficient and thermally advantageous solution for all construction needs. These panels are
the rigid foam insulation that provides long term thermal resistance that does not need to be adjusted for age.

Acoustic Performance
The panels have superior sound dampening capability compared to masonry walls and this can be further en-
hanced by increasing the core thickness. Up to 50 dB insulation.

Behavior in moisture/humidity
The panel is excellent for preventing condensation/absorption on interior walls. The external walls/roof can use
waterproofing mortar for additional protection.

Optimize Energy Performance

• QuikBuild panels are an efficient and thermally advantageous solution for all construction needs. The panels
are manufactured in varying thicknesses to meet the environmental design criteria to deliver a range of R-
value specifications.

Recycled Content
• About 10% to 20% of the materials are recycled.

PRECAUTIONS
• Do not overload partition walls on one side only. Instead, spray the concrete on both sides alternatively
• If the panel is cut during erection and its meshwork has no wire-crossing points, panels should be joined with
flat meshwork (min. width 225 mm)

APPLICATIONS

• The technology is used in the construction of exterior and interior load-bearing walls upto 3 storeys and
non-load bearing walls and floors of buildings of all types of construction.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

MAJOR WORKS COMPLETED

• Christ College, Kilacherry (T N) in February 2012

• Meridian Hotel, White Field, Bangalore in May 2013
• Bethany School, Koramangalka, Bangalore in October 2013
• Sure Energy Systems Pvt. Ltd., Hyderabad (AP) in November 2013
• VTRC Ponmeni, Madurai (TN) in December, 2013
• Vineetha Industries, Adugodi, Bangalore in January 2014
• SERC Taramani, Chennai (TN) in February 2014
• VME Reality, Chembarabakkam (TN) in May 2014
• KPCL Wood House, Kovalam (TN), August 2014
• Champs Empowering Education, Hyderabad (AP) in August 2014

CERTIFICATION

Performance Appraisal Certificate No. 1019-S/2015 issued to Beardsell Ltd, Chennai by BMTPC.

STANDARDS/REFERENCES

• Axial Compression Test and Static Flexural Test on Panels as Wall elements and Roof or Slab elements respectively
by IIT Madras
• Pull off test on plastered surface of structural concrete insulated panels at Bangalore by Civil-Aid Technoclinic Pvt.
Ltd. Bangalore
• Report on Shaking Table Test of a 1:2.35 Scale 4-Story Building Constructed with 3D Panel System University of
Technology, Iran.
IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 875 (Part 1):1987 Code of Practice for Design Loads (Other than Earthquake) for buildings & structures: Part 1 Dead
Loads (Reaffirmed 2013)

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Concrewall Panel System

(Suitable for Low Rise to Medium Rise Structures)

ABOUT THE TECHNOLOGY

The Concrewall System is an industrial system for the construction of structural walls of
reinforced concrete for building in single panel up to G+3.

The system is composed of a factory produced panel of undulated (wave shape) poly-
styrene covered on both sides by an electro-welded zinc coated square mesh of galva-
nized steel and linked by 40 connectors per sq m made of high-elastic-limit, 3 mm dia
wires realizing a 3 dimensional hyper-static reinforced steel. (Figs 1 & 2)

The panels are assembled on site and in-situ concrete (double panels, floors, stairs)
Fig.1: Single (core)
and shotcreted concrete sprayed (single panel) to realize the following different ele-
ments of the system:
• Vertical structural walls
• Horizontal structural elements
• Cladding element
• Internal walls.
Fig.2: Cros-section

PANEL TYPES

Single Bearing Panel – Used as Load Bearing Wall

Fig. 3 Single Bearing Panel Fig. 4 Single Non-load Bearing Panel

Mesh
Width : 1235 mm
Longitudinal wires : 2.5/3.0 mm ø @ 80 mm c/c (max)
Transverse wires : 2.5/3.0 mm ø @ 75 mm c/c (max)
Connectors & cross wire : 3.0 mm ø @ 150 mm c/c

EPS
Density : ≥ 15 kg/m3
Thickness : 40 mm to 240 mm
Wave Depth : 15 mm

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Single Non Load Bearing Panel

Mesh
Width : 1235 mm
Longitudinal wires : 2.5/3.0 mm ø @ 80 mm c/c (max)
Transverse wires : 2.5/3.0 mm ø @ 75 /150 mm c/c (max)
Connectors & cross wire : 3.0 mm ø @150 mm c/c

EPS
Density : ≥15 kg/m3
Thickness : 40 mm to 280 mm
Wave Depth : 5 /15 mm

Single Floor Panel

Used as floors or roofs span upto 5 m x 5m and supported by the walls in all
the sides. The panels are finished on site by 50 mm of casted concrete in up-
per side and 30 mm of projected plaster in the lower side.

Mesh
Width : 1235 mm
Longitudinal wires : 2.5 / 3.0 mm ø @ 80 mm c/c
Transverse wires : 2.5 / 3.0 mm ø @ 75 mm c/c
Connectors & cross wire : 3.0 mm ø @ 150 mm c/c

EPS
Width : 1200 mm Fig. 5 Single Floor Panel

Thickness : 80 mm to 200 mm
Density : ≥15Kg/m3

Floor Panel with Joists

Galvanized steel wire mesh

Longitudinal wires : 2.5 mm ø every 70 mm
Transversal wires: : 2.5 mm ø every 70 mm
Cross steel wire: : 3.0 mm ø (approx. 68 per m2) Fig. 6 Floor Panel with Joists
Polystyrene slab density : ≥15 kg/m3

This panel is used for the floor and the roof system and it is reinforced in
the joists with concrete casting on the site.

The reinforcement of the panel is integrated during the panel assembly by

additional reinforcing bars inside the joists as per the design.

These are suitable for slabs having spans up to 8 m and with live loads up
to 4 kN/m2.

MATERIAL REQUIREMENTS

Raw Materials
• Steel for both wire mesh and connectors
Zinc Coating – The zinc covering is variable with the diameter of the wire mesh. Standard wire mesh shall
be of 2.5/3.0 mm ø and zinc coating galvanizing shall be of 60/90 gm/m2 with a tolerance of ± 5 gm/m2.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Mechanical characteristics
Tensile strength (2.5mm ø) : 750 N/mm2
Yield strength (2.5mm ø) : 680 N/mm2
Tensile strength (3.0mm ø) : 700 N/mm2
Yield strength (3.0mm ø) : 600 N/mm2
Elongation : > 8%
Chemical characteristics
%C : < 0.24
%P : < 0.055
%S : < 0.055
% Ceq : < 0.52

• Expanded Polystyrene – Self-extinguishing type EPS in accordance with IS 4671:1984 (UNI EN 13163:2013)
having density not less than 15 kg/m3.

PRODUCTION PROCESS

Concrewall Panels of different dimensions are produced with two raw materials namely steel wire in coils and
polystyrene blocks.

1. Galvanized wire: It includes the following phases:

• Perfect straightening and cutting of the required wires
• Assembly by electrical welding of the wires of different dia to make mesh of pre-established lengths

2. Polystyrene blocks EPS: The most complete hypothesis shall include the following:
Shape the dried blocks and cut sheets of a specific form and dimension according to the final type of product.
The possible scraps are grounded and recycled, within certain limits, in the production of EPS blocks on the
condition that these are first cleaned and are without any foreign substance, with particular attention to the
presence of dust.

3. Assembly:
Assembly of the Concrewall panel shall be made by electro-welding no.6 wires (in transversal and
perpendicular position with respect to the panel surface) with two meshes, forming a sandwich including the
EPS sheet between these, which has been previously inserted.

4. Operations ‘out of line’:

The production line is complete after cutting and bending of the external overlapping meshes.

INSTALLATION PROCEDURE

1. Foundations
Where Foundations for the Concrewall System are used, they should be levelled and stepped as this makes
panel positioning easier.
For concrewall panels, parallel sided timber or metal template of the width of panel shall be required to mark
the position of the wall panels on the foundation and the spacing of the starter bar holes.

2. Wall start up
• Line wall positions shall be marked and profiled.
• A timber or metal template of the exact width of panel (from wire to wire) shall be used to mark the
position of the panels with chalk or pencil lines.
• On the panel lines, positions shall be marked to drill the starter bar holes. These should be in a zig
zag pattern at 600 mm centres on each side of the panels. Starter bars should be at all panel joints
and on the opposite side in mid panel plus at all wall corner joints.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

• Starter bars should be either 6mm or 8 mm dia, 500 mm long with 100 mm drilled into the foundations
and 400 mm above.
• Drill bits shall be used to give a tight fit with the starter bars.
• Once starter bars are in position, place the Concrewall panels between the starter bars starting
from a corner. Starter bars shall be wire-tied to the panel mesh and the panels to each other on the
overlapping mesh.

3. Wall construction
• All corners and wall joints should be reinforced with right angled wire mesh to the full height of the
walls.
• To cut panels to fit for door & window openings, wire should be cut with a wire cutter or angle grinder.
Measure and mark the cut lines before starting to cut.
• After the wire mesh has been cut, EPS shall be cut with a hacksaw blade or stiff blade hand saw.
• Added steel mesh reinforcement shall be required around door and window openings to ensure that
no plaster cracks form in these areas. Mesh reinforcement strips shall be tied diagonally at every
corner of openings before plastering.
• Once wall panels are in place and tied together, bracing shall be required to hold them vertical before
plastering. This shall be done only on one side of the panels.
• Once the panels are plastered on one side, the wall bracing shall be removed after 24 hours. The
panels are now sufficiently stiff so that plastering on other side can be done without bracing.

4. Door and Window fittings

• Before plastering metal ‘cliscoe’ type window and door frames (which should be sized to the width of
the panels) may be fitted into the pre-cut panels.
• Metal ‘cliscoe’ type window frame fitted into future house panel before plastering.
• Metal lugs from the back of metal frames shall be wire tied to the panel mesh to keep the frames in
position.

For any other kind of frames, suitable method in accordance with the manufacturer’s specifications may be
used.

5. Plastering
• Plastering shall be done by machine or hand. The indicative quantity of each material per cum.
should be as follows:
• Cement: 350 kg
• Sand with mixed granulometry: 1600kg. Sand should be without clay or any organic substance and
totally washed.
• Water – 160 litres. The quantity of water may be different according to the natural sand humidity. The
parameters that should be constant are: W/C = 0.52 and I/C = 4.50.
• Any problem of workability should be solved without adding water. The retraction cracks formation
may be avoided by adding Polypropylene fibers in the mix (1kg/m3).
• In order to control the final plaster thickness, some guides should be used. These shall be removed
as soon as the plaster ‘sets up’ and the spaces are filled and are smoother before the plaster gets
dry.
• Spray application should be done in two steps with a first layer covering the mesh applied on both the
sides of the wall and the finishing layer as soon as the first layer gets dry.

6. Roof/floor panel
• After the vertical panels are assembled, verticality of the walls should be checked and the bending
meshes positioned on all the corners. Thereafter, horizontal bending meshes shall be placed to
connect the floor/roof to the vertical panels. The bending meshes should be fixed throughout the
perimeter of the floor/roof, at the level of intrados.
• When the horizontal bending meshes are fixed and checked floor/roof panel shall be placed on these.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

The lower mesh of the panel shall be fixed by steel wire to the bending meshes.
• Between the edges of floor/roof panel and vertical panel, gap of 35 mm should be left to ensure
structural continuity. The plaster applied on the walls shall be continued from one level to another
level.

Placing of the Concrewall elements for the floor and/or roof should be done before the application of the
external layer of plaster on the walls. Casting of concrete on the floor/roof panels (after placing the additional
reinforcing bars, if required) should be done after the walls are plastered and a number of props shall be put
to limit the deformation of the panel.

7. Plumbing and electrical fittings

• Plumbing and electrical conduits shall be behind the panel wire mesh before plastering.
• The space behind the wire mesh shall be opened up by using a blow torch to partially melt the EPS
along the lines of the conduits.
• As the EPS used in the panels is fire retardant, it will melt under the flame but not burn.
• The wire mesh shall be cut with wire clippers to make space for DB boards, switches and plug
boxes.

ADVANTAGES

Fast Construction
The speedy construction represent additional savings.

Design Flexibility
The building system gives full design flexibility as it offers a complete range of building elements such as load-
bearing walls, curtain walls, floors and stairs.

Ease of Use
The panels are easy to use in the construction of any type of structure, and can be shaped to any geometric
requirement i.e. flat or curved by simple cutting the panels at site.

LIMITATION OF THE TECHNOLOGY

Economical for mass housing only.

SPECIAL FEATURES

Structural Stability
The System receives its outer plane strength and rigidity by truss action where the shotcrete layers are the chord
members.

Durability
Durability shall be in accordance with IS 456:2000 which specifies exposure conditions, concrete strength and
cover requirements

Behavior in earthquake
Being light in weight, earthquake forces are less in the structure. With proper design and detailing, the structure
can be made safe.

Fire Safety
During the fire ignited inside the building (temp. raised up to 163°C), no distress/distortion of panels was observed
in any part of the unit except breaking of a window glazing.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Water Proofing
No dripping or leakage of water through slab during 24 h of ponding was observed except for minor damp patches
on the ceiling at few places.
The inner face of the wall was observed to be free from which was found to be within the permissible limits dampness
or sweating during 10 h of jetting at regular intervals of 30 min.

Thermal Performance
The reduction in outside and inside temperature was recorded up to 5.8°C indicating a good thermal comfort.

Acoustic Performance
Sound intensity was measured outside and inside the unit to know the difference in sound levels using sound
level meter. The results showed reduction of sound level by 35dB indicating a good acoustic comfort.

Behavior under high winds

The design of roof to wall connections shall be to a specific design to ensure that the roof structure is properly
restrained against uplift.

WORKS COMPLETED

Following 3 plants in India have been set up using Schnell

Machineries
• West: Maad Constructions Co Ltd, Pune, Maha-
rashtra
• East: Jindal Steel & Power Ltd, Angul, Odisha
• North: Synergy Thryslington, Mohali, Punjab

Buildings Constructed
• Industrial Township at Angul, Odisha
• Mass Housing, G+3 Buildings, at Vasai, Maharah-
stra
• Hostel & Hospital Buildgins in Punjab & Himachal
Pradesh
• Anganwadi Buildings across India by Vedanta
Group
• In-fill Wall used in different regions

Use with Other Systems

• In-fill Walls for Steel-frame & Floor Buildings
• Use with Al/Plastic Monolithic Formwork

CERTIFICATION

Performance Appraisal Certificate No. 1031-S/2017 issued to M/s Schnell Home, Italy by BMTPC.

STANDARDS/REFERENCES

IS 456:2000 Code of practice for plain and reinforced concrete (Reaffirmed 2016)
IS 4671:1984 Specifications for expanded polystyrene for thermal insulation purposes
BS 476(Part 22):1987 Fire resistance

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Precast Sandwich Panel Systems
Other Systems

Aerocon Panel Prefab Structur

Installation Guide
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Glass Fibre Reinforced Gypsum (GFRG) Panel

Building System
(Suitable for Low Rise to High Rise Structures)

About the technology

Glass Fibre Reinforced Gypsum (GFRG) Panel also known as

Rapidwall is 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. In recent times, 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 infilled for walling & floor/roof slab, suitable for low rise to medium rise (single to 10 storeys) building.

Classification

Class – 1 – Water resistant grade – GFRG panel for external walls, in wet areas and / or as floor and wall formwork
for concrete filling.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Class – 2 – General Grade – GFRG panels for structural application or

non–structural application in dry areas. These panels are unsuitable for use
as wall or floor formwork and

Class – 3 – Partition Grade – GFRG panel as non–structural internal

partition walls in dry areas only.

Application

GFRG panels may generally be used in following ways:

i) As load Bearing Walling – With cavities filled with reinforced concrete

is 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.

ii) As partition walls in multi storeyed frame buildings. Panels can also be filled suitably. Such walls can also be
used as cladding for industrial buildings or sport facilities etc.

iii) As compound walls / security walls.

iv) As horizontal floor slabs / roof slabs with reinforced concrete micro 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 (as shown below)

Enlarged view of a Typical Cell of GFRG Panel

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Mechanical Properties (unfilled panels) : test results

Mechanical Properties Nominal Value Remarks

Unit weight 0.433 kN/m2

Modulus of elasticity, EG 7500 N/mm2

Strength obtained from longitudinal
Uni-axial compressive strength, Puc 160 kN/m (4.77 MPa)
compression / tension tests with
ribs extending in the longitudinal
Uni-axial tensile strength, Tuc 34 – 37 kN/m
direction.
Ultimate shear strength, Vuc 21.6 kN/m

Out-of-plane moment capacity, Rib

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 1.6

Out-of-plane flexural rigidity, EI, Rib

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 Average water absorption by weight
Water absorption
3.85% : 24 hrs % after certain hours of immersion.
Fire resistance :
140/140/140 minutes CSIRO, Australia/ IS 3809:1979
Structural adequacy / integrity / insulation

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

Design

The design capacities of GFRG panel is based on limit state design procedures, considering the ultimate limit state
for strength design, treating the 3.0 m high GFRG panel as the unit material and considering the strength capacity
as obtained from the test results. The design shall be carried out by considering all possible loads (as per relevant
Indian Standards) to which the structure is likely to be exposed in its service life. 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 available 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 competent structural
engineer. Manufacture of GRFG Panels with increased thickness (150 mm – 200 mm) with suitable flange thickness
can facilitate design and construction of taller buildings.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

The basis arrangement of GFRG Panel Building System is as fol-

low:

Transportation

The GFRG panels are transported from factory to site, generally

through trucks or trailers. The panels are kept in a vertical position
using “stillages” so as to avoid any damage during transportation.
The panels after reaching the site are taken out from trucks using
cranes. Forklifts can be used for easier movement of panels.

Construction

The foundation used for the construction is conventional and is

designed generally as strip footing depending upon the soil condi-
tion.

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 waterproof-
ing are required to be followed during construction.

Limitation

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

• The system is ideal if the same floor / roof is replicated for all floors in multi storeyed structure. For any variations,

92
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

a structural designer needs to be consulted.

• The panels are not suitable for curved walls or domes. In case it is essential, use masonry / concrete for that
particular area.
• The electrical / plumbing system should be such that most of the pipes go through the cavities (in order to facilitate
minimum cutting of panel)

Other Features

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 materials. 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 storeyed mass housing.

Versatility
Panels can be used not only as walls but also as floors, roofs and staircase.

Speed of Construction
Using the system, the construction of a building is relatively faster as compared to the conventional building. One
building of two storeyed (total 185 sqm with four flats) was constructed in IIT Madras in one month.

Lightness of structures bringing safety against earthquake forces

These panels are very light weight (43 kg/m2). Even after filling some of the cavities with concrete, the overall build-
ing weight is much less, contributing to significant reduction in design earthquake forces and savings in foundation
and overall buildings cost especially in multi – storeyed buildings.

Few Building Constructed/under construction in India

• Residential buildings at Udipti Karnataka owner Mr. Satish Rao, built by
Harsha Pvt. Ltd., Udipi, Bangalore.
• Utility Building for Konark Railways at Madgao, South Goa, built by Harsha
Pvt. Ltd., Udipti, Bangalore.
• Residential building at Udipti by Harsha Pvt. Ltd.
• 3 storey residential building at Calicut by NMS Rapidwall Construction
Company, Calicut (2014).
• Two storeyed building at IIT Madras.
• Residential building at RCF Mumbai.
• Model house at Cochin.
• Demonstration houses (36 DUs) at Nellore, Andhra Pradesh.
• Construction of IIT Tirupati Building at Tirupati.

Certification
• Performance Appraisal Certification PACs No. 1008-S/2011 issued to M/s Rashtriya Chemicals and Fertilizers
Limited, “Priyadarshini”, Sion, Mumbai.
• Performance Appraisal Certification PACs No. 1009-S/2012 issued by FACT – RCF Building Products Ltd.,
FACT Cochin Division Campus, Ambalamedu, Kochi.

References
• GFRG / Rapidwall Building Structural Design Manual, prepared by IIT Madras, published by BMTPC, New Delhi.
• Schedule of Item & Rate Analysis for GFRG Construction, BMTPC, New Delhi.
IS 3809:1979 Fire Resistance Test of Structures

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Prefabricated Fibre Reinforced Sandwich Panels (Aerocon)

(Suitable for Load Bearing Panels in Single Storey and as Non-Load Bearing Panels for Low to High Rise Structures)

About the technology

Aerocon
Aerocon Panelare
panels Prefab Structures
Prefabricated Fibre Reinforced Sandwich Panels, made of two fibre reinforced cement facing
Installation Guide
sheets, on either sides of a lightweight concrete core. The core is made from a mix of Portland cement, binders and
silicaceous & micaceous material aggregate. These panels have a unique tongue and groove jointing system that
facilitates rapid construction and are fully cured at the factory itself. These panels are of manufactured by using
Flexo Board (FOB)/ Fibre Cement Board (FCB). Details of these panels are shown in Figs. 1 to 3:

Product range:

S.No Fig.1
HIL LTD
Sizes Thickness
Fig.2 Edges
Fig.3

(Formerly Hyderabad Industries Limited)

1 2400 Height x 600mm width

(a C.K Birla Group Company)
The product range of these panels shall be as under:
Square edge
2 2700 Height x 600mm width 50 & 75mm
S. No Sizes Thickness Edges
Recess edge
1. 3 30002400 mm x
Height height
600mmx 600 width
mm width 50 mm & 75 mm Square edge
(Fig. 4)
2. 2700 mm height x 600 mm width
Recess edge (Fig. 5)
3. 3000 mm height x 600 mm width

Square edge Panel Recess edge Panel

Partition
Fig.4 Square edge Panel
Partition (flush joint)
Fig.5 Recess edge Panel

94
Roofing Pre-fab. Structure / Partition
Mezzanine
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Uses of Aerocon Panels

These panels may be used for following applications:

hh Partitions - In Offices, malls, educational institutions, hotels/restaurants, Residential, commercial, educational
and industrial buildings
hh Prefab Structures (Single story- as load bearing & Non-load bearing applications)- Accommodation units,
site offices, security & store rooms, warehouse/go-downs, schools, army barracks, low-cost housing
hh Mezzanine Flooring - Industrial/SEZ, warehouse/go-downs, storerooms, shopping malls, etc.
hh Cladding - Shopping malls, school/college/university, duct covering, site offices & administration offices
hh Boundary/Fencing - Residential, commercial, defence, etc.
hh Fire Separation walls - Shopping malls, hotels, stair case enclosures etc.

Manufacturing Process

Prefabricated Fibre Reinforced Sandwich Panels are made up of two fibre reinforced cement sheets with a core
separating sheets. The core of the panels is of binders like portland cement and reinforcing bars such as cellulose
and synthetic binders. The core contains materials such as pulverized fly ash, light weight aggregates as fillers and
foaming agents. These materials are mixed thoroughly with water in conventional manner and sandwiched between
a pair of fibre cement facing sheets which is separated and supported by using conventional jigs and fixtures.

The adhesion between the core material and fibre cement sheets is achieved by inorganic bonding by aeration while
manufacturing the panel in-situ. The panels are allowed to harden for a predetermined period and thereafter jigs/
fixtures are separated. The panels are cured by retaining the humidity of the composite by wrapping the composite
with polymeric films. No water is used for curing.

Technical Specification

S. Properties Test Method Requirements *

No.
50 mm thick 75 mm thick
FOB FCB FOB FCB
1. Weight (dry) (kg/m2) Nominal weight 39 38 54 51
2. Axial load (kN/m) Factor of safety = 2.5
53 50 83 65

3. Bending (kg/m2) Factor of safety = 2.5

(a) 1.5m span 66 -- 95 --
(b) 2.9m span 198 300 265 400
4. Flexural strength (kg/cm2) IS 2380 (Part 4):1977 67 42 58 48
5. Compressive strength (kg/cm )2
Typical test results 30 -- 40 --
6. Thermal conductivity (W/mº.K) IS 3346:1980/ BS 4370
0.22 0.16 0.21 0.17
(Part 2): 1993
7. Sound transmission class (dB) IS 9901 (Part 3): 1981/
34 37 37 39
IS 11050 (Part 1):1984
8. Fire resistance (minutes) IS 3809:1979/ BS 476
60 120 120 120
(Part 20-22):1987
9. Surface spread of flame BS 476 (Part 7): 1997 Class I Class I
10. Fire propagation index (I) BS 476 (Part 6): 1989 3.7 4.7 3.7 4.7
11. Ignitability BS 476 (Part 5): 1979 Class P Class P
(not easily ignitable) (not easily ignitable)
* The above requirements are the minimum values for the panels.

95
 taking normal to hard knocks and pressure in their stride.

4. a Full Height Partition - Laying Procedure :

 Recess or square edge panels are recommended for full height partitions.

Building Materials & Technology Promotion Council,

 Mark Ministry
the of Housing
floor & Urban
plan as Affairs drawing
per approved

 Cut the floor channels (F.C.) as per required lengths. Mark the ceiling with plumb to F.C. and fix ceilin
Installation of PanelS Applications & Jointing Procedure
channels with self-expansion screws.

Partition Walls  Place & fasten the F.C. with self expansion screws of size N 6 x 50mm at every 600mm centers on 50m
Laying Procedure for Partitions: Aerocon
facepanels are offered as a total system with a tongue and
of channel.
groove jointing system along with accessories like pre-designed steel channels.These panels slide in and rest snugly
Fullatheight partition
the base ,and you have ready –made system for easy  andTherapid
height needs to be checked
assembly.Aerocon panelsforare
each individual
strong enoughpanel
to before inserting, follow the same method for a
• Recess panels.
withstand orthesquare
rough andedge panels
tumble shall life.Mainly
of everyday be used for full height
because of their partitions.
high strength ratio, they are capable of
• Floor
taking plan
normalshall beknocks
to hard marked andas per approved
pressure  drawings.
Clean the The
in their stride. floor floor channels
channels, (F.C.)
tongue and groove& ceiling
portion Channels
of panels forshall be used
firm fixing.
for fixing of panels with self-expansion screws of size N 6x50 mm at every 600 mm center to center on 50 mm
4. a Full Height Partition - Laying Procedure
face of channel. Lift & keep the : 600mm side of panel parallel to floor. Keep the groove side of panel towards wall or colum
end.
• The heightorneeds
 Recess square shall be checked
edge panels for eachfor
are recommended individual
full heightpanel before inserting, the same method shall be followed
partitions.
for all panels.  Insert the panel by tilting it into ceiling channel first and then position the same from 14mm side of the F.C.
 Mark the floor plan as per approved drawing
• The 600 mm side of panel shall be lifted & kept parallel to floor. The groove side of panel shall be kept towards
wall
 Cut column
or the floor end.
channels (F.C.) as per required lengths. Mark the ceiling with plumb to F.C. and fix ceiling
channels
• The panel shall with self-expansion
be inserted screws.
by tilting it into ceiling channel first and then position the same from 14 mm side of
the floor channel as shown in Fig. 6.
 Place & fasten the F.C. with self expansion screws of size N 6 x 50mm at every 600mm centers on 50mm
• Thefacepanel shall be slowly pushed into the floor channel with two heavy duty screw drivers without damaging the
of channel.
corners as shown in Fig. 7.
 The height needs to be checked for each individual panel before inserting, follow the same method for all
• Thepanels.
panel shall be positioned & pushed towards wall and right angle of panel shall be checked as shown in Fig.
8.  If required insert plugs/ packings in Floor Channel to ensure right angle.
 Clean the floorshall
• Plugs/packings channels, tongue and ifgroove
be inserted, portion
required in of panels
floor for firmto
channel fixing.
ensure right angle.
 Apply the Jointing material entire length of tongue and groove for jointing and insert the next panel P
• The jointing material shall be applied along entire length
 Lift & keep the 600mm side of panel parallel to floor. Keep the groove of tongue
side
panel and
to of groove
panel
secure towards
a rattle forjoint.
free jointing
wall and inserting the next
or column
panel. The panel shall be pushed to secure
end.  a Slowly
rattle free
push joint.
the panel into the F.C. with two heavy duty screw drivers without damaging the corners a
 Complete the partition by joining panel by panel as per above procedure.
• The partition shall be completed by jointing panel aboveby fig.panel as per the above procedure.
 Insert the panel by tilting it into ceiling channelfirstPosition
and thenthe
position
panel &thepush
same from 14mm
towards side Check
wall. And of the F.C.
the right angle of panel
 For Joint finishing & Service lines refer Page No.19 & 22.

4. b Half Height Partition:

 If required insert plugs/ packings in Floor Channel to ensure right angle.
 AEROCON panels are ideal for half height partitions as these are single monolithic in nature and th
offer sturdiness.

 Apply the Jointing material entire length of tongue and groove for jointing and end
 Always insert the nextinpanel
the partitions Push
’L’ or ‘T’ the
shape of 300 to 600mm Panel width as shown in below fig.
panel to secure a rattle free joint.

 Complete the partition by joining panel by panel as per above procedure.

 For Joint finishing &Fig.6

Service lines refer Page No.19 & 22.
Fig.7 Fig.8
 Slowly push the panel into the F.C. with two heavy duty screw drivers without damaging the corners as
above fig.
Half height partition
Position the panel & push towards wall. And Check the right angle of panel
• The partitions shall always end in ’L’ or ‘T’ shape of 300 to 600 mmchannel
Fix floor panelwithwidth as shown
self -expansion in Fig
screws 9. 600 mm center to center.
at every
4. b Half Height Partition:
• The floor channel shall be fixed with self -expansion screws at every 600 mm center to center.
 The first panel starting from the existing brick wall should be fixed as below two options.
• The first panel starting from the existing brick wall should be fixed as per the following two options:
 AEROCON Option – 1are
panels Starting with
ideal for existing
half height brick wall, as
partitions a drill
theseshall be made
are singleOption to
– 1brick
monolithic inwall
Start with andand
existing
nature panel
brick atmake
wall,
thereforetheadistance of 300
two drill to brick wall and panel at the distance of 3
from top and bottom side of the panel and insert the steel rod.
offer sturdiness.
mm as shown in Fig. 10 from top and bottom side of the panel and insert the steel rod.
 Option – 2 Fix the L angle cleat at corner with Nut and bolt as shown below.
 Always end the partitions in ’L’ or ‘T’ shape of 300 to 600mm Panel width as shown in below fig.
7

 Fix floor channel with self -expansion screws at every 600 mm center to center. Fig.10
Fig.9 Option -1 Option -2

 The first panel starting from the existing brick wall should be fixed as below two options.

96
 Option – 1 Start with existing brick wall, make a two drill to brick wall and panel at the distance of 300mm
from top and bottom side of the panel and insert the steel rod.

 Option – 2 Fix the L angle cleat at corner with Nut and bolt as shown below.
 finishing & Service lines refer Page No.19 & 22.

f Height Partition:
ON panels are ideal for half height partitions as these are single monolithic in nature and therefore
diness.
Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition
nd the partitions in ’L’ or ‘T’ shape of 300 to 600mm Panel width as shown in below fig.

Option – 2 The L angle cleat shall be fixed at corner with nuts and bolts as shown in Fig. 11.
 The top end & free end walls must be covered using beading.
• The top end & free end walls must be covered using beading as shown in Fig. 12.
• Different materials like timber, medium density fibre boards, PVC, Aluminium etc. as per required design shall
 be Theusedtop asend
shown& free in Fig. 13. must be covered using beading.
end walls
• Fevicol shall be applied on the inner surface of the beading before fixing to the panels.
channel with self -expansion screws • at every
All 600
screws should
mm center to center.be dipped in Fevicol before fixing to the beading. In factories and workshops Aluminium/
galvanized iron
panel starting from the existing brick wall should be fixed as belowchannels
two options. (ceiling channel) shall be used as beading.
• Jointing material shall be applied on entire length of tongue & groove portion before fixing panels to improve
1 Start with existing brick wall, make a two drill to brick wall and panel at the distance of 300mm
and bottom side of the panel and insert thestability
steel rod. & prevent the lateral movement.

• NutWith
2 Fix the L angle cleat at corner with this
and bolt halfbelow.
as shown height partition will be ready for finishing.
 Different materials like timber, medium density fibreboards, PVC, Allumi
 The top end & free end walls must be covered
can beusing
usedbeading.

 Different materials like timber, medium density fibreboards, PVC, Alluminium etc. as per required design
can be used

 Different
Fig.11 materials like timber, medium density
Fig.12 fibreboards, PVC, Alluminium etc. as per required design
Fig.13
Option -1 Option -2  Apply Fevicol on the inner surface of the beading before fixing to the panels
can be used

Jumbo height partitions (above 3.0m)  AII screws should be dipped in Fevicol before fixing to the beading
 Apply Fevicol on the inner surface of 8the beading before fixing and
In factories to the panels. Aluminium / galvanized iron channels (ceiling c
workshops
•  Panel
AII partition work can
screws should be done
be dipped withoutbefore
in Fevicol steel frame up to 4.50 m height & 4.80 m width.
fixing to the
Apply beading
Jointing material on entire length of tongue & groove portion b
• Frame work shall not be required for these type
In factories and workshops Aluminium / galvanizedstabilityof partitions up
iron channels to 4.5 m. channel) can be used as beading.
(ceiling
& prevent the lateral movement.
• Panels shall be staggered for strength & rigidity as shown in Fig. 14. Height of the panels shall be decided
Apply Jointing material on entire length of tongue & groove portion before fixing panels to improve
 accordingly.
 Now the half height partitions are ready for finishing. For Joint finishing ref
• stability
Partition & prevent
shall be 
the
supplied withTop
lateral top support,
movement.
support, such
 Apply Fevicol on the inner surface of the
such
as steel, asbefore
steel,
beadingconcrete etc.concrete
fixing to the panels.
etc, is a must for such type
The floor & ceiling channel shall be fixed as per4. laidc procedure.
Jumbo Height Partitions
page no.22 (above 3.0 m)
•
 Now the half height partitions are ready for finishing. For Joint finishing refer
• For horizontal joining, the full length panel shall be before
 AII screws should be dipped in Fevicol fixing
fixed first to jointing
and the beadingmaterial shall be applied in the groove
 and Fix
In factories theAluminium
workshops floorAerocon
&/ galvanized
ceiling
Paneliron channel
partition
channelswork ascanper
(ceiling laid
be done
channel) procedure
without
can be used Steel . up to 4.50 m
frame
as beading.
4.portion.
c Jumbo Height Partitions (above 3.0 m)
• Hexagonal PVC/wooden beading shallon beentire
placed onFrame
top groove
workup of
is the
not 3 m panel
required forbefore
these placing
type the 1.5tomimprove
of panels
partitions panel
Aerocon Panel Apply Jointing
partition work canmaterial
be done length
without Steelofframe
tongue &to groove
4.50 portion
mtr. before
height fixing
& 4.80 mtr width. up to 4.5 mtrs.
and the same pushed into the ceiling channel
stability & prevent the lateral movement.as shown in Fig. 15.
• The 1.5 m panel should  comeFornext horizontal
in lower side andPanelsjoining
3 meter firstin upper
panel
are4.5
staggered
fix the
side full
for strength && lengthshown
proceed
rigidityinasthe
panel
similar and apply Jo
way.
below.
 Frame work is not
Nowbe required
thecompletedfor these
half height by type
partitions of partitions
are readyonefor byup to
finishing. mtrs.
The partition  shall fixing panels one asFor perJoint
thefinishing refer page no.22
above procedure. For joint finishing of
 panels,
PanelsClause 2.3.2.7 for
are staggered may be referred.
strength  Height
& rigidity as shown below. of the panels is to be decided accordingly.
•
4. c Jumbo  HeightPlacePartitions
hexagonal (above PVC 3.0 /m)WOODEN beading on top groove of
If the partition exceeds 4.50 m length and 4.80 m width, then steel support shall be provided as shown in
Height of the panels is to bepanel
 Fig.16. Aerocon Panel partition work and push the sameframe
can be
decided accordingly. done without Steel into the
up to 4.50ceiling
mtr. heightchannel as per below fi
& 4.80 mtr width.

 Frame work is not required for these type of partitions up to 4.5 mtrs.

 Panels are staggered for strength & rigidity as shown below.

 Height of the panels is to be decided accordingly.

9
Fig.14 Fig.15

 Next, the 1.5 Mtr panel should come in lower side and 3 Mtr
97
way. Complete the partition by fixing panels one by one9 as per
  Next, the 1.5 Mtr panel should come in lower side and 3 Mtr panel in upper side & proceed in the similar
way. Complete the partition by fixing panels one by one as per the above procedure.

 Now the Jumbo height partitions are ready for finishing. For Joint finishing refer page no.22

*Note: If the length of the Partition exceeds up to 4.50 mtrs length and 4.80 mtrs width then need to
provide the steel& support
Building Materials TechnologyasPromotion
per below fig. Ministry of Housing & Urban Affairs
Council,

1. Aerocon Pre-fabricated Structures: (Load Bearing Structure)

Aerocon Pre-fabricated structures are of two types:

a. Load bearing structures
b. Non-Load bearing structures

Aerocon Pre-fab. Structures: (Load Bearing)

Aerocon Load-bearing structures can be made based on size, location, Functional requirements we can
decide whether to go for Load bearing or Non load bearing structures.
1. Aerocon Pre-fabricated Structures: (Load Bearing Structure)

Aerocon Pre-fabricated structures are of two types: 10

1. Aerocon Pre-fabricated
a. Structures:
Load bearing structures (Load Bearing
Fig.16 Structure)
b. Non-Load bearing structures
Load-bearing structures (Single storey)
Aerocon
Aerocon Pre-fabricated Pre-fab. Structures:
structures are of two(Load Bearing)
types:
These structures
Aerocon shall be made
Load-bearing based
structures on
can size,
be
These load-bearing structures can made
be
location
based
designed
and
to on size,functional
a maximum location, requirements. These load-bearing
span ofFunctional
5200 mm requirements we can
a. Load bearing structures
structures decide
can bewhether
designedto to for
go a maximum
Load span
bearing or of 5.2
Non m bearing
load as these are suitable with roofing option of the panels
structures.
b. Non-Load bearing structures
as shown below Fig.
The17. Theoflength
length of each
each room can beroom
uptocan bei.e.
6 mtr. upeach
to 6room
m i. with
e. each room
a carpet with
area a carpet
of 5.2 x 6 mtr.area
Theseof 5.2 x 6
meter. These rooms cancan
rooms bebeconstructed inaarow,
constructed in row, with
with multiples
multiples of 5.2ofx 65.2
mtr.morxlesser
6 m.sizes also.
Aerocon Pre-fab. Structures: (Load Bearing)
Aerocon Load-bearing structures can be
Typical layout made based
for possible on size,
load bearing location, Functional requirements we can
structures.
Typical layout for possible load bearing structures is shown in Figs. 18 to 20.
decide whether to go for Load bearing or Non load bearing structures.
Individual House. Row Houses

These load-bearing structures can be designed to a maximum span of 5200 mm

The length of each room can be upto 6 mtr. i.e. each room with a carpet area of 5.2 x 6 mtr. These
rooms can be constructed in a row, with multiples of 5.2 x 6 mtr. or lesser sizes also.

Typical layout for possible load bearing structures.

These load-bearing structures
Fig.17 can be designed to a maximum span of 5200 mm
Fig.18

Individual House. Row Houses

The length of each room can be upto 6 mtr. i.e. each room with a carpet area of 5.2 x 6 mtr. These
rooms can be constructed in a row, with multiples of 5.2 x 6 mtr. or lesser sizes also.

Typical layout for possible load bearing structures.

Individual House. Row Houses

Back to Back Row Houses.

Fig.19 Fig.20
Note : Foundation & basement to be made as per site soil conditions and requirements.

98
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition
Back to Back Row Houses.
Details of typical foundation for walls and columns are shown below Figs. 21 & 22
Note : Foundation & basement to be made as per site soil conditions and requirements.

Fig.21 Fig.22

 Aerocon Panels with Recess/Square edge are recommended for construction of walls

Panels
 with
MarkRecess/Square edgeand
the four corners shallposition
be usedthe
for ‘L’
construction
Base plateofcomponent
walls. and check diagonals as per the
approved drawing.
• The four corners shall be marked and position the ‘L’ Base plate component and diagonals checked as per the
drawing as shown in Fig. 23.

Fig.23
Fix the base plate by drilling 12mm dia holes with Hammer drill and fasten self expansion Anchor
• The base plate shall
Fasteners
 Fix the base be
of fixed
plate size by8drilling
M x 12mm
by drilling 65 mm12mm dia/ holes
(Hilti
dia holes withwith
Fischer) hammer
Hammer drilldrill
andand fasten
fasten selfself - expansion
expansion anchor
Anchor
fasteners of size of
Fasteners M size
8 x 65
M 8mm (Hilti/Fischer)
x 65 as shown in Fig. 24.
mm (Hilti / Fischer)

  Fasten
Fasten the Floor
the Floor Channel
Channel with Nwith N 6 x 60mm
6 x 60mm Self expansion
Fig.24
Self expansion screws atscrews
600mmatcenter
600mm to center
center.to center.

  Start
Start erecting
erecting the Aerocon
the Aerocon panelspanels
from a from a corner.
corner. Ensure
Ensure with withthat
plumb plumb thatpanel
the first the first panel is perfectly
is perfectly 99
vertical.
vertical. After After
fixing fixing
at leastattwo
least two panels
panels on one on
sideone side
start start
fixing thefixing theatpanels
panels at right
right angle angle
as per theas per the
drawing to ensure
drawing stability
to ensure to the to
stability structure.
the structure.
 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

• The floor channel shall be fastened with N 6 x 60 mm self-expansion screws at 600 mm center to center.
 The day’s work must be stopped only after completing the four walls a
• The panels shall be erected from a corner. It shall be ensured with plumb that the first panel is perfectly vertical.
After fixing at least two panelstruss on oneand purlins
side start fixing the panels at right angle as per the drawing to ensure
stability to the structure.
• The corner cover plate shall be fixed from outside to make the corner rigid as shown in Fig. 25.
• Jointing material shall be applied on tongue & groove portion of the panels to make the joints firm.
• The second panel shall be positioned 550 mm away from the first panel and slowly drop slide towards first
panel. This technique enables fast & proper joining of panels. It must be started from the gable side and all sides
 The day’s work must be stopped only after completing the four walls and tying each other by
complete one by one.
truss and purlins
• During installation suitable temporary support shall be provided using 75 mm dia. timber log or M.S. pipes of
the Floor Channel50mmwith N 6grouted
dia firmly x 60mm Self
into the expansion
ground on either screws at 600mm
side of panels center to center.
in 450 angle.
• Every 3rd panel on either side should be tied with temporary support.
• Fixing of purlin shall be completely resting on panels and duly connected with base plates by fixing with M 10
ecting the Aerocon panels from a corner. Ensure with plumb that the first panel is perfectly
bolts & nuts.
. After fixing
• atTheleast
day’s two panels
work shall on one
be stopped onlyside
after start fixing
completing the the panels
four walls and at right
tying each angle
other byas per
truss the
and purlins.
g to ensure • stability
All panelstoshall
thebestructure.
fastened to the plinth with anchor bracket of size 75 x 75 x 75 x 6 mm thick as shown in Fig.
26.
• After completion of erection of pre-fab structure, the exposed anchor brackets shall be covered using M20
corner cover plate
concretefrom outside
with baby chips to
All make
frompanels the
outside. arecorner
fastenedrigid.to the plinth with Anchor bracket of size 75x75x75x6
 All panels are fastened to the plinth with Anchor bracket of size 75x75x75x6mm thk

 After completion of erection of pre fab structure, the exposed anchor brackets are to be covered
using 1:2:4 concrete with baby chips from outside.

Fig.25
After completion of erection of preFig.26
fab structure, the exposed anchor brac
Corner Joints
Corner Joints using 1:2:4 concrete with baby chips from outside.
The ‘L’ and ‘T’ joints shall be made by fastening straight ends of the panels with self-expansion screws or 10 dia. x
 The ‘L’and ‘T’ joints can be made by fastening straight ends of the panels with self expansion screws
100 mm long pin as shown in Figs.27 & 28.
Corner
or 10 dia. x 100 Joints
mm long pin.

 The ‘L’and ‘T’ joints can be made by fastening straight ends of the panels wit
or 10 dia. x 100 mm long pin.

Fig.27 Fig.28

 Position the panels in right angle (90 )and fasten with 150mm long self expansion screws at every
0

• The900coremmof one panel shall

lengthwise beHilti
using removed
makeupto 15 mm
or 150 mm depth in which
long pin the pin
as shown will be fastened only in the core,
above.
for filling grout cement.
• The panels shall be positioned in right angle and fastened with 150 mm long self-expansion screws at every
900 mm lengthwise using Hilti make or standard bolts 150 mm long galvanized/zinc coated threaded rod
dipped in sodium silicate. The bore shall be filled with sodium silicate & fly-ash.

100

 Position the panels in right angle (900)and fasten with 150mm long self exp
900 mm lengthwise using Hilti make or 150 mm long pin as shown above.
  Aerocon panels can be used for non-load bearing structures for walls in Multi-storey buildings to
replace claybricks or cement blocks.

 Aerocon panels are extensively used for non-load bearing structures without size & shape
constraints.
Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

 For non-load bearing structures, Steel Columns, Trusses and Purlins will designed as per soil
• 8mm dia. holes
condition shall be
and wind drilled at 600 mm centres height wise and 15 mm prepared groove shall be filled with
velocity.
grout cement using cocking gun.
•  The facing
Ensure forofquality
core (exposed part) shall
workmanship be structure
of the finished using siliconstage
at every acrylic
of paste. In case
fabrication asofper
external application,
drawings and
the joints shall
specification. be covered with steel cover plate to protect the corner from knocks and other mechanical
impacts.
•  Lintel
Ensurepanels shallstructure
that the be firmly is
fixed with fastening
complete the same
in all respect to lateral
before panels
erection with 12 mmpanels
of AEROCON dia. rods and cement
grout. Minimum bearing of 150 mm shall be maintained on either side.
 Fix the floor channel between two columns using self expansion screws at every 600 mm center to
Non-load bearing
center, structures
leaving gaps at door positions.
For non-load bearing structures, steel columns, trusses and Purlins shall be designed as per soil condition and
wind velocity. The floor channel shall be fixed between two columns using self- expansion screws at every 600 mm
centers,
Typicalleaving
Floor gaps at door
Plan for Nonpositions.
Load bearing structure:

Typical layout plan for a non-load bearing structure is shown below in Fig.29.

Fig.29 Typical layout plan for a non-load bearing structure

Doors and Windows

Mild Steel, Wooden and Aluminium doors and windows can be fixed with Prefabricated Fibre Reinforced Sandwich
Panels.

Electrical Wiring

External wiring : External wiring shall be done on the panels by using PVC caps/pipes duly fixed to the surface.

Concealed wiring
• Surface routing shall be done by cutting the facing sheet and removing core.
• Face chasing should be avoided for panels used in prefab structure external and load bearing especially the
panels on which the trusses & purlins are fixed.
• Maximum depth of route shall be 50 percent of the thickness of material
• Switch box upto 40 mm depth shall be fixed in 50 mm panels and upto 60 mm depth in 75 mm panels.
• Load bearing walls should not be routed horizontally.

101
 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Plumbing Installation
• In Prefab structures, the toilets can be constructed with these panels. The required pipelines shall be fixed
on the panel externally.
• If pipe lines need to be concealed, a false wall should be created with 50/75 mm panel to the required height
on the internal side only.
• Water Closet (WC) shall be fixed with bolts & nuts. However, detailing needs to be worked out based on site
conditions. The WC shall preferably be fixed on floor and bolted to the panel wall.
• The surface of the panel shall be treated with marble/ granite/ceramic/glazed tiles using appropriate tile
adhesive chemicals as per the procedure recommended by the tile adhesive manufacturer. It is recommended
to use smaller tiles.

Supply of the Panels

The manufacturer has supplied the panels as per the details given below:

S. Name & location of the Client Quantity supplied Period of

No. (sqm) approx. supply
1. Classic Mall, Mumbai for construction of Phoenix Mall 20000 2012
2. D B Reality Pvt. Ltd., Mumbai for construction of Millan Mall 13000 2014
3. Runwall Builders, Mumbai for construction of apartments 20000 2014
4. Piramal Group, Mumbai for construction of housing complex 8000 2015
5. Royal Palm, Mumbai for construction of a hotel 15000 2015
6. ITC Ltd., Hyderabad for construction of a chocolate factory 6000 2015
7. Gannon Dunkerley, Tanda, UP for construction of industrial 5000 2015
complex
8. Patel Engineering, Jammu (J&K) for construction of a hydro 1000 2015
project
9. DRDO, Panagarh (WB) for construction of staff accommoda- 8000 2015
tion
10. Future Group, Mumbai for construction of City Centre Mall 4000 2015
11. DLF, Noida for construction of Mall of India 3500 2015
12. Larsen & Toubro, Hyderabad for construction of TOD Mall 4000 2015-16
13. NTPC (Simplex), Noida for construction of industrial complex 5000 2015-16
14. Shapoorji & Pallonji, Hyderabad for construction of warehouse 6000 2016
15. Jaya Shree Textiles, Kolkata for construction of textile factory 6500 2016
16. BGR Energy, Vijayawada for construction of housing complex 15000 2016
17. MES, Leh (J&K) for construction of army accommodation 20000 2016
18. Bihar Construction Deptt., Bihar for construction of District 10000 2016
counselling centers
19. Prime Hospitals, Hyderabad construction of a hospital 4500 2016
20. GMR Infra, New Delhi for construction of Cargo at IGI Airport 4000 2016

CERTIFICATION

Under Performance Appraisal Certification Scheme, Prefabricated Fibre Reinforced Sandwich Panels has been
evaluated and certified by BMTPC PAC No.: 1030-S/2017 has been issued to M/s HIL Ltd., Hyderabad.

102
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

STANDARDS AND REFERENCES

Indian Standards

IS 712:1984 Specification for building limes (Reaffirmed 2014)

IS 2380 (Part 4):1977 Methods of test for wood particle boards and boards from other lignocellulosic materials –
Determination of flexural strength (Reaffirmed 2013)
IS 2380 (Part 2):1977 Methods of test for wood particle boards and boards from other lignocellulosic materials –
Determination of dimensional stability (Reaffirmed 2013)
IS 2547 (Part 1): 1976 Specification for gypsum building plaster: Part 1 excluding premixed lightweight plaster
(Reaffirmed 2017)
IS 3346:1980 Method of determination of thermal conductivity of thermal insulation materials
IS 3809:1979 Fire resistance test for structures
IS 3812 (Part 2):2013 Specifications for pulverized fuel ash - Part 2 : for use as admixture in cement mortar and
concrete (Reaffirmed 2017)
IS 11050 (Part 1):1984 Rating of sound insulation in buildings and of building elements - Part 1 : airborne sound
insulation in buildings and of interior building elements (Reaffirmed 2017)
IS 12089:1987 Specifications for granulated slag for manufacture of portland slag cement (Reaffirmed 2013)
IS 12269:2013 Specifications for 53 grade Ordinary Portland Cement
IS 13000:1990 Specifications for Silica-Asbestos-Cement Flat Sheets (Reaffirmed 2015)
IS 14862:2000 Specifications for fibre cement flat sheets (Reaffirmed 2015)
BS 476 (Part 4):1970 Test method for non-combustibility of building and structures
BS 476 (Part 5):1979 Method of tests for ignitability
BS 476 (Part 6):1989 Method of tests for fire on building materials and structures
BS 476 (Part 4):1997 Method for fire classification of surface spread of flame
BS 476 (Part 20-22):1987 Fire resistance test to building materials and structures
BS 4370 (Part 2):1993 Method of tests for rigid cellular materials
ASTM E 72:2015 Standard test method for conducting strength test of panels for building construction

References

Fire propagation, fire resistance, Ignitibility evaluation & Surface spread of flame by Fire Research Laboratory, CBRI, Roorkee
(IS 3614:1979)

Thermal Conductivity & Thermal Resistivity study of Panels by Indian Institute of Technology Bombay, Mumbai

Dimensions, Transverse strength, Deflection & Compressive strength study of Panels by JNTUH College of Engineering,
Hyderabad

103
 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Rising EPS (Beads) Cement Panels

(Suitable for Non Load Bearing Structures)

About the technology

These are lightweight composite wall, floor and roof sandwich panels made of thin fiber cement/calcium silicate
board as face covered boards and the core material is EPS granule balls, adhesive, cement, sand, fly ash and other
bonding materials in mortar form.

The core material in slurry state is pushed under pressure into preset molds. Once set, it shall be moved for curing
and ready for use with RCC or steel support structure beams and columns. These panels are primarily used as
walling material but can also be used as floor and roof panels. These are non-load bearing panels to be used with
structural support frame only.

Size and Type of Panels

Size : Panels are normally produced in sizes

and dimensions as given below:
Length : 2440 mm (may be increased up to 3000
mm)
Width : 610 mm (may be altered as per re-
quirement but should not be too wide
since handling of the panels become
difficult)
Thickness : 50-250 mm. Dimensions are shown in
Fig.1
Fig. 1.

Type: Panels are produced in 4 types as shown in Fig. 2 below:

Pole holes Solid heart Rod holes Block hole

Fig.2

The above four types of panels have different applications depending on the requirements e.g. Solid heart should
be used as walling material in any type of construction and pole, rod and block hole may be used where different
types of inserts are used like iron rods or wires for security etc.

RAW MATERIALS

(i) OPC 43/53 grade cement shall conform to IS 8112:2013/12269:2013.

(ii) Fly ash shall conform to IS 3812 (Part 2):2003.
(iii) EPS beads shall conform to IS 4671:1984 and shall have density not less than 15 kg/m3.
(iv) Fibre cement board shall conform to IS 14862:2000.

104
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

(v) Calcium silicate board shall conform to EN 14306:2009

(v) Fine (sand) & coarse aggregate shall conform to IS 383:2016.
(vi) Water shall conform to IS 456:2000.
(vii) Addage RD Powder, AKULPOL-9192, Akulcel 48000 (Additives & Bonding agents) shall conform to the manu-
facturer Ms. Sakshi Chem Science Pvt. Ltd. Mumbai specifications.

Performance Criteria

Rising EPS panels shall meet the following performance criteria when tested in accordance with the relevant Stan-
dards:

Sl.No. Performance Characteristics Criteria Test Method

1. Flammability of EPS ≥ 600kgs/M³ IS ASTM D 7309:2013
2. Axial compression ≥ 3.5MPa IS 2095 (Part1):2011
3. Resistance to continuous heating ≥ 70ºC ASTM F 1939:2015
4. Flexural Strength ≥ 1N/mm² IS 516:1959
5. Acoustic Performance ≥ 35dB IS 9901:1981
6. Thermal conductivity ≥ 0.1W/M² k IS 3346:1980
7. Thermal Resistance ≥ 0.40M² k/W IS 3346:1980
8. Water penetration There should be no dam- EN1609:2013
age or leakage
9. Fire rating of the panels Should be Grade 1/3 Hrs BS 476 (Part 20 & 22)
10. Resistance to structural damage There should be no col- BS 5234 (Part 2):1992, Annex E
from a large light body lapse or dislocation
11. Anti-bending damage load ≥ 1.5 times of its weight BS 5234(Part 2):1992
12. Non-combustibility Should be ‘A’ level GB 8624:2012
13. Water tightness behind panels after No droplets should be ASTM C1185:2016
24 Hrs at 250mm water head observed
14. Drying Shrinkage value ≤ 0.1% IS 2185 (Part 1):2005
15. Single point hanging strength ≥ 1000N BS 5234 (Part 2):1992

Installation of EPS Cement Panel, Applications & Jointing procedure

Procedure

With RCC frame structure: If RCC frame structure is used in the construction, then the panels should be directly
fixed on the walls, pillars, beams and floor with the help of cement glue and later iron locking rods should be inserted
into the panels and the pillars, beams and floors at 45° so that they are firmly locked with each other and become
one single unit.

The manufacturer shall inform the specialized chemical “cement glue”, if available in India/manufactured by reputed
chemical/ water proofing companies to the customers.

With Steel frame structure: If steel structure frame is used in the construction, then U type channels should be
used to hold the panels with the structure. In this case additional clips should be welded with the frame pillars and
beams to hold the U cannel firmly with the pillars/beans and floor. Then only the panels should be inserted into
the U channels. There after PU glue should be applied to hold the panels firmly. The thickness of the panels shall
determine the size of U channel.

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After installation of the panels in both the above systems, all gaps should be checked and filled with additives, PU
and cement mixers and later thin putty should be applied to give uniform smooth surface ready for paint.

Installation of Panels

Receipt and inspection of Panels

Once the panels are received, it should be checked if the edges are safe and also there are no cracks or damages
on the surface of the panels which can happen during transportation and handing.

Laying of panels as per drawings

Once panels received are as per the drawings, then it should be separated and laid down as per the drawings for
easy installation and to avoid extra handling.

Marking and sizing the panels

Once panels are placed at the proper place, marking should be down as per drawing and proper sizing should be
cut of the required panels as per the drawings. (See Figs. 3 & 4)

Fig.3 Marking of the panels as per drawings Fig.4 Cutting of panels as per drawings

Actual installation as wall

The panels are lifted and placed as per the drawings. Fo installation of the panels, following points should be
considered:

1.1 Joining of panels with each other

• The panels shall be placed at the marked space and adjusted together. Dust should be cleaned on the
tongue and groove of the panel to be installed. Cement mortar shall be applied and glue filled in the gaps on
the panel joining parts and force them together to form one panel. Levels of both panels shall be checked.
(See Figs. 5 & 6)
• The panels shall be fixed with steel bar between each other or between the panels and the floor to lock them
together. (See Fig. 7)

Fig.5 Placing panels together Fig.6 Applying cement and glue Fig.7 Part elevation of wall panels

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1.2 Typical Joint between two panels side by side:

• The panels shall be fixed with dowel bars and the bars inserted in one panel at 45° and hammer it down to
lock both the panels. (See Figs. 8, 9 & 10)

1.3 Typical joint with floor:

• The panels shall be placed on floor, cement and glue applied between panels and floor and L type steel bars
inserted through the panels edge at 45° in the floor. The panel will then be locked to the floor. (See Figs. 11
& 12)

Fig.8 Steel bars Fig.9 Fig.10

Fig.11 Fig.12

1.4 Typical L and T joint with panels:

Fig.13 Fig.14

1.5 Joining of upper and lower panels together:

• The panels shall be placed one over the other vertical/ horizontal after applying cement and glue. The steel
rod shall be inserted from the sides of the panels into each other to join them together and locked. (See Figs.
15 & 16)

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Fig.15 Fig.16 Fig.17

• A wall of these panels shall be inter-connected with steel bars inserted at 45° and fixed with cement and glue
in between panels. (See Fig. 17)

2.1 Connecting panels with RCC pillar/RCC Walls/RCC beams:

• For connecting these panels with RCC pillars, the panels shall be placed with the pillar after applying cement
and glue on the side of the panels and pushed to make the perfect position.

Following are three types of connections depending on the situation:

Steel rods/screw or bolt shall be inserted in the pillar and the panels locked with the help of the above. Thus
the panel will be fixed and becomes part of wall connected with pillars. (See Figs. 18, 19 & 20)

Fig.18 Fig.19 Fig.20

2.2 Wall head fixing:

• Dowel bar of 250mm length and 8mm dia shall be fixed into pre-drilled hole of the panels and lock the panel
to the overhead beams or RCC roof slab. (See Figs. 21, & 22)

Fig.21 Fig.22

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2.3 Fixing panels to the Steel frame (Pillars & Beams)

• Connection of wall panel to RHS column

Steel L-angle/C Channel/Z channel shall be welded to the side of RHS column and the panel inserted inside
the angle/channel and locked. The thickness of the panels shall determine the size of angle/channel. (See
Figs. 23, 24 & 25)

Fig.23 Fig.24 Fig.25

3.1 Cutting of space for doors and windows

• The space on the drawing where doors and windows are required to be placed shall be marked and then
while making walls keep that space. There is another way also where the space is cut later on once the walls
are set fully.

3.2 Door Opening

• The panels shall be placed horizontally to keep space for doors. (See Figs. 26 & 27)

3.3 Window Opening

• The panels shall be placed horizontally to keep space for windows. (See Figs. 28 & 29)

Fig.26 Fig.27 Fig.28 Fig.29

3.4 Cutting space for doors and windows after the panels are fixed.

• The position of steel inserts shall be marked to protect the wall from any movement while cutting of panels.
All the steel bars shall be inserted at 45° angle to lock the panels with each other to stop further movement.
(See Fig. 30)

Fig.30

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3.5 Frame Fixing (See Figs. 31, 32, & 33)

Fig.31 Fig.32 Fig.33

4. Laying of electrical conduits

• The wire shall be embedded from the ceiling into the trench. (See Figs. 34 & 35)

Fig.34 Fig.35

5. Hanging Force (See Fig. 36)

• Expandable metal bolt shall be used and hooked on the wall panel.
• Tile adhesive shall be used for fixing heavy granite tiles.

Fig.36
6. Fixing the Panels as floor (See Fig. 37)

• Steel frame shall be fixed if this is to be a raised platform otherwise the panels can be used directly as floor
after making the ground level properly.
• Floor tiles can be fixed on these panel, if required.

Fig.37 (Screeding concrete not shown in these drawing)

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7. Fixing the Panels as roof (See Figs. 38 & 39)

• These panels can be used in the roofing as long as it is non-load bearing application.
• Steel frame shall be fixed as base for fixing the panels as roof.

Fig.38 (Screeding concrete not shown in these drawing)

Fig.39 (Screeding concrete not shown in these drawing)

CERTIFICATION

Under Performance Appraisal Certification Scheme, the present formwork system has been evaluated and certified
by BMTPC PAC No. 1032-S/2017 has been issued to M/s Rising Japan Infra Pvt. Ltd., New Delhi.

EXECUTED PROJECT

• These panels are presently manufactured by the firm in China. The firm has constructed, as reported, a 4
storey prototype residential complex at Nagpur using the panels from China. The firm proposes to install the
plant in India shortly for manufacture of the panels.
• The Panels, manufactured in China by the said firm, have been installed at the third floor of G+6 residential
Complex being constructed by NBCC at Kidwai Nagar, New Delhi

USES, LIMITATIONS AND CRITICAL DETAILS OF PANELS

Uses:
These panels may be used for the applications in Housing, Commercial complexes, Schools, offices, Electric
sub-stations, Hotels and resorts, High rise buildings, Boundary walls, Highway railings, Bridges side support,
river lining etc.

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Limitations on the basis of performance, safety, geo-climatic conditions:

These are non– load bearing panels and should be used as walling, floor and roofing with additional struc-
tural support, steel or RCC depending on the design. However, these may be used as single floor construc-
tion or stairs case slabs, kitchen/bathroom slabs etc. without support structure.

These panels are non- load bearing only if they are used without any pillar and beam support. However, they
may be used as walling material with RCC or steel frame structure.

The panels, if used for floors/roofs, shall require screeding concrete of 35mm thick with nominal reinforce-
ment/ GI wire mesh for shrinkage monolithic action to avoid leakage through the panel joints.

Standards And REFERENCES

IS 383:2016 Coarse and fine aggregate for concrete - specification (Third Revision)
IS 456:2000 Plain and reinforced concrete - code of practice (Reaffirmed 2016)
IS 2185 (Part 1):2005 Specification for Concrete Masonry Units - Part 1 Hollow And Solid Concrete
Blocks (Reaffirmed 2015)
IS 3346:1980 Method of determination of thermal conductivity of thermal insulation materials
IS 3809:1979 Fire resistance test for structures
IS 3812 (Part 2):2003 Specifications for pulverized fuel ash - Part 2 : for use as admixture in cement
mortar and concrete (Reaffirmed 2017)
IS 8112:2013 Specifications for 43 grade Oordinary Portland Cement
IS 9901:1981 Measurement of sound insulation in buildings and building elements
IS 12269:2013 Specifications for 53 grade Ordinary Portland Cement
IS 14862:2000 Specifications for fibre cement flat sheets (Reaffirmed 2015)
IS 516:1959 Method of test for strength of concrete (Reaffirmed 2013)
IS 4671:1984 Specifications for expanded polystyrene for thermal insulation purpose.
IS 2095 (Part 1):2011 Specifications for gypsum plaster boards - part 1 plain gypsum plaster boards
(Reaffirmed 2011)
ASTM C 1185(08):2016 Standard test method for sampling and testing non-asbestos fibre cement flat
sheets
ASTM F 1939:2015 Standard test method for radiant heat resistance of combination of materials
BS 476 (Part 20-22): 1987 Method of determination of fire resistance of building materials and structures
BS 5234 (Part 2):1992 Specifications for performance requirements for strength and robustness of parti-
tions including method of tests
EN 1609:2013 Specifications for thermal insulating products for buildings
GB 8624:2012 Classification of burning behavior of building materials

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Light Gauge Steel Structural Systems
 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Light Gauge Steel Framed Structures (LGSF)

(Suitable for Low Rise to Medium Rise Structures)

About the technology

Light Gauge Steel Framed Structures (LGSF) is based on

factory made galvanized light gauge steel components,
designed as per codal requirements. The system is
produced by cold forming method and assembled as
panels at site forming structural steel framework of a
building of varying sizes of wall and floor.

The basic building elements of light gauge steel framing

are cold formed sections which can be prefabricated at
site using various methods of connection. The assembly
is done using special types of screws and bolts.

Cold formed sections are widely used in construction

including residential floors, industrial buildings,
commercial buildings, hotels and are gaining greater
acceptance in the residential sector. LGSF is a well
established technology for residential construction in
North America, Australia and Japan and is gaining
ground in India.

LGSF is typically ideal for one to three storey high

buildings, especially for residential and commercial
buildings. Due to its flexibility, fast construction and
durability, this technology has great potential for counties
like India.

LGSF can be combined with composite steel / concrete

deck resting on light steel framing stud walls. Apart from
having potential for mass housing, modular buildings
can be used for long term temporary or permanent
structures such as schools and classroom, military and
civil housing needs, post – disaster relief structures and
industrial buildings. Advisable maximum span for LGSF
buildings should be 7.5 m.

Specifications for the System

Structural Section

Main Section are Studs & Track Studs serve as a general all purpose framing component used in a variety of
applications including external curtain walls, load bearing walls, headers floors & roof joists, soffits and frame com-
ponents.

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Track is used as closure to stud and joists end as well as head and sill conditions. It is also used for blocking and
bridging conditions.

Load bearing steel framing members shall be cold – formed to shape from structural quality sheet steel complying
with the requirements of one of the following:
i) ASTM A 653 / A 653 M -13 Grade 33, 37, 40 & 50 (Class 1 and 3) or
ii) ASTM A 792 / A 792 M -13 Grade 33, 37, 40 & 50; or
iii) ASTM A 875 / A 875 M – 13 Grade 33, 37, 40 & 50; or
iv) Sheets, that comply with ASTM A 653 except for tensile and elongation with requirements, shall be permitted,
provided, the ratio of tensile strength to yield point is at least 108 and the total elongation is at least 10 percent
for a 5 mm gauge length or 7 percent for a 20 mm gauge length.

Wall frame

Consists of top track (U shape configuration) with a depth compatible

with that of the studs of the same nominal size. Minimum height of
track flanges shall be 19 mm.

Load Bearing Walls

C section studs with depth of 90 and 200 mm and thickness between

2.7 mm and 2.0 mm shall be provided at a distance of 300 mm / 400
mm / 610 mm to ensure efficient use of cladding material. Multiple studs
are used at heavily loaded application such as adjacent to openings or
in braced panels. C section with 94 x 50 mm is used for noggins.

Alteration shall be required for the local details at the head & the base
of the wall to ensure that loads are adequately transferred without local
deformation of the joists & studs.

Non Load Bearing Walls

It is similar to that of load bearing walls except that noggins and di-
agonal bracing are not required to stabilize the studs.

Deflection Limit of Walls

Suggested deflection limit for external walls subject to wind loading

are as follow:
Full height glazing Height / 600
Masonry wall Height / 500
Board / reduced finish Height / 360
Steel cladding Height / 250
Other flexible Cladding Height / 360

Wall cladding

Wall cladding shall be designed to resist wind load. Sheet has to be

screwed to the joist / purlin with maximum spacing of 300 mm c/c. All
the joints of sheet in longitudinal direction require a minimum lap of
150 mm in order to make them leak proof.

Following materials are generally used on wall cladding:

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• Gypsum board conforming to IS 2095 (Pt. 1): 2011

• Heavy duty cement particle board conforming to IS
14862:2000.

Bracing

Bracing and bridging shall have configuration and steel thick-

ness to provide secondary support for the studs in accordance
with the relevant specification for the design of Cold – formed
steel structure of members.

Floor frame

For speed of construction, floor joist may be pre-assembled to

form floor cassettes. This works well for regular floor places but
care shall be taken when the geometry of the building requires
the cassettes to vary in size with location or when non – right
angel corners are required. Resistant may be provided to the
top flange of the joists by the flooring board. The floor should be
designed for the combined effect of dead and imposed load.

The construction of a suspended floor comprising cold formed steel floor joists is similar to that for a floor using timber
joists. The strength to weight ratio of light steel joist is higher than that of other material. Steel joists are stable and
do not suffer, the long term problems of drying out, creep and Shrinkage. Joists are generally positioned at 300, 400
& 600 mm centres, depending on the spacing capabilities of the floor materials used.

Roof frame

Flat roof is made up of joists, where steel decking form a flat roof, a minimum fall of 1:4 should be introduced to ensure
that any moisture runs off. To avoid local ponding to rain water, the pitch may need to be increased to overcome the
effective reduction in roof angle caused by the deflection of long span roof purlin or decking.

Roof truss

Use of Light Steel roof truss is economical for larger span building. In attic or open roof truss creates usable roof
space, uses fewer components than Fink truss and provides an economical solution, since it utilizes the high strength
of the steel members.

The trusses are placed at 600 mm maximum spacing and are battened and tiled in a conventional manner.

Lipped C rafter

Single bolt con-

Lipped C ceiling joist
nection

Plain C hangers

Lipped C bottom chord

75mm bearing 75mm bearing

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Screws

Screws as per the details given below shall be used:

• Panel Assembly – Low profile screws
• LGS-LGS Wall panel to roof cassette – 12-14x15mm
• LGS to concrete – Tapcon screw 14-12x60mm Hex
head
• Wire mesh = EPS board – SDS Hex head with Ceresin
without washer
• HRS-LGS – Hex heat
• CP board 6mm – WT 8 CSK Phillips
• Gypsum board – Flat heat self-driven type
• Deck sheet/Wire mesh – SDS WT, CSK, Flat head

Extended Polystyrene Panel

Shall be of minimum density of 15 kg/m3.

Wire Mesh

Shall be made of 4 mm dia wire of UTs 480 MPa with spac-

ing 150 mm x 150 mm or 1.4 m dia of spacing 40 mm x
40 mm.

Shotcrete

Shortcrete when used shall be of minimum grade M 25

Grade of concrete.

Design

The LGSS is designed based on provision of the following

standards:

●● Indian Standard IS 801: 1975 Code of Practices for use

of cold formed and welded section and light gauge steel
structural members in general building construction.
●● British Standard BS 5950 (Part 5):1998 – Structural use
of steel in Building Part 5 – Code of Practice for design
of cold formed thin gauge structure.
●● British Standard BS 5950 (Part 1): 2000 Structure use of steel work in Building Part 1 with loading requirement
as per IS 875 (Part 1)
●● Indian Standard IS 875 - Code of Practice for design loads
Part 1 - Dead Loads - Unit Weights of Building Material and Stored Materials
Part 2 - Imposed Loads
Part 3 - Wind Loads
●● IS 1893 (Part 1):2002 Criteria for Earthquake Resistant Design of Structures - Part 1 : General Provisions and
Buildings

Manufacturing

The sections are manufactured using Centrally Numerical Control (CNC) automatic four Pinnacle Roll Forming
machine having production speed of 450-900 m/hr with very high precision.

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Construction

Foundations for light steel framing are essentially the same as

for any form of construction, although dead loads applied by
the light steel frame will be much lower than in the concrete
or masonry construction.

Construction phases of steel buildings resembles the phases

of conventional reinforced concrete buildings. The sections
manufactured as per design are numbered properly. The pro-
files are sent to site either as profile or panellized parts, con-
sidering the distance of the construction site and transportation
conditions. Profiles are assembled by trained assembly team
at the construction site in line with the architectural plan. Only
special studs are used during assembly, no welding is done.
Once the assembly is done, the frame is filled with insulation
materials (fibreglass, rockwool etc). Walls are then covered
with standard boards or similar approved materials.

The sequence of construction comprises of foundation laying,

fixing of tracks, fixing of wall panels with bracings as required,
fixing of floor panels, fixing of roof panels, decking sheet, fixing
of electrical & plumbing services and finally fixing of insulation
material & walling panels.

Electrical Gas and plumbing, services are installed through

pre-punched service holes in the web of the steel forms.
Plastic grommets and silicon seals are used to fasten and
protect wiring and pipes from corrosion and damage arising
from vibrations

Electrical cables running within floor insulation layer in the

separating floor construction should be protected with cartridge fuses or mini circuit breaker.

Wall panels are generally made by using heavy duty Cement Particle Board and Gypsum board. It can also be made
using high density extended polystyrene core plastered from outside using wire mesh and chicken mesh. Galvolume
sheet of appropriate thickness can also be used as cladding. This technology is certified by BMTPC under PACS.

Advantage

LGSF is based on established system of light gauge steel structures and designed as per codal provisions with
loading requirements as per Indian Standards. The merits of the system encompasses:

High Precision
• Fully integrated computerised system with CNC machine provides very high accuracy upto 1 mm.

Structural
• High strength to weight ratio. Due to low weight, significant reduction in design earthquake forces. Chance of
progressive collapse are marginal due to highly ductile and load carrying nature of closely spaced studs/joists.

Speed in Construction
• Construction speed is very high. A typical four storeyed building can be constructed within one month.

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Saving in foundation
• Structure being light, does not require heavy foundation.

Mobility
• Structural element can be transported any place including hilly places to remote places easily and structure can
be erected fast.
• Structure can be shifted from one location to other without wastage of materials.

Environment friendly
• Steel used can be recycled when required.

Certification

Under Performance Appraisal Certification Scheme, the Light Gauge Steel Framed Structures (LGSF) has been
evaluated and certified by BMTPC PAC No. 1014-S/2014 has been issued to M/s JB Fabinfra Pvt. Ltd., New
Delhi.

StandardS

IS 801: 1975 Code of practice for use of cold formed light gauge steel structural members in general
building construction (Reaffirmed 2016)
IS 2095 (Part 1) : 2011 Specification for Gypsum Plaster Boards - Part 1 Plain Gypsum Plaster Boards
(Reaffirmed 2016)
IS 14862 : 2000 Specification for Fibre Cement Flat Sheets (Reaffirmed 2015)
ASTM – A653/ A 653 M -13 Specification for steel sheet, zinc coated (galvanized) on zinc – iron alloy coated by hot
dip process.
ASTM – A 792/792 M -13 Specification for steel sheet, 55% aluminium zinc alloy coated by hot dip process
ASTM – A 875/875 M -13 Specification for steel sheet, zinc 5% aluminium alloy coated by hot dip process.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Light Gauge Stell Framed Structure with Infill Concrete

Panel (LGSFS-ICP) Technology
(Suitable for Low Rise to Medium Rise Structures)

ABOUT THE TECHNOLOGY

Light Gauge Steel Framed Structure with Infill Concrete Panels (LGSFS-ICP) Technology is an innovative emerging
building and construction technology using factory made Light Gauge Steel Framed Structure (LGSFS), light weight
concrete and precast panels. The LGS frame is a “C” cross-section with built in notch, dimpling, slots, service holes
etc. produced by computerized roll forming machine. These frames are assembled using metal screws to form into
LGSF wall and roof structures of a building. Provisions for doors, windows, ventilators and other cutouts as required
are incorporated in the LGSFS.

Fig.1 Structural Details of LGSFS-Infill Concrete Wall

The LGS frames are manufactured in a factory and assembled in to LGSF wall structures and then transported to
the construction site and erected wall by wall on a pre-built concrete floor as per the floor plan of the building. Steel
reinforced concrete panels of size 610 mm x 305 mm x 20 mm thick are manufactured at factory and transported
to site. These panels are fixed on either side of the LGSFS wall using self-drilling/tapping screws to act as outer
and inner faces of the wall leaving a gap between them. This gap is then filled with light weight concrete using a
special mixing and pumping machine. Electrical and plumbing pipes/conduits are provided in the service holes of
the LGSFS before concreting is done. Self-compacting concrete is mixed and pumped into the gaps between two
panels. The concrete flows and fills the gap and provides adequate cover to the LGS frames and joints. The con-
crete shall also adhere to the concrete panels. After curing, LGSFS with in-fill concrete and panels (LGSFS-ICP)
forms a monolithic sandwich composite wall structure with thermal and sound insulation properties.

The roof structure of LGSFS-ICP building is constructed using metal/plastic formwork system with steel reinforced
concrete as per structural design. Standard procedures are employed to concrete the roof slab. After curing for 96
h, the formwork is de-moulded and the wall and roof are putty finished. Door and window frames are fixed to the

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LGS frames and shutters fixed with necessary accessories. Finishing work such as laying floor tiles, fixing electrical
and sanitary fixtures and painting is carried out using standard conventional methods.

After completion of ground floor, first, second and third floors of the building is constructed using the same pro-
cedure that of the ground floor. The staircase, chajja and parapet walls of the building are also constructed using
LGSFS-ICP Technology.

MATERIAL REQUIREMENTS

1. Raw Materials
i. LSG Coil of galvanized steel shall conform to IS 277:1992.
ii. Fasteners and Connectors
(a) Frame assembly screws: Shall be galvanized steel screws self-drilling type of size 10 x 25 mm having
Truss-head and shall be as per ASTM C 1513-10.).
(b) Wall Erection Screws: Shall be galvanized steel screws self-drilling type of size 8 x 25 mm having Hex
Washer head and shall be as per ASTM C 1513-10
(c) Precast Concrete Panels Fixing Screws: Shall be of galvanized steel screws self-drilling type of size 8 x
50 mm having CS head and shall be as per ASTM C 1513-10.
(d) Wall and Foundation Anchor Bolt: Shall be of high tensile galvanized steel of size 10 x 100 mm/ 10 x
150 mm and 12 x 100 mm/ 12 x 150 mm and shall be as per ASTM C 1513-10.
iii. Foaming Chemicals: Shall be made from protein foam concentrate and FC-lite foaming agent
iv. Gypsum plaster board: Shall be of size 1830 mm x 1220 mm and 12.5mm to 20 mm thick and shall conform
to IS 2095 (Part 1):2011
v. Water Proofing Treatment: Shall be using integral waterproofing compound as per IS 2645:2003
vi. Putty: Shall be as per IS 63:2006
vii. Ordinary Portland cement (OPC) shall be of 43/53 grade as per IS 269:2015
viii. Sand and Aggregates shall be as per IS 383:2016
ix. Reinforced Steel: Shall be as per IS 1786:2008
x. Structural steel: Shall be as per IS 800:2007
xi. Steel fiber: Shall have length of 60 mm &dia. 0.75 mm and shall be as per EN 14889-1:2006
xii. Glass fiber: Shall be made from Fiber mesh 303 E3 and shall be as per EN 14889-2:2006

2. Light gauge steel frame/ structure

The Light gauge steel frame structure (LGSFS) comprises of “C “cross section studs (vertical members) and tracks
(horizontal members) frames assembled together by
means of mechanical screws. The joints between wall &
roof junctions/wall to wall junctions are designed as rigid
joints

3. Precast concrete panels

Precast Concrete Panels are used as facing sheets for
construction of walls. Self-compacting concrete of M20
grade is used. Metal modes, concrete mixing machine
and vibration tables are used for manufacturing the pan-
els. The panels are designed to withstand the concrete
weight pumped in between the gap of the panels without
failure and buckling.

The steel reinforced precast concrete panels (PCP), has

one side rough surface and the other side smooth sur-
face. The PCP’s are fixed on either side of Light Gauge
Steel Frame Structures (LGSFS)–studs and tracks using

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mechanical fasteners. While fixing, the rough side of the pan-

els are facing inside and smooth side is facing outside. Each
PCP is fixed with 6 screws. Light weight concrete is pumped
in to the gap between two PCPs. The concrete bonds with the
rough surface of the panels. Thus, the LGSFS and PCPs are
firmly joined to make a monolithic steel–concrete structure.

4. Concrete/light weight concrete

The concrete used for infill wall is light weight and free flow.
The density shall be 1500-1800 Kg/m3 after adding/mixing
foam or EPS beads as per the design mix developed by the
agency. The light weight concrete shall be of grade M5 to M10,
as required. The light weight concrete shall be mixed and used
at site.

MANUFACTURING PROCESS

The manufacturing process of the constituents of LGSFS-ICP system is as follows:

1. Light Gauge Steel Frame Structure

Cold formed Light gauge steel frame super structure is manufactured out of min. 0.95 mm pre-treated factory
finished hot dipped GI high tensile steel sheet (AZ 150 GSM Aluminium zinc alloy coated steel and having yield
strength of 550MPA) which shall be as per IS 800:2007 and conforms to AISI specification and IBC 2009. The wind
loads shall be as per IS 875 (Part 3):2015. The framing section is cold form “C’ type of 0.55 mm to 1.55 mm thick-
ness in required length as per structural design requirements, duly punched with dimple slots at required locations
as per approved drawings. The slots shall be along center line of the web and shall be placed at 250 mm min. away
from both edges of the member. The frame is supplied in specified dimensions and fastened with metal strip of 25
mm x 25 mm x 0.50 mm to both adjoining walls.

2. Precast Concrete Panels

Precast concrete panels are manufactured using cement, sand, aggregates, glass &steel fibers, water and admix-
tures using a design mix and curing cycle developed by the agency. It is steel fibre reinforced precast concrete
panel. It gets strength as steel reinforced concrete.

The overall dimensions of the panel are 1220 mm x 610 mm x 20 mm thick and the weight shall be around 36 kg.
The panels are designed to have smooth or textured outside surface and rough inside surface. The panels are also
designed to withstand green concrete load of 200 kg without failure and deflection shall be less than 1.0 mm.

The concrete used for the panels shall be of grade M20 having water absorption less than 8%.
Mix ratio of light weight aggregate for 1.0 cu.m is as follows:
Cement = 300 kg
Sand = 400 kg
Flyash = 300 kg
6mm-8mm Aggregate = 1350 kg
PPfibre + steel fibre = 4.14 kg
Water = 150 kg
Admixtures = 150 ml

3. Concrete/Light Weight Concrete

The wall or the roof is constructed using M20 grade concrete and M5 –M10 grade light weight concrete. The con-
crete used is light weight and free flow. The light weight concrete is mixed and used at site. The concrete/light weight
concrete is pumped into the gap between the panels.

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4. Assembly/Connecting Screws and Anchoring Bolts

LGS frames are assembled together to fabricate LGSF structures using self-taping screws. The LGSF structures
such as wall, roof, truss and staircase are connected by using special screws which shall conform to ASTM C 1513.
The anchoring boards used for connecting LGSF wall structure to the foundation shall conform to relevant Indian/
American Standards.

Applications

The technology is used for construction of Low rise residential buildings up to G+3 storey – EWS, LIG & MIG
houses, Schools, Health centers, Community centers, independent houses and rehabilitation buildings.

INSTALLATION/ CONSTRUCTION OF LGSF STRUCTURES

1. Construction of Foundation and Plinth

The foundation and plinth is constructed confirming the floor plan of the building. The foundation depth, width,
steel reinforcement, grade of concrete etc. is determined by structural analysis report prepared on the basis of soil
condition, height of building, number of storeys, special live load requirement, if any.

2. Assembly of LGS Frames and Construction of Wall

The LSG frames manufactured using numerically controlled roll forming machine using CAD design shall be trans-
ported to the construction site. The frames shall be assembled into wall structure. All the wall structures shall be
connected together one by one as per the building plan by connecting screws. The wall position shall be marked
on the floor and the wall structure placed on the marking. After completing the same, straightness, square and the
levels shall be checked by magnetic spirit level. The bottom track shall then be connected with the floor using an-
chor bolts at every 600 mm bolts.

3. Fixing of Pre-cast Panels

The precast concrete panels shall be fixed on the LGSF wall structure on studs and tracks by using metal screws.
The panels shall be fixed first on the outer side of the LGSFS wall. Electrical/plumbing pipes/conduits shall be fixed
as per the electrical and plumbing layout. After completion, the panels shall be fixed inside the LGSFS walls and
allocations for electrical and plumbing cutouts shall be marked on the panel.

4. Concrete Mixing and Pumping

Self-compacting concrete of required grade/light weight concrete shall be mixed using concrete mixing machine
and then pumped into the gap between two panels using a special pumping unit. Care shall be taken to pump the
concrete gradually and uniformly on all the walls. Concreting shall be done till the gap is completely filled up to the
top of the LGSFS wall.

5. Construction of Roof Slab

The roof slab of the building shall be constructed by using metal/plastic shuttering and conventional concreting.
Necessary steel reinforcement as per design shall be provided over the formwork and concreting shall be done to
required thickness. Balcony and chhajja etc., wherever required shall also be constructed using formwork. After
curing the slab, shuttering shall be removed and bottom of the roof slab putty finished.

6. Reinforcement
Deformed steel bars of 8mm/10mm dia. as per design shall be used.

7. Staircase and Railing

Staircase and balcony railing shall be fixed using conventional methods.

8. Fixing Electrical and Plumbing Fixtures

The panels shall be cut at the marked locations for fixing electrical and plumbing fixtures.

9. Fixing of Doors, Windows & Ventilator Frames and Shutters

The doors, windows & ventilator frames shall be fixed on the cutouts provided in the LGSFS. The frames shall be

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made of WPC, uPVC and other materials, as required. Thereafter, the doors and windows shutters shall be fixed
to the frames. The shutters shall be made of glass fibre/ HDF sandwich composite materials.

10. Fixing Floor Tiles

Floor tiles of desired quality and make shall be fixed to the floor, as required. Similarly, wall tiles of desired quality
and make shall be fixed in the kitchen, bath and toilet using conventional methods, as required.

11. Surface Finishing and Painting

Cement based putty shall be applied on the outside and inside walls and then painted with desired colour.

SPECIAL FEATURES

Structural Stability
Due to low weight, significant reduction in design earthquake forces. Chance of progressive collapse are marginal
due to highly ductile and load carrying nature of closely spaced studs/joists.

Durability
Buildings shall be designed as per codal provisions of IS 456.

Behavior in earthquake
The buildings shall be designed for loads in accordance with IS 875 (Part 1 to 5) and IS 1893 (Part 1).

Behavior in wind
The wind loads shall be as per IS 875 (Part 3).

Fire Safety
During fire performance oriented test, it was observed that there was some minor cracks on the surface of all the
walls.

Rain
During the ponding on roof slab for 24 hours, no dripping or leakage of water through roof slab or drop patches were
observed on underside of the roof slab.
During rain simulation of external face of the wall by jetting for 12 hours, no leakage of water, dampness or sweating
were observed on inner face of the wall.

Thermal Performance
There was a reduction in temperature upto 4ºC inside the unit indicating that it has got a good thermal comfort.

Acoustic Performance
The unit has got a good acoustic comfort.

Light weight
Weight of the LGSFS-ICP building is about 20-30% lighter when compared to conventional building thereby result-
ing in material and energy savings.

Limitation of Use
• LGSFS-IPC Technology may be used for construction upto G+3 storey Buildings only.
• For more than G+3 storey buildings, hybrid construction methods shall be used.

Critical Details
• 10 mm thick plaster on external walls shall be provided to take care of water proofing.
• Guard bars and wooden/steel windows shall be provided. Aluminium sliding windows shall be avoided.
• Sun shades shall be provided for all windows/external doors as per design.

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WORKS COMPLETED

1. Police Constable Quarters (G+1) building for Karnataka State Police Housing Corporation Ltd., Bangalore in
2012.

CERTIFICATION

Performance Appraisal Certificate No. 1028-S/2016 has been issued to M/s Society for Development of Compos-
ites, Bangalore by BMTPC.

STANDARDS/REFERENCES

• Design and Construction of “2 Police Constables Quarters (G+1) building for Karnataka State Police Housing Corporation
Ltd., Bangalore” by the manufacturer
• Technical Report on “Light Gauge Steel Frame Structure with Infill Concrete Panels for Fast Tack and Disaster proof Hous-
ing”
• Structural Analysis Report for “G+2 storey building constructed using LGSFS-ICP Technology” by M/s Nagesh Consultants,
Bangalore
IS 277:2003 Specifications for Galvanized Steel Sheets (Plain & corrugated)
IS 383:2016 Specifications for fine and coarse aggregates for concrete
IS 456:2000 Code of practice for Plain & Reinforced concrete (Reaffirmed 2016)
IS 800:2007 Code of practice for general construction in steel (Reaffirmed 2012)
IS 801:1975 Code of practice for use of Cold Formed Light gauge Steel structural members in General
building construction (First Revision) (Reaffirmed 2016)
IS 875 (Parts 1,2,4&5):1987 Code of Practice for Design Loads (other than earthquake) for buildings & structures
(Reaffirmed 2013)
IS 875 (Part 3):2015 Code of Practice for Design Loads (other than earthquake) for buildings & structures - Part 3
Wind Loads
IS 1786:2008 Specifications for high strength deformed steel bars and wires for concrete reinforcement
(Reaffirmed 2013)
IS 1893:2016 Criteria for Earthquake Resistant Design of Structures (Part 1) - General Provisions and Build-
ings
IS 1904:1986 Code of Practice for design and construction of foundations in soils: General requirements
(Reaffirmed 2015)
IS 2062:2011 Specifications for hot rolled medium & high tensile structural steel
IS 2095 (Part 1):2011 Specifications for gypsum plaster boards - Part 1 plain gypsum plaster boards
(Reaffirmed 2016)
IS 9012:1978 Recommended practice for shotcreting (Reaffirmed 2016)
ASTM C1513-10 Standard specification for steel taping screws - cold formed steel framing connections
EN 14889-1-2006 Fibre for concrete, steel fibres - definitions, specifications and conformity
EN 14889-2-2006 Fibre for concrete, polymer fibres - definitions, specifications and conformity

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Factory Made Fast Track Modular Building System

(Suitable for Low Rise to High Rise Structures)

About the technology

Factory Made Fast Track Modular Building System

comprises of prefabricated steel structure with different
walling components. About 70 percent of the work is done
in the factory with minimal usage of concrete, which enables
system to deliver the building within a few days of work at
site. The steel moduled are pre-fitted with flooring, ceiling
tiles, electrical and plumbing fittings. The assembled steel
modules are transported to the site for installation which is
done using crane and other required machineries. Once all
the components are assembled and erected at site, factory
made 3–D Expanded Polystyrene (EPS) wall panels are fixed
and shotcreting is done from both sides.

The uniqueness of system is the efficient and simultaneous

activities of site preparation and building construction in
factory, rather than two phased customary process.

Details of Structure

Foundation

Foundation shall be either strip or raft as per site conditions.

The design and construction of foundation shall be carried
out as per IS 1904:1986 and other related Indian Standards,
as applicable.

Steel Structure

The structure consists of steel pillars, modules and other

components designed for worst loading conditions as per IS
800:2007 and IS 801:1975. In addition, the structure shall
be designed in accordance with IS 1893(Part 1) & IS 875 for
seismic and wind load considerations, both individually and
in combination, as applicable. Steel pillars shall be made by
welding MS plate of 16mm thickness and steel tubes of size
200mm x 200mm having wall thickness varying from 3mm to
16mm depending upon the number of floors. The smaller pillar
is fixed with sub-assemblies for modules. All the columns shall
be checked for their safety and computations shall be done for
the same for satisfying requirements of IS 800 and IS 801.

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Steel Staircase

Steel staircase shall be designed and fabricated using

HR steel sheet of thickness 3mm / 4mm with MIG weld-
ing process. Staircase is pretreated for surface cleaning
using steel cleaning agent and painted with two coats
of anti-corrosion primer and fire proof paint.

Flooring

The floor is made up of deck sheet and wire mesh of size

100mm x 100mm x 3mm thickness. The deck sheet is
fixed on the modules ready after providing with utilities
like plumbing and electrical etc. Flooring, roofing and
ceramic tiles are fixed as per relevant specifications.

Walling

Walling is completed by using factory made EPS based

wire mesh welded 3D panels. The panels are easy to
install and manufactured using insulated polystyrene
core covered on both sides by hot GI coated round
wire square mesh, duly connected by 33 connectors
per m2.

Door and Window

The structure can accommodate any types of door and

window frames and panels. Metal door frame pressed
from 1.2/1.5mm thick galvanized steel sheet with mi-
tered and welded construction may also be fixed. The
doors used, however, should satisfy the performance
requirements as per relevant Indian Standards. For
doors not covered by any Indian Standards, third party
certification may be adopted. Performance character-
istics for dimensions & squareness, general flatness,
impact indentation, flexure test, edge loading, shock
absorption, buckling resistance, slamming and misuse
as per relevant parts of IS 4020:1998 shall be required
before accepting any doors for use.

Utilities

i) Once the steel structure module is ready for electri-

cal and plumbing work as per the drawings, these
utilities are planned & executed based on the ser-
vices/utilities layout design and requirement of the
floor area.
ii) After completion of services/utilities, the module is
covered with deck sheet. Wire mesh and MS studs of required size are fixed on the deck sheet before laying of
PCC flooring. After decking, PCC of M25 grade is laid for a total depth of 76mm and flooring tiles are fixed wher-
ever required depending upon utilization of area. With all fittings the module is ready for shifting to the site.

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Transport of Modules and Pillars along with accessories

All the handling/transportation at site for erection are done by means of mechanical equipments such as tower &
mobile cranes and trucks etc. Due care should be taken to avoid any damage to these modules, pillar and other
elements. Special lifting points are provided in these modules so that handling stresses are kept to a minimum.
Transportation are carried out in mainly two stages:
i) From manufacturing plant to stacking yard.
ii) From stacking yard to erection site. The transportation is carried out by using trucks of desired capacity and
length. Erection are carried out by cranes of suitable capacity at site.

Performance Evaluation

Structure
Seismic Performance Evaluation of a G+7 CRC framed structure model for ground motion compatible to Seismic
Zone V was performed at SERC, Chennai and found to be satisfactory.

Walling Component
Evaluation on the behavior of reinforced EPS Panel under flexural and Axial Compression load on 100 mm and 150
mm thick panels were satisfactory. Other performance characteristics are:

Thermal transmittance of Single Panel 0.537 w/m2k

Acoustic Behavior 37 dB (noise reduction)
Water Penetration No penetration after 3h
Resistance to impact with softbody and hardbody Impacts of 90 & 1200 J –No crack

Certification

Under Performance Appraisal Certification Scheme, PAC No. 1011-S/2013 has been issued for the system to M/s
Synergy Thrislington, A1 Phase- I, Industrial Area, Mohali.

STANDARDS/References

• Report of Seismic Evaluation of Model of G+7 CRC framed structure for a ground motion compatible to zone V spectrum by
SERC, Chennai.
• Inspection Report of the visit for Performance Appraisal Certification.
IS 800:2007 General Construction in Steel - Code of Practice
IS 801:1975 Code of Practice for Use of Cold Formed Light Gauge Steel Structural Members In General
Building Construction
IS 875(Part 1):1987 Code of Practice For Design Loads (Other Than Earthquake) For Buildings And Structures Part
1 Dead Loads - Unit Weights of Building Material And Stored Materials (Incorporating IS 1911
: 1967)
IS 875(Part 2):1987 Code of Practice for Design Loads (Other Than Earthquake) For Buildings And Structures: Part
2 Imposed Loads
IS 1893(Part 1):2002 Criteria for Earthquake Resistant Design of Structures - Part 1 : General Provisions and Build-
ings
IS 4020(Part 1 to 16):1998 Door Shutters - Methods of Tests
SP 7:2016 National Building Code of India 2016.

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Speed Floor System

(Suitable for Low Rise to High Rise Structures)

About the technology

The Speed Floor System is a suspended concrete flooring system using

a roll formed steel joist as an integral part of the final concrete and steel
composite floor. It is essentially a hybrid concrete/steel tee-beam in one
direction and an integrated continuous one-way slab in other direction.
The joists of different depths are manufactured from pre-galvanized
high tensile steel in a one pass roll former, where it is roll formed,
punched, pressed and slotted in a fully computerized machine. The joist
depth and the concrete thickness are varied depending on the span,
imposed loads and other functional considerations. The Speedfloor
composite floor system is suitable for use in all types of construction.
The Speedfloor joists are designed and custom manufactured to suit
particular job conditions.

Design

The design of the speed floor system is based on NZS 3404 (Part 1
&2), AS/NZS 4600 and the Australian Composite Standard AS 2327
(Part-I). The design load shall be taken as prevalent in IS 875 (Part
1 & 3). Earthquake forces shall be taken in accordance with IS 1893
(Part-1).

The section properties and design parameters are calculated from the
section geometry, supplementary full scale tests and finite elements
analysis.

The Joist

The joist is manufactured from G 350 Z 275 pre-galvanized steel

conforming to AS 1397:2001. Size may be any one of the following i.e. 200mm, 250mm, 300mm, 350mm and 400mm,
depending upon the design requirements. Concrete thickness may be 75mm or 90mm as required.

The joist weight vis-à-vis the depth are given below:

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Depth (mm) Weight (kg/ ln m)

200 9.41
250 10.59
300 11.76
350 12.94
400 14.12

The top section of the joist is embedded in concrete and has

following functions:
• It is the compression element of the non-composite joist during
construction
• It is a ‘chair’ for the welded mesh or the reinforcement which
develops negative moment capacity in the concrete slab over
the joist
• It locks in and supports the slab shuttering system (lock bar
and plywood forms)
• It becomes a continuous shear connector for the composite
system. The bottom section of the joist acts as a tension
member both during the construction phase and when the
joist is acting compositely with the slab.

The mid section or web of the joists has the flanged service hole
and the lock-bar hole punched into it. The flanging of the service
hole provides stability to the web and services can pass through
without requiring protection from the sharp edges of the punched
material.

The bottom triangular section of the joist acts as a tension

member both during construction phase and when the joist is acting
compositely with the slab.

The Lockbar

The lockbars support the temporary plywood formwork between the

joists during construction. They shall be spaced approx. 300mm
apart and engage in the slotted holes punched in the top section
of the joist. They also maintain the exact spacing of the joists.

The standard lockbars when installed will position the joists 1230mm, 930mm or 630mm apart. There are also
special adjustable lockbars that will position the joists in increments of 50mm from 330mm to 1530mm. Other type
of lockbars are provided for special situations such as cantilevers or lowered soffits.

Temporary plywood formwork

High density paper overlaid 12mm shuttering plywood conforming to IS 4990:2011 or equivalent is used as formwork to
produce a good finish to the underside of the slab. The rigid plywood sheets are used in conjunction with the lockbars
and when locked in place, provide lateral stability to the entire Speedfloor system during the construction phase.

Reinforcing mesh

Welded reinforcement mesh made of 8mm dia bar (fy 415 N/m2) placed @ 200mm c/c in both directions, is laid
and tied into place. No chairs are required as it is held off the plywood forms by the top section of the joist, which
becomes embedded in the concrete.

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Concrete

i) Minimum grade of concrete shall be M25 as per IS 456:2000. It should preferably be batched at 60mm and
super plasticized to 110mm slump to provide good placement and shrinkage characteristics. A curing compound
should be used and an expanding agent may be introduced in consultation with the engineer to further control
shrinkage during the curing period.
(ii) The concrete should initially be placed evenly and continuously over the area to be formed. Special attention
should be given to ensure the concrete is screened and finished to the specified thickness so that designed
deflections are achieved in the Speedfloor joists and the supporting structures.
(iii) In structures for carparking, an expanding agent is generally used to reduce the effect of shrinkage during initial
cure and a curing compound is used to help control the curing process.

Accessories

Edge angles
A standard edge form is available in two heights – 75mm & 90mm.Special heights and specially shaped edge angles
may be manufactured but would require longer lead times.

Jointers
Precut sections of galvanized sheet steel may be provided to overlay joints in the ply to ensure they are flush and
remain well supported while the concrete is poured.

Lockbar Hanger Angles

A galvanized steel angle with pre-punched lockbar holes is used for situations where the lockbars need support on
slab edges parallel to the joists.

Limitations

The system is used as framed steel structure in all types of construction for
laying RCC roof.
Maximum length of joist which can be used is 10m.

Durability

The technology provider shall provide necessary structural warranty ensuring

durability of the system to the user, on demand.

Installation Process

Installation process is as follows:

(i) Lightweight bundles of joists is lifted into position and then individual
joists are placed by hand.
(ii) Speedfloor joists are generally placed at 1250 mm c/c.
(iii) Joists are held in place using the lockbars which slip into slotted holes.
(iv) The lockbars is placed at 300mm apart to support plywood formwork.
The propping is not required.
(v) Full sheets of 12.5mm plywood formwork is to be laid from above creating
a working platform. Cam action of lockbars secures plywood.
(vi) Mesh is placed on top section of joist thereby embedded in the concrete
poured thereafter.
(vii) After three days of concreting, lockbars and plywood are removed from
the underside revealing a clean surface ready for services or a fire rated
suspended ceiling.

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Maintenance Requirements

Speedfloor is a composite floor system using both steel and concrete. The two materials must be treated and
maintained separately.

Steel : If the joists are in a clean and dry environment, they may not require any maintenance. If it is exposed to
aggressive environment, they shall require maintenance to ensure that the expected performance is achieved.
Guidelines given below should be followed for maintenance
a) Keep surfaces clean and free from continuous contact with moisture, dust and other debris.
b) Periodically inspect the joists for any signs of corrosion. Remove any by-products of the corrosion by mechanical
means and spot prime the exposed steel substrate with an appropriate steel primer. Repaint the area using an
appropriate paint.

Concrete: During the service life of the Speedfloor system, if any cracks appear in the concrete floor, they should
be filled using an epoxy injection grout or equivalent, to completely close the crack and prevent moisture ingress.

For detailed Installation process, manufacturer’s Installation Manual shall be referred.

Applications

The Speed floor composite flooring system is suitable for use in all types of construction including:

• Steel frames structures

• RCC frame buildings
• Poured insitu or precast concrete frames
• Light gauge steel frames
• Conventional Structural brick wall constructions etc

The range of end uses include :

• General individual Houses
• Multi-storey residential blocks
• Single and multi-storey retail developments
• Mezzanine floors
• Car parks and storage buildings
• Multi-storey office complexes etc.

STANDARDS/references

IS 277:1992 Specifications for Galvanized Steel Sheets (Plain & Corrugated)

IS 456:2000 Code of Practice for plain & reinforced Concrete (Fourth revision)
IS 875 (Parts1to3):1987 Code of Practice for Design Loads (other than earthquake) for buildings & structures
IS 1893 (Part-1):2002 Criteria for Earthquake Resistant Design of Structures - Part-1: General Provisions and
Buildings
IS 2062:2011 Specifications for hot rolled medium & high tensile structural steel
IS 11384:1985 Code of Practice for Composite Construction in Steel and Concrete
AS/NZS 1170-2 (Parts 0 & 2) : Structural Design Actions—General principles and Wind actions
2002
AS 2327(Part1):1996 Design of simply supported Composite structures
NZS 3101(Part1):2006 Design of Concrete Structures
NZS 3404 (Part1):1997 Design of Steel Structures
AS/NZS 4600:2005 Design of Cold Formed Steel Structures
AS/NZS 4671: 2001 Specifications for Steel reinforcing materials

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SRPL Building System (Waffle Crete)

(Suitable for Low Rise to Medium Rise Structures)

ABOUT THE TECHNOLOGY

Waffle-Crete Building System consists of large, structural,

ribbed panels of reinforced precast concrete, bolted together
and the joints between the panels are caulked to form the
walls, floor and pitched or flat roofs of buildings.

The surface of each panel consists of 51 mm thick slab or

skin, stiffened with the ribs around the perimeter and across
the panel, giving an overall panel thickness of 152 mm or 203
mm.

In single storey buildings, floors are constructed using precast

reinforced concrete floor panels supported on precast con-
crete grade beams on well- compacted earth. The walls are
constructed of 152 mm thick wall panels of precast reinforced
dense concrete.

For buildings of more than one storey, the walls are supported on foundations designed as per the soil condition.
A concrete apron are laid around the perimeter of buildings where there is a danger of water or wind erosion of the
ground adjacent to the building. Metal or timber window and door frames are incorporated into the wall panels dur-
ing casting or fitted after erection into openings that are formed in the panels during casting.

Internal walls consist of either reinforced precast concrete ribbed panels, conventional masonry walls or concrete
walls. Where precast concrete panel or masonry internal walls are used in single storey buildings, these are nor-
mally be erected on a concrete surface bed or on concrete strip footings and not on suspended floor.

Services like water supply and electricity shall be normally accommodated in preformed slots in the ribs of panels,
before the walls are lined. The casting can be done in casting yard while foundation is done, which reduces the
construction time. Curing time is reduced by trapping the moisture generated from the concrete. The building after
construction can be shifted from one place to another as the structure is joined using bolt connections.

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The Waffle-Crete system consists of the following core elements:

• Lightweight insulated precast insulated molds
• Insulated curing covers that are used in conjunction with Waffle-Crete molds
• Specialized equipment are designed for use with Waffle-Crete molds and covers
• A construction methodology for casting and erecting concrete panels with molds and equipment.

Concrete panels cast in molds and then covered with a curing cover are removed from the mold and erected.
Modular panels and bolted connections speed up the erection process. The system can be utilized for a variety of
structural applications.

TYPE OF PRECAST CONCRETE PANELS & WALLS

1. Standard reinforced precast concrete wall, floor and roof panels are 2.43 m wide and are manufactured in
lengths of 3.65 m, 4.26 m, 4.87 m, 5.48 m, 6.09 m & 7.31 m. The surface of each panel shall consist of a 51mm
thick slab, stiffened with tapered ribs around the perimeter and across the panel. The ribs shall be at approx. 1214
mm centres in one direction and 610 mm in the other and give an overall panel thickness of 152 mm or 203 mm,
as required.

2. Harmonized reinforced precast concrete wall panels are 2.58 m high and are manufactured in lengths of 3.65
m, 4.26 m, 4.87 m, 5.48 m, 6.09 m & 7.31 m. All harmonized panels shall be 152 mm or 203 mm thickness. The
surface of these panels shall consist of a 51 mm thick slab, stiffened with ribs around the perimeter and across the
panel. The ribs shall be at approx. 610 mm centers,with
two horizontal ribs along its length, one approx. 836 mm
from the bottom and the other 418 mm from the top. These
panels are used for window/door and window cut-outs.

3 Accessory Panels
a) Eave panels are used as decorative building
trim and also cover waffle voids that may be
exposed on the edges of cut roof panels.
b) Grade beams are used to cast a first floor
foundation. Grade beam panel are keyed to
fit floor panel ribs.
c) Stair panels are included an adjustable
blockout to cast concrete stairs of variable
width up to 2.44 m. Stair molds are avail-
able in 3.66 m & 6.10 m lengths with 164
mm risers.

4 Waffle-crete Floor Slabs

Thickness of concrete of topping may vary for different
requirement of fire ratings. Floor slabs with a 60 minute
fire-resistance rating shall require a minimum of 38 mm concrete topping and floor slabs with a 120 minute fire-
resistance rating shall require a minimum concrete topping of 75 mm or cladding to the underside.

The joints between the plasterboard shall be sealed according to the manufacturer’s recommendations. Floor slabs
with a 30 minute fire-resistance rating shall not require a concrete topping. Thickness of concrete topping may vary
for different requirement of fire-ratings.

5 Type of Walls
5.1 There are six types of internal and external walls which are used in conjunction with brick or concrete masonry
walls etc. The wall panels are 152 mm or 203 mm thick overall.

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i. Type 1 152 mm or 203 mm panels, unlined.

ii. Type 2 Wall panels lined on one side with 12.5 mm thick gypsum plasterboard on 38 mm x 38 mm
timber studs at 600 mm centers fixed to the panel ribs with screws into nailer blocks cast into concrete
at 600 mm centers.
iii. Type 3 Wall panels lined on one side with 12.5 mm thick gypsum plasterboard of 63.5 mm x 35 mm
x 0.71 mm thick on galvanized steel studs spaced at maximum 450 mm centres fixed to the ribs of
the panels with 18 gauze steel galvanized wire wound around threaded 6 mm dia. galvanized steel
fasteners hand-driven into a previously drilled hole in the rib of the floor panel.
iv. Type 4 Wall panels lined on one side with two layers of 12.5 mm thick gypsum plasterboard on gal-
vanized steel studs with staggered joints similar to those used in Type 3 wall fixed to the panel ribs in
the same manner as wall Type 3.
v. Type 5 Wall panels lined on one side with 12.5 mm thick gypsum plasterboard on top hat section
galvanized steel channels fixed to the panel ribs as for wall Type 3 and insulated with 150 mm thick
glass fibre.
vi. Type 6 Wall panels lined on one side with 12.5 mm thick gypsum plasterboard on timber studs fixed
to the panel in the same manner as for wall Type 2 and insulated with 50 mm thick glass fibre.

MATERIAL REQUIREMENTS

Rebar Fe 415/485 are in accordance with IS1786:2008 and of dia. 12 mm, 16 mm & 20 mm.

Wire mesh is made of 6 mm dia. bar as per IS1786:2008 @ 300 mm c/c.

Connection bolts M 16 x160 mm, M 16 x 380 mm & M 16x310 mm conforming to ASTM A 307 Gr A/IS 1363
(Part1-3):2002.

Anchor bolts HIT V M16 & HY 200R chemical conforming to ASTM A 307 Gr A/ IS 1363 (Part 1- 3):2002.
Concreting to be of M 30 grade concrete in accordance with IS 456:2000, without fly ash and coarse aggregate
shall be not more than of 20mm size. Water-cement ratio to be 0.40. Mix design with admixtures conforming to IS
9103:1994 shall have compressive strength of 19 N/mm2 in 18-24 h.

Swift lift Anchor have two anchors in each wall panel and four anchors in each floor panel. Spacing of anchors to be
according to cut-outs provision in respective panel.

Gypsum board conforming to IS 2095 (Part 1):2011.

MANUFACTURING PROCESS

Process of manufacturing of the panels is as follows:

i) Waffle-Crete components shall either be cast on site or in casting yard. An inverted panel or a concrete sur-
face bed shall be used as a base on which the components shall be casted.
ii) The heavy quality insulated plastics and aluminium molds shall be blocked off at any point if a particular non-
standard sized panel is required.
iii) Holes for bolted connections between components shall be usually formed during the casting of the compo-
nents.
iv) Metal, RCC or timber window and door frames shall be fitted in the block-outs left for the purpose.
v) Steel rod and mesh reinforcement shall be placed in the mold as specified by the professional engineer
responsible for design of the building. Spacer blocks shall be used to correctly locate the reinforcement to
ensure that the specified concrete cover is achieved.
vi) Concrete of minimum grade of M 35 MPa shall be poured into the molds from ready mix trucks / dumpers or
other suitable means.
vii) Specially designed vibrator shall be used to strike off and compact the concrete in one operation.

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viii) The insulated plastics and aluminium cover

to the molds keep the heat and moisture dur-
ing curing of the panels.
ix) The concrete components shall be lifted us-
ing specially designed lifting beam, or with
cable slings and embedded lifting anchors at
appropriate positions.
x) The panels shall be stacked horizontally on
top of each other, supported on timber spac-
ers and stored in the casting yard until re-
quired at site.
xi) Panels shall be de-molded after checking the
results by rebound hammer
xii) Molds shall be stacked in the casting yard
and curing of panels shall be done
xiii) The panels shall be transported to the erec-
tion location by trailer
xiv) The panels shall be lifted using crane and
fixed on the location by connection bolts
xv) After connection bolts are fixed, panels shall
be covered with high strength chemicals
xvi) Thereafter, finishing items like flooring, door & window fixing and painting etc. shall be done.

ERECTION PROCEDURE

(i) The properties of the soil on site shall be es-

tablished by a professional engineer and the
foundations and floors designed accordingly.
(ii) The conventional cast-in-situ concrete foun-
dations and surface beds with thickened
edge beams or footings, shall be constructed
on site in accordance with IS 1904:1986. The
surface beds shall be laid on well compacted
earth.
(iii) When suspended floor panels and founda-
tions are used, the grade beams shall be located under the longitudinal external walls of the building. They
shall be placed in position on the surface of the ground on well compacted and levelled earth, laid end-to-end
with butt joints.
(iv) Where the span between the grade beams on either side of the building is such that it is necessary to use two
or more floor panels across the width of the building, the ends of the panels at the joints where they meet shall
be supported by additional grade beams, laid parallel to the external grade beams.
(v) A continuous damp-proof membrane of a suitable plastic material, at least 0.25 mm thick, shall be provided
under conventional concrete foundations and surface beds.
(vi) The wall panels shall be hoisted and set in a vertical position, onto hardwood shims on the panel floor, con-
crete footing or surface bed, to create a space of uniform thickness under the bottom ribs of the wall panels,
for the grouted joint.
(vii) After levelling and aligning the wall panels on the shims, these shall be bolted to the floor panels and grade
beams, or to the cast-in-situ concrete surface bed or foundations.
(viii) Where threaded galvanized steel or stainless steel rods are used instead of anchor bolts, the ends of the rods

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shall be embedded in epoxy grout in holes drilled into the concrete, in strict accordance with the manufac-
turer’s instructions.
(ix) Sand-cement grout having a compressive strength of 35MPa at 28 days shall be used in all horizontal joints
between precast concrete components, unless otherwise specified by the engineer. A vibrator rod shall be
used to ensure that the grout completely fills the joints.
(x) Intermediate floors shall always consist of panels which are bolted together. There are three types of floor to
wall connections. In the first case the floor panel shall be supported on top of an external wall, in the second
case two floor panels shall be supported on an internal wall and in the third case a floor panel shall be sup-
ported on a ledger beam.
(xi) Staircases which are of precast concrete shall be deigned in the normal manner and bolted to the supporting
structure. At the beginning of a rise, the staircase shall be bolted with a 19 mm dia. vertical expansion anchor
through a 76 mm x 76 mm 38 mm recess in the first step to the supporting structure. At the upper end of
the rise, the staircase shall be fixed with a minimum of three 19 mm dia. x 254 mm long expansion anchors
through the floor.
(xii) On the outside of the building, the grout shall be partially raked out of the horizontal joint all round between
the bottom of the external walls and the floor, concrete surface bed or footing to allow for the insertion of butyl
rubber rope, followed by a bitumen impregnated foam plastics backer rod or bond breaker and caulked with
one component polyurethane sealant.
(xiii) The adjoining vertical ribs of the external panels shall be bolted together with 12.7 mm dia. galvanized steel
or stainless steel bolts at 1.2 m centres through preformed or drilled holes for 152 mm thick panels or 20 mm
dia. bolts at 1.2 m centres for 203 mm thick panels.
(xiv) The vertical joints between external wall panels shall be caulked on the outside of the building with one com-
ponent polyurethane sealant a bitumen impregnated foam plastics backer rod or bond breaker.

Roof Construction and Gable Wall

(i) Triangular wall in-fill panels shall be hoisted into position on hardwood shims on top of the end walls of the
building and bolted together through the adjoining outer horizontal ribs with 12.7 mm dia. galvanized steel or
stainless steel bolts at 1.2 m centres.

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(ii) Precast concrete roof panels which span between the gable ends shall be hoisted into position on the sloping
tops of the gable wall panels and bedded in 6 mm thick 4:1 sand: cement mortar, to form a pitched roof. The
pitch shall generally be 30º.
(iii) Galvanized steel plates, 60 mm long x 100 mm wide x 10 mm thick, at 2.4 m centres and cast into the ribs on
the underside of the roof panels on either side of the ridge, shall be connected at the apex by welding a steel
rod at the joint between each pair of plates.
(iv) Depending on the structural design of the building and span of roof, the roof shall be supported at its apex by
a ridge beam spanning between the gable wall infill panels at each end.
(v) The adjoining roof panels shall be bolted together with 12.7 mm dia. galvanized steel or stainless steel bolts
at 1.2 m centres, through preformed or drilled holes in the ribs of the panels. Before fully tightening the bolts,
butyl rubber rope shall be inserted into the joint between the panels, followed by a bitumen impregnated foam
plastics backer rod or bond breaker and the joint shall be caulked externally with one compound polyurethane
sealant or equivalent.
(vi) Flat roof shall consist of 152 mm or 203 mm thick precast reinforced ribbed wall panels bolted together and
covered with a conventional waterproofing system on screed. Precast roof copings shall be bolted to the roof
panels with 12 mm dia. bolts at 1219 mm centers.
(vii) Internal walls on suspended floors shall usually be constructed of timber with 12.5 mm thick gypsum plas-
terboard cladding on both sides. Conventional burnt clay or concrete masonry internal walls shall usually be
erected on conventional concrete surface beds and foundations.
(viii) Internal walls shall also be plugged and screwed by means of steel brackets and bolts to the adjacent vertical
ribs of the external walls at T-junctions and bolted or plugged and screwed to concrete surface beds or precast
floors.

Windows, Doors, Services and Attachment of Fittings

Timber or steel window and door frames shall be fitted into preformed openings in the wall panels and sealed all
round with silicone sealant, unless they have been cast in during manufacture of the panels.

Electrical and plumbing services shall be installed in the preformed notches on inside of the wall panels, or through
sleeves cast into the ribs.

Sanitary fittings, cupboards, shelving, and other heavy fittings shall be attached to the walls with galvanized steel
bolts taken through holes drilled in the backing skin of the wall panels, or with expansion bolts fixed to the panel
ribs.

Protection against corrosion and finishes

Steel bolts, anchor bolts, nuts, washers, threaded rods, brackets and cleats used at connections and joints in exter-
nal walls, roofs, floors and foundations are hot-dip galvanized in accordance with IS 4759:1996 and coated with a
metal primer, a good quality bituminous paint or epoxy painting or they are of stainless steel.

The exterior surface of roofs and external walls shall be painted with two coats of suitable exterior grade acrylic
emulsion paint. Painting of reminder of the building shall be carried out in accordance with the manufacturer’s re-
quirements.

APPLICATIONS

The system is used for low rise to mediurm rise mass housing projects, commercial buildings, manufacturing facili-
ties, retaining walls etc.

SPECIAL FEATURES

Structural Stability
The strength of connections between components and with recessed bolts shall be determined by test before use.
In addition to conventional structural design aspects, the design of the building shall address the following:

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• Stability of gable walls

• Bracing of façade walls against wind loads
• Structural integrity and resistance to progressive collapse due to accidental damage to local elements.

Durability
The structural design shall comply with all the relevant Indian Standards, including IS 456:2000, IS 875 (Part 1, 2
& 3):1987, IS 4326:2013, IS 1893 (Part 1):2016, IS 13920:2016 & National Building Code of India 2016. Reference
shall also be made to the design recommendations given in Waffle-Crete’s design manual and specifications.

Behavior in earthquake and wind

All precast concrete floor, wall and roof panels and grade beams shall also be designed for loading conditions dur-
ing de-molding, transportation and erection.

Fire Safety
Floor slabs with a 60 minute fire-resistance rating shall require a minimum of 38 mm concrete topping and floor
slabs with a 120 minute fire-resistance rating shall require a minimum concrete topping of 75 mm or cladding to
the underside

MAJOR COMPLETED PROJECTS

• 464 Dwelling units under IHSDP for slums of Anand Nagarpalika (Gujarat)
• 480 Dwelling units of Dahod Nagarpalika (Gujarat)
• 512 Dwelling units Housing (G+3) at Bharuch Nagarpalika, Bharuch (Gujarat)

CERTIFICATION

Performance Appraisal Certificate No. 1021-S/2015 issued to M/s Shaival Reality Pvt. Ltd., Ahmedabad.

STANDARDS/REFERENCES

No. 97/260 South Africa Agreement Certificate No. 97/260 for Waffle-Crete Agreement System of Waffle-
Crete International Inc
IS 158:1981 Ready mixed paint, brushing, bituminous, black, lead free, acid, alkali and heat resisting
IS 456:2000 Code of Practice for Plain and Reinforced Concrete (Reaffirmed 2016)
IS 875 (Parts 1&2):1987 Code of Practice for Design Load of Buildings and Structures (Reaffirmed 2013)
IS 875 (Parts 3):2015
IS 1363:2002 Hexagon Head Bolts, Nuts and Screws of Product
IS 1367:2002 Technical Supply Conditions for Threaded Steel Fasteners
IS 1786:2008 High strength deformed steel bars and wires for concrete reinforcement - specification
(Reaffirmed 2013)
IS 1893 (Part 1):2016 Criteria for Earthquake Resistant Design of Structures (Part 1). General Provisions and
Buildings.
IS 1904:1986 Code of practice for design and construction of foundations in soils – general requirements
(Reaffirmed 2015)
IS 2095 (Part 1):2011 Specifications for gypsum plasterboards –Plain gypsum plaster boards (Reaffirmed 2016)
IS 4326:2013 Code of Practice for Earthquake Resistant Design and Construction of Buildings
IS 4759:1996 Hot Dip Zinc Coating on Structural Steel Products
IS 7215:1974 Tolerances for Fabrication of Steel Structures (Reaffirmed 2016)
IS 9103:1999 Concrete admixtures - Specification (Reaffirmed 2013)
IS 10505:1983 Code of practice for construction of floors and roofs using precast concrete waffle units
(Reaffirmed 2013)
IS 13920: 2016 Code of practice for ductile detailing of Reinforced Concrete Structures subjected to seismic
forces.

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Precast Large Concrete Panel System

(Suitable for Low Rise to High Rise Structures)

ABOUT THE TECHNOLOGY

Precast Large Construction Panel (PLCP) system consists of various precast elements such as walls, beams,
slabs, columns, staircase, landing and some customized elements that are standardized and designed for stability,
durability and structural integrity of the building. Precast residential building construction involves design, strategic
yard planning, lifting, handling and transportation of precast elements. This technology is suitable for construction
of high rise buildings resisting seismic and wind induced lateral loads along with gravity loads. The building framing
is planned in such a way that maximum number of repetitions of moulds is obtained. These elements are cast in a
controlled factory condition. The factory is developed at or near the site which provides an economical solution in
terms of storage and transportation.

TYPES OF PRECAST ELEMENTS AND MOULDS

Two main types of precast concrete elements, namely precast reinforced concrete elements and precast pre-
stressed concrete elements are used as per the details given below:

i. Precast reinforced concrete elements

These shall consist of reinforcement bars and/or welded wire meshes within the elements to provide the tensile
strength and resistance against cracks such as façade walls, beams, columns, slabs, refuse chutes, staircases and
parapet walls.

ii. Precast pre-stressed concrete elements

These shall consist of pre-stressing tendons within the elements to provide a predetermined force needed to resist
external loadings and cracks such as hollow core slabs, beams and planks.

Typical size of precast elements is given below:

Sr. No. Precast Components Typical Sizes*

1 Wall Panels 5m x 2.85m
2 Slabs 3m x 5m
3 PODS 1.52m x 1.36m x 2.83m
4 Beam 0.20m x 0.40m x L
5 Staircase As per design
6 Columns 0.90m x 0.35m x 2.85m
* Sizes of panel slabs may vary as per the architectural and construction requirement.

iii. Moulds
Moulds for precast elements shall be of steel and concrete. For design of the moulds for various elements, special
importance should be given to easy de-moulding and assembly of the various parts. At the same time rigidity and
strength and water tightness of the mould are also important taking into consideration forces due to pouring of green
concrete and vibration. The type of moulds used for pre-casting various elements with various methods is given
below:

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Sr. No. Mould Type Uses

Ribbed slab, beams, window panels, box type units and special
1 Conventional moulds
elements
2 Battery moulds Interior wall panels, shell elements, roof and floor slabs
Exterior wall panels where special finishes are required on one
3 Tilting moulds
face or for sandwich panels
4 Long line prestressing beds Double tees, ribbed slabs, piles and beams
5 Extrusion machine Roof slabs and hollow core slabs

Battery Mould Tilting Mould POD Mould

MATERIAL REQUIREMENTS

Ordinary Portland Cement: Shall be of 43 grade as per IS 269:2015.

Fine aggregate (M Sand): Shall be as per IS 383:2016 & IS 1542:1992 and 4.7 mm.
Coarse Aggregates: Shall be as per IS 383:1970 and of 20 mm, 40 mm size
Steel reinforcement: Shall be as per IS 1786:2008
Concrete: The grade of concrete shall be M 30 and slump for walls, floors and roofs shall be as per IS 456:2000.
Brick masonry: Shall be designed as per IS 1905:1987
Solid Block work: Shall be as per IS 2185 (Part 1):1979
Aluminium: Shall be as per IS 733:1983
Glass: Shall be as per IS 2835:1987
Non-shrunk non-metallic grout: Cement based flowable grout shall have compressive strength of 65 N/mm2, flexural
strength of 9 N/mm2 at 28 days and E-modulus of 37000 N/mm2.
Water proofing membrane: Fibre reinforced repair mortar shall have compressive strength of 45 N/mm2 at 28 days
and density 2250 kg/m3
Baker Rod: Closed cell polymer based product shall have compressive strength of 0.45 kg/cm2 min. at 25% de-
flection, density 22 kg/m3 min. and water absorption 0.14 gm/cm3 max.
Corrugated sleeve: Hot dipped galvanized prime steel sheet shall be as per IS 277:2003.

APPLICATIONS

The system is used economically for mass housing projects and commercial buildings, etc.

INSTALLATION

1. Precast Installation
Proper planning and preparatory works shall be required before the actual installation of precast concrete elements
in order to ensure quality installation. The following items shall be planned in advance:

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i. Method of sequence of assembly and installation: Precast elements should be identified based on their loca-
tion number and the tagged.
Ii. Method of providing temporary support: Elements should be supported temporarily before these get sta-
bilized. Generally structural members with adjustable ends shall be used for securing the panels. Shims
should be used to adjust the panels to ensure dimensional correctness.
iii. Installation tolerances: Installation tolerances should be based on codal provisions and design consider-
ations should be clearly indicated.
iv. Handling and rigging requirements: Elements should be checked for handling stresses before lifting and the
cranes should have sufficient capacity to handle the precast panels. At least 10% impact should be consid-
ered while calculating the lifting capacity of the crane.

At site locations, panels shall be first unloaded and stacked or directly lifted by the crane. The element shall then be
installed on the site and supported by temporary jacks. The cranes shall be released for next lifting once the tempo-
rary supports are in place. Shims shall be used to carefully align the element before grouting. The panels shall be
grouted after the final adjustments are done.

2. Waterproofing
External joints shall be sealed with baker rods and sealants after filling the joints with grout to avoid the leakage.
Additional waterproofing treatment shall be provided at external joints and wet areas to ensure water tightness.

3. Mechanical, Electrical & Plumbing Fittings

• Mechanical, electrical & plumbing fittings shall be kept open or concealed as per the requirements. For
concealed fittings, provision for grooves, blockouts shall be made in casting moulds.
• The conduits and electrical boxes shall be embedded and fixed in moulds before casting. For open fittings,
these shall be fixed after erection at site.
• For firefighting systems, provision of National Building Code (NBC) and local Building Byelaws shall be ad-
hered to.

4. Fire Rating
• Precast concrete shall be designed for fire rating of 1 to 2 h based on codal requirements.
• Minimum precast concrete wall thickness of 120 mm shall be provided for 1 h fire rating as per IS
456:2000.

5. Finishes
• Variety of shapes, colours, textures and finishes may be obtained with precast concrete.
• The surface treatments shall be done by rebating, grooving, surface coatings, cement based renders, oxide
coloring etc.
• Precast concrete facades of various shapes, colours and textures may be moulded and installed.

IMPLEMENTATION OF PRECAST ELEMENTS

1. Casting Concrete
The procedure for casting concrete shall be as follows:
i. Precast concrete elements shall be produced on horizontal/vertical, flat steel surfaced tilting tables.
ii. Prior to casting, electrical conduits and other required shall be fixed in position and the mould treated with
mould release agent.
iii. Steel reinforcement shall be kept in position using adequate spacers to ensure correct position and concrete
cover.
iv. After that side shutter shall be fixed. The high quality concrete shall be transported from batching plant to the
precast yard through transit mixer.
v. Thereafter, concrete shall be carried to mould by gantry crane with concrete bucket.
vi. During casting, table vibrators (as & when required) shall be used to achieve the best compaction. Top sur-
face shall be finished with hand operated trowel which gives smooth finish.

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Wall Panels Parapet Beams Spandrel

Solid Slab Panels POD Elements Staircase

Precast Elements

vii. Care should be taken on embedded items while concreting.

viii. After casting, all exposed surfaces shall be covered with a tarpaulin (as and when required) to avoid va-
porization. Casted elements shall be de-moulded once the strength meets the design requirements and the
units are then shifted to the stockyard. Thereafter, curing shall be carried out for 5 days.

2. Curing
The curing of the prefabricated elements may be done by the normal methods of curing by sprinkling water and
keeping the elements moist. This can also be done in the case of smaller elements by immersing them in spe-
cially made water tanks.

3. Screed Concrete for Flooring

The surface for screed concrete shall be clean, free from dust, loose materials, lumps and foreign material.

The screed shall generally be provided over the entire slab. In this case the entire slab shall act as a continuous
structural diaphragm providing optimum load transfer mechanism for lateral loads. The screed shall be treated as a
part of the compression zone for gravity loads on the slab. The design shall consider composite action between the
slab & screed and compressive strength of screed in slab. Further, the interface shear between the slab & screed
shall be checked for verifying adequate shear transfer capacity at the interface.

i. Screed on haunches may be provided, only if the conduits are exposed, with the mutual agreement between
the project authority and the technology provider. In such cases, additional water proofing treatment of a
reputed company shall be provided at the precast slab and site concrete stitch.
ii. Electrical conduits or any other embedment shall be laid as per approved drawings before screed concrete
flooring.
iii. The reference level from main survey pillars shall be transferred and marked on side channels.
iv. While marking level, sloping direction in flooring shall be taken care as per approved drawing.
v. Before laying the concrete, cement slurry shall be spread on the slab surface for better bonding and filling of
gaps between wall and slab soffit junction.
vi. The concrete should be placed from one end and shall be compacted immediately after placing and levelled
uniformly.
vii. The vibrator should be applied smoothly and concrete compacted well.

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viii. The concrete shall be allowed to set so as to be in dry condition.

ix. The trowelling shall start after concrete is set and reach dry condition.
x. Curing shall be done by using bunds over the screed surface/wet hessian cloth.

4. De-moulding and Stacking

4.1 Lifting of elements from mould

i. It must be ensured that all the elements should have identification mark.
ii. It must be ensured that all side shutters are loosened so that the elements may be lifted without any dam-
ages.
iii. Before demoulding, it must be ensured that compressive strength of the cubes should meet the specified
requirements.
iv. The lifting clamps/clutches shall be fixed to lifting beam at proper positions.
v. Then the elements shall be lifted carefully to the stocking area.

4.2 Stacking of elements

i. The surface of stacking area should be horizontal.
ii. The wooden runner shall be placed perpendicular to lifting points and the elements placed over runner.
iii. Number of the elements per lot should not exceed man height.
iv. In case of vertical stacking, the gap between the elements should be 150mm to 200 mm.
v. Stacking shall be done in such a way that slabs of longer span should be placed below that of shorter
span.

5. Transportation of Elements

5.1 Loading of slab over trailer

i. It must be ensured that the identification mark on the slab should be the same as per dispatch list.
ii. Any damage occurred during loading should be informed to the concerned authority.
iii. The lifting clamps/clutches shall be fixed to the lifting beam at proper position.
iv. The lifting beam shall be placed over the precast elements and ensured that the clutches are locked properly
before lifting.
v. Instruction regarding loading height, positioning of precast elements over the trailer should be followed as
per capacity of trailer.
vi. The wooden rubber shall be placed in between the slabs at 500 mm from each end.
vii. Some of precast elements should be placed vertically and transported through “A” frame fixed vehicle.
viii. The slab shall not be overhanging from trailer.
ix. The slab shall be tied firmly to the trailer by means of belt/rope as moving the load without proper tie will
cause damage.
x. While transporting elements vertically, the vehicle should be loaded equally on both sides.

5.2 Unloading of slab from trailer and placing in site yard

i. Every slab shall be inspected for dimensions/identification mark and damages etc. prior to unloading at
site.
ii. The stacking area should be levelled and hard enough for stacking the elements.
iii. There should be proper access for trailer movement.

6. Erection

The process of erection and installation of panels during the construction cycle by using tower cranes shall be as
follows:

i. Before starting erection a survey of the area to receive precast elements shall be done to monitor any dif-
ference in dimensions or levels exceeding the tolerances. In case of unacceptable tolerances, necessary
action shall be taken for rectification.
ii. Installation shall be done by tower crane with sufficient capacity. Panels shall be shifted from the stack rack/
truck from yard to the nearest point of construction site and shall be kept above the truck during the construc-

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tion or inside the storage racks as per the site situation.

iii. The necessary access for the truck to reach the nearest
point of the tower shall be prepared before starting erec-
tion of the panels.
iv. Once the truck reaches the tower, chain and lifting clutch
with required capacity and guide rope shall be attached
to the precast panels to allow the workers to control the
load to its final place.
v. As the elements are lifted to its final position above the
cast-in-situ slab/precast panel, vertical and horizon-
tal alignment of the panel shall be adjusted. The gap
between the element and adjusted elements shall be
maintained as per the drawings within the allowable tol-
erances. Shims and spacers shall be used for levelling
and adjustment.
vi. Temporary propping jacks shall be provided for restrain-
ing the walls laterally until grouting.
vii. After completion of fixing, alignment of the panels shall
be checked again.
viii. Minor damages, if any to the precast panels shall be re-
paired by approved materials.
ix. After completion of installation and alignment, elements
shall be handed over for inspection.
x. The joints between the precast wall panels shall be filled with joint filler material.
xi. Precast slab shall be erected above the wall panels without any scaffolding system. The electrical conduit/
fitting shall be done. After electrical works are completed, screed concrete shall be laid over the precast
slab.
xii. Installation of the next floor shall start only after completion of screed concrete of the previous floor.
xiii. The sequence of erection shall be as follows:
• Installation of precast wall panels above cast-in-situ slab
• Provide temporary props/jacks for restraining of the walls laterally.
• Grout the connection between the wall panels & ground floor slab and the joint between each wall panel.
• Installation of precast slab panels above the erected precast wall panels.
• Screed concrete above the slab after placing of electrical conduits / fittings
• Installation of the wall panels over the floor slab.
• Installation of the roof panels such as parapets etc.

SPECIAL FEATURES

Structural Stability
The overall behavior of a precast structure is dependent on the behavior of the connections which must provide:
• Resistance to all design forces
• Ductility in case of excessive deformation
• Resistance to volume changes and related forces
• Adequate durability
• Required fire resistance
• Feasible production considerations
• Feasible construction considerations

The overall design of the structure shall be done in accordance with IS 875 (Part 1 to 5), IS 456:2000, IS
1893(Part 1): 2016, IS 13920:2016 and IS 15916:2010, as applicable.

Large panels shall be in accordance with the provisions of IS 11447:1985.

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Durability
Structural load bearing walls shall be designed as per codal provisions of IS 456:2000 and IS 13920:2016 as ap-
plicable.

Behavior in earthquake and wind

The components of the structure shall be designed for loads in accordance with IS 875 (Parts 1-5):1987 and IS
1893 (Part 1):2016. In addition members shall be designed for handling, erection and impact loads that might be
expected during handling and erection.

Fire Safety
Period of fire resistance of RCC buildings is based on NBC requirements. To meet the fire rating requirement, provi-
sion specifications.

WORKS COMPLETED

1. Construction of (G+23) Pragati Towers at Mumbai in 1972 (2024 units).

2. Construction of (G+12/G+14) Provident Sunworth Project at Bangaluru in 2015 (5952 units).

CERTIFICATION

Performance Appraisal Certificate No. 1027-S/2016 issued to M/s Larsen & Toubro Ltd., Mumbai by BMTPC.

STANDARDS/REFERENCES

• Suitability of Precast Concrete Large Panel system for Mass Housing Projects by IIT Madras
• Design & Construction Methodology Review for Rehab Bhiwada Precast Project, Mumbai by IIT Madras
• Verification of Thermal Performance Reports – Evaluating RCC Wall apartments in Ahmedabad & Chennai by Indian Institute
of Science, Bangalore.
IS 456:2000 Code of Practice for Plain and Reinforced Concrete (Reaffired 2016)
IS 875 (Parts 1,2,4&5):1987 Code of Practice for Design loads (other than earthquake) of buildings and structures
IS 875 (Part 3):2015
IS 1786: 2008 High strength deformed bars and wires for concrete reinforcement (Reaffirmed 2013)
IS 1893 (Part 1):2016 Criteria for Earthquake Resistant Design of Structures (Part 1) - General Provisions and Build-
ings
IS 1904:1986 Code of practice for design and construction of foundations in soils – general requirements
(Reaffirmed 2015)
IS 2062:1992 Hot Rolled Medium and High Tensile Structural Steel
IS 7215:1974 Tolerances for Fabrication of Steel Structures (Reaffirmed 2016)
IS 9103:1999 Specifications for Concrete admixtures (Reaffirmed 2013)
IS 11447:1985 Code of practice for construction of large panel prefabricates (Reaffirmed 2013)
IS 13920:2016 Code of practice for ductile detailing of Reinforced Concrete structures subjected to seismic
forces.
IS 15916:2010 Code of practice for building design and erection using prefabricated concrete (Reaffirmed
2013)

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Industrialized 3-S system using RCC precast with or

without shear walls, columns, beams, Cellular Light
Weight Concrete Slabs/Semi-Precast Solid Slab
(Suitable for Low Rise to High Rise Structures)

About the technology

The industrialized total prefab construction technology, being used since 1972, is based on factory mass manufactured
structural prefab components conforming to provisions of relevant Indian Standards. The major precast elements
are:
• RCC hollow columns with notches
• RCC solid beams (T/L/Square Shape)
• Staircase
• RCC precast slab
• AAC precast slab
• AAC precast block

In the system, precast dense concrete hollow column shell of appropriate sizes are used in combination with
precast dense concrete rectangular / ‘T’ shape / ‘L’ Shape beams with light weight reinforced autoclaved cellular
concrete/Precast RCC slabs for floors and roofs. The hollow columns are grouted with appropriate grade of in situ
concrete. All the components and jointing of various structures are accomplished through on-site concerting along
with secured embedded reinforcement of appropriate size, length and configuration to ensure monolithic continuous
resilient, ductile and durable behaviour. Autoclaved Aerated Concrete (AAC) slabs can be used as floor / roof slabs.
Joints are filled with reinforced screed concrete (minimum 40 mm thick) of M20 grade minimum. RCC screed is laid
over entire area of slab before flooring / water proofing.

Basic Material Requirements

RCC hollow columns & Beam

Concrete
Shall conform to appropriate grade based on environmental and
structural requirements condition as per IS 456 : 2000
Reinforcement
Shall be of Fe 415 Grade or Fe 500 Grade as per
IS 1786:2008

AAC Precast Slab

Grade 1 of Density 551 – 650 Kg/m3 of IS 6073:2006

AAC Precast Block

Density 451-550 Kg/m3 for internal wall, 551-650 Kg/m3 for
external wall as per IS 2185 (Pt. 3) :1984

Other Requirements:
Evaluation of Structural Requirement of Joints

Against vertical load

• Full Scale load test on assembly of precast elements by Tor Steel Research Foundation in India, Bangalore

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

found it safe.
• Structural Design evaluation for HIG – II Buildings at Powai by Shri
H.P. Shah; Stanford University found that based on the design concept,
design calculation and detailing; the structure is safe against vertical
loads, seismic loads and the wind loads.
• Scrutiny of design for S+24 type buildings by IIT Mumbai found it safe.
• Scrutiny of design details for Delhi project by IIT Roorkee found jointing
& connections ensuring monolithic, durable & ductile behaviour.

Against seismic and wind load

A Test was performed by CBRI on full-scale building to establish behaviour
of various joints under all design loads including seismic Zone IV. The
experimental results on Full Scale Building Structure demonstrated the
desired performance and behaviour of the 3S system under all loading
condition as envisaged.

When designed for use in Zone V, independent verification may be needed.

Durability

• Anti corrosive treatment given to reinforcement used in AAC slab

panels for durability, was evaluated by CBRI, Roorkee with satisfactory
results.
• Concrete and cover requirement are as per durability clause of IS 456 :
2000, to ensure adequate durability.

Fire Resistance property of block / slab as dwelling unit

AAC blocks / Slabs used will have fire rating as per the NBC norms for dwelling units.

Thermal Behaviour

Kvalue – 0.122 k cal/h/moc of AAC blocks*.

Acoustic Comfort Test

For 100 mm ACC Wall, Sound absorption is 38

– 40 db*

Impact Resistance

Not tested*

Ease of Fixing services

(Electricity & Plumbing)

With pre-planning, electricity & plumbing

services can easily be placed.

Availability of Plants & Machinery

Plants & Machineries for production of Components available in Pune, Mumbai, Bangalore and Delhi

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

economy of Scale

• For a new plant to be setup, a minimum project of 5000 dwelling

units may be needed.
• In places, where plant is already set up, smaller project may also
be viable.

Essential Requirements

• Precasting yard / factory set up is required with facilities such as

Casting Yard, Computerised batching plant, Moulds, Transportation
facility, Stacking yard for materials & components, Lifting and
loading facility, Laboratory to test raw material & finished products,
Water tank of enough holding capacity as required for 2 – 3 days,
Service road, etc.
• Utmost attention is required for process engineering before taking
up any field work. Close co-ordination between design crew, field
staff and quality crew is essential.

Limitation

The project is taken as turnkey project by the agency M/s B.G.Shike &
Co., Pune. No other agency is involved in this propriety system.

Major Construction work done

1. Multistoried prefab residential buildings comprising over 400

Lacs sft built area have been completed since 1974
2. Residential EWS, LIG, MIG and HIG housing projects at
Kharghar, Navi Mumbai for CIDCO.
3. Residential mass housing project of MHADA, Powai, Mumbai.
4. S+24 Multistoried Residential Building for mill workers & transit
accommodation for 1000 families at Mumbai.
5. Mass Housing Projects at Delhi for DDA.
6. S+14 multi storeyed MIG & HIG type buildings at Versova, Mumbai for MAHADA.
7. Multistoried residential buildings of Transit, LIG, MIG & HIG type of 10,650 families at SION Mumbai.
8. Several projects are being taken up / completed in the state of Maharastra, Karnataka, Andhra Pradesh,
Tamil Nadu & Delhi.

Standards/Guidelines Referred:

IS 456:2000 Code of Practice for plain and reinforced concrete (Reaffirmed 2016)
IS 875 (Pt.3):2015 Code of Practice for Design Loads (Other than Earthquake) for Buildings and Structures - Part 3 : Wind
Loads
IS 1786:2008 High strength deformed steel bars and wires for concrete reinforcement - Specification (Reaffirmed
2013)
IS 1893 (Pt.1):2016 Criteria for Earthquake Resistant Design of Structures - Part 1 : General Provisions and Buildings

IS 1950:1962 Code of practice for sound insulation of non-industrial buildings (Reaffirmed 2015)
IS 2185 (Pt.3):1984 Specification for Concrete Masonry Unit - Part 3: Autoclaved Cellular (Aerated) Concrete Blocks
(Reaffirmed 2015)
IS 3792:1978 Guide for heat insulation of non-industrial buildings (Reaffirmed 2013)
IS 6073:2006 Autoclave Reinforced Cellular Concrete Floor and Roof Slabs - Specification (Reaffirmed 2017)
IS 13920:2016 Ductile detailing of reinforced concrete structures subjected to seismic forces - Code of practice
NBC 2016 National Building Code, 2016

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Walltec Hollowcore Concrete Wall

(Suitable for Non Load Bearing Structures)

About the technology

These are extruded non-load bearing concrete hollowcore wall panels manufactured in fully automated machines.
Walltec wall panels are factory produced using light weight concrete made of river sand, crushed stone aggregate,
light weight aggregate and Ordinary Portland cement. The concrete are extruded and cut while still wet to the requi-
site length. Curing and sealing are followed for 24 to 48 hours by stacking and palletizing after which the walls are
watered and cured for a further period of 7 to 8 days. After 15 days the panels are ready for transportation to site.

Walls have cylindrical hollow cores incorporated with 7 No. 53 mm dia voids in the 92mm thickness and 6 No. 74
mm dia. voids for the 120 mm thickness panels. The corresponding nominal weight shall be 140 kg/m2 and 170 kg/
m2 for 92 mm and 120 mm thick panels respectively. Hollows are incorporated in Walltec walls to reduce weight,
facilitate mechanical, electrical and plumbing services through hollows, thereby increasing sound and thermal insula-
tive properties. The sides of all panels are tongued and grooved to facilitate positive jointing.

Walltec walls do not require stone or wood sills/frames to level surfaces for windows and openings. Lintels need not be
cast as panels may be placed horizontally as lintels wherever required. Wash basins, cup-boards, mirrors, paintings
etc. may be hanged with regular plug screws. Details of the wall panels showing hollow cores is given in Fig.1

Fig.1

Type and size

Walltec walls are produced in standard widths & thicknesses and in lengths to suit room height as per the details
given below and shown in Figs. 2 & 3:
Wall width : 600 mm
Wall thickness : 92 mm & 120 mm
Wall Height : 2.40 m, 2.60 m, 2.85 m, 3.00 m, and 3.30 m
Weight : 92 mm : 140 kg/m2, 120 mm :170 kg/m2

Fig.2 Fig.3
Walltec walls use regular concrete of density 2350 kg/m3 and Walltec Lite uses light weight concrete of density 1550
kg/m3.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Tolerances

The panels shall be produced in accordance with the following tolerances:

Length : ±10 mm,
Width : ±3 mm,
Thickness : ±3 mm,
Squareness of end : ±6 mm
Differential bowing between adjacent panels of the same Length : =15 mm

Raw materials

i) OPC 53 grade cement shall conform to IS 12269:2013

ii) River sand and coarse aggregate 2-6 mm shall conform to IS 383:2016
iii) Flyash shall conform to IS 3812 (Part 1):2013
iv) Crushed Autoclaved Aerated Concrete (AAC) Waste

Manufacturing Process

The manufacturing process of Walltec wall panels is as follows:

Raw Material
Sieved River Sand, 6mm Stone Aggregate, AAC Waste shall be supplied to the plant by supplier where it shall be
weighed and sieve analysis & silt content checked as per the quality assurance norms. Cement shall be supplied
in closed bulkers directly from the manufacturers’ plant and fed into cement silo directly using blower. AAC Waste
shall be crushed and sieved in using crusher & sieve combo machine which also has a dust collector shall collect
superfine particles and the crushed AAC aggregate (8mm and lower fineness) shall be fed directly into the LWA (light
weight aggregate) aggregate bin which shall be equipped with a moisture probe.

Concrete Mixing
Concrete required shall be batched and mixed at an automatic batching and mixing plant with Planetary Pan Mixer
and Moisture probes. The relatively dry aggregates shall be automatically weighed & batched into the mixer from
Aggregate Bins. Two of the Aggregate bins shall be equipped with moisture probes to ascertain accurate weighing
and water content calculation later in the final concrete mix. Afterwards cement and water shall be added into the
mixture. A low water-cement ratio of about 0.3 ensures that concrete is zero-slump and gains about 70% of its design
strength within 12-24 hours of casting. Moisture content of the mixed concrete shall also be automatically controlled
and adjusted by the software thus ensuring consistent concrete mix at all times. The software auto adjusts for water
content based on readings of the moisture probes. After mixing, the concrete batch shall be fed to the conveying
system, which brings fresh concrete to the hopper of the Acotec Wall – line where Walltec-Walls shall be cast, cut,
trimmed, stacked, pre-cured, restacked and strapped into bundles.

Extrusion
The Walltec-Wall elements shall be formed in a continuously operating extruder. The concrete shall be compacted
onto thin base moulds, which support the products during the pre-curing time. Base moulds shall be automatically
fed to the extruder as a continuous ribbon. The base mould length shall determine standard length of the products.
There can simultaneously be maximum five plate lengths in the system. The extruder shall compact the concrete
with extrusion screws against the packing bar and side walls. Top surface of the product shall be vibrated by a
vibrating plate.

Cutting
After extruding, the products shall be cut according to the base mould length. A circular saw shall cut the fresh concrete
on each base mould seam. Then the cut product together with the supporting plate shall be pulled to the stacker.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Trimming
When necessary, the fresh product shall be stopped at a specified point, where the manually adjusted circular saw
cuts off the wanted trimming piece. Trimming length shall be max. 20 cm. The trimmed off concrete shall be recycled
back to the extruder.

Stacking
Cut, fresh products shall be stacked into pre-curing stacks. Depending on the product thickness and weight each
stack shall contain 4 to 10 products and base moulds. Stacks shall be supported by steel pallets, which are auto-
matically fed underneath each stack.

Pre-curing
The stacks shall stay 12 to 24 hours in the pre-curing indoor storage area where natural pre-curing occurs for each
stack which is covered with tarpaulin to stop any evaporation and moisture loss. The storage shall be an area where
natural curing occurs. Product stacks shall be moved into and out from the stock area by a forklift.

Restacking
After pre-curing the products are strong enough to stand automatic handling. Products shall be separated from the
base molds. Base molds shall be returned back to circulation trough a cleaning and oiling unit. The products shall
be restacked to form delivery stacks with 4 - 10 products on top of each other. The stack shall be pushed against
a wooden delivery pallet and turned on its side. Delivery stacks shall be strapped before transportation to delivery
storage. Stacks must stay in the delivery storage where they shall be kept moist by external manual water sprinkling
for at least 7 days before transporting to a construction site after 15 days on a Truck or Flat-bed Trailer. Loading of
trucks shall be done with Forklift or Hydraulic Cranes.

Performance Criteria

Walltec wall panels shall meet the following performance criteria:

S.No Properties Test Method Requirements as per relevant Standards

92mm 120mm

1. Dry density (kg/m2) IS 516:1959 140 min. 170 min.

2. Flexural strength N/mm 2

IS 516:1959 2.4 max. 3.5 max.

3. Compressive strength N/mm2 IS 516:1959 15 min. 25 min.

4. Moisture content (%) IS 516:1959 4.8 max. 4.8 max.

5. Impact strength (Falling weight) (N) ISO 179 2: 1997 >5 --

6. Drying shrinkage (%) IS 2185 (Part 1):1979 0.04 min. 0.04 min.

7. Thermal conductivity (m2.k/W) IS 3346:1980 0.4 min. > 0.4

8. Sound transmission Class (dB) IS 9901:1981 42 max. 44 max

Installation Procedure

i) Only two stacks shall be put on top of each other during stocking and transportation.
ii) Panel stacks shall always be lifted from under wooden pallet with a lifting fork or belt.
iii) The panel stacks shall be moved by forklift or trolley to construction site. Individual panel may easily be moved
by a simple wheel. Panels can also be moved manually by inserting a short tube (500mm) into the second
hollow as handle. These shall always be transported sideways.
iv) Gluing agents (cement based adhesives) as per IS 9103:1999 shall be mixed as per the manufacturer’s
instructions.
v) The line of wall shall be marked on the floor and ceiling before start of installation.

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 Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

vi) Guiding boards shall be fixed on the floor and ceiling. The guiding support will automatically align the wall
when lifting the panels straight into upright position.
vii) The gluing agent shall be spread on the side of the already installed panel.
viii) Before the panel shall be lifted to upright position, it should be moved so that the panel bottom is as close as
possible to its correct position. After that the panel shall be lifted to upright position.
ix) This panel shall be pushed against the previous panel (and move up and down) so that tongue and groove are
carefully positioned against each other and gluing agent is squeezed out. Correct thickness of joint between
two panels shall be 1 to 2 mm.
x) The panel shall be positioned to correct level by using wooden wedges at the bottom and top of the panel
erected earlier. The height of the panel should be about 10 to 50 mm shorter than free-room height.
xi) The top joint shall be filled with polyurethane foam. Correct thickness of joint shall be 5 to 10 mm.
xii) Alternatively, when same gluing agent as in sides is used for top joint, the panel shall be pushed against
ceiling so that gluing agent is squeezed out. Correct thickness of joint shall be 1 to 2 mm. The surplus gluing
agent shall be removed from joints after installation.
xiii) Bottom joint of the panel shall be filled with mortar or concrete. Correct thickness of joint shall be 10 to 40
mm.
xiv) ‘Shoulders’ shall be sawed or flat steel bar for door top portion fixed to the panels next to the door. The door
top piece shall be glued by using polyurethane foam or gluing agents. The joints should be as thin as pos-
sible.
xv) All corners shall be strengthened with nail plugs (3 per corner).
xvi) Paper or fibre tape shall be glued on to the corner joints and to the joints at a door top portion before plaster-
ing.
xvii) Flexible joints between panels shall be built after each 5 - 6m. Polyurethane foam or mineral wool may be
used as elastic joint material.
xviii) The hollow boxes may be used for the cables and electrical boxes shall be fixed at the desired points after
drilling.
xix) The panels need only a very thin skin coating (1-2 mm) before surface finishing. It may be easier to do with
a wide trowel.
xx) All kinds of drilling and sawing can be easily made in the panels.
xxi) The necessary tools required for installation shall be hammer, saw, screw driver, level, meter rule, trowel,
drill, trolley concrete cutter, steel bar, buckets and lifting bars.

Plumbing & Electrical
Walltec panels shall have hollows of 53mm dia. in 92mm wall and 74mm dia. in 120mm wall to allow the passage of
water pipes, electrical wiring, HVAC and hydraulic installations without making holes/chases. Plumbing and Electrical
service fittings shall be pre-planned and shall be passed through hollow portions of the wall panels.

Painting, Tiling and Cladding

Painting shall be done directly or after applying a 2mm wall putty coat. Texture paint coat shall be directly applied
to external surface for decorative effect.

All tiling and cladding shall be directly fixed using regular cement mortar or tile adhesive.

Use of the Walltec walls & Its Limitations

Uses
These walls shall be used as non-load bearing walls/partition walls and compound/ boundary walls in residential/
commercial/ industrial/ institutional buildings.

Limitations of Use
For non-load bearing walls only. Not to be used as load bearing walls.

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

CERTIFICATION

Under Performance Appraisal Certification Scheme, the present formwork system has been evaluated and certified
by BMTPC PAC No. 1022-P/2015 has been issued to M/s B. N. Precast Pvt. Ltd., Gandhinagar.

Standards And references

IS 383:2016 Specifications for coarse and fine aggregate for concrete (third revision)
IS 516:1959 Method of test for strength of concrete (Reaffirmed 2013)
IS 2386(Part 3):1963 Methods of test for aggregates for concrete - Part 3 specific gravity, density, voids,
absorption and bulking (Reaffirmed 2016)
IS 3346:1980 Method of determination of thermal conductivity of thermal insulation materials
IS 3812 (Part 1):2013 Specifications for pulverized fuel ash - part 1 : for use as pozzolana in cement, ce-
ment mortar and concrete
IS 9103:1999 Specifications for concrete admixtures (Reaffirmed 2013)
IS 9142:1979 Specifications for artificial light weight aggregates for concrete masonry units
(Reaffirmed 2016)
IS 9901:1981 Measurement of sound insulation in buildings and of building elements
IS 12269:2013 Specifications for 53 grade ordinary Portland cement
IS 15916:2010 Code of practice for building design and erection using prefabricated concrete
(Reaffirmed 2014)
ISO 179-2:1997 Determination of charpy impact of plastics

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APPENDICES
Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Appendix-1

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

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Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Appendix-2

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

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Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

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Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

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Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition

Appendix-3

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 Building Materials & Technology Promotion Council, Ministry of Housing & Urban Affairs

Appendix-4

172
 than 330 kg per cum sqm 498.45
26.38.2 50mm thick in Grade M 25 with cement content not less
than 330 kg per cum sqm 831.30
26.38.3 75mm thick in Grade M 25 with cement content not less
than 330 kg per cum sqm 1217.60
Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition
26.39 Providing and inserting 12mm dia galvanised steel injection nipple
in honey comb area and along crack line including drilling of holes
of required diametre (20mm to 30mm) up to depth from 30mm to Appendix-4
80mm at required spacing and making the hole & crack dust free by
SCHEDULE OF RATES
blowing compressed ISSUED
air, sealing BY CPWD
the distance ON injection
between NEW TECHNOLOGIES
nipple with adhesive chemical of approved make and allow it to cure
complete as per direction of Engineer-In-Charge. each 147.50
26.40
A - DELHI SCHEDULE OF RATES 2016 (VOLUME 2)
Providing and fixing hard drawn steel wire fabric of size 75 x25 mm
mesh or other suitable size wire mesh to be fixed & firmly anchored
Code to the concrete surface by means of "L" shaped mild steel
Description Unit Rate
No. shear key welded with existing reinforcement including the cost of
materials, labour, tool & plants as approved by engineer-in-charge. sqm 601.60
Rates shall include
Note:TECHNOLOGY
NEW ITEMS the providing necessary ground wires
etc. The levelling gauges, if used, shall be paid for separately.
26.41 Designing,
Payment underproviding, installing
this item shall beand
made fixing
onlyfactory finished
after proper wetcustom
curing
designed cold form Light Gauge Steel Framed super
has been done and surface has been satisfactorily evaluated structure
by
comprising of steel
sounding/tapping wall
with panel,
a blunt trusses,
metal purlins etc manufactured
instrument.
out of minimum 0.75 mm thick steel sheet as per design
26.38.1
requirements.25mm
Thethick
steelinsheet
Gradeshall
M 25be with cement content
galvanized not gms
(AZ-150 less
thanAlloy
Aluminium Zinc 330 kg per cum
coated steel having minimum yield strength sqm 498.45
300-
26.38.2550 Mpa) 50mm conforming to AISI
thick in Grade Mspecifications
25 with cementand IBC 2009
content not less for
cold formed than steel330framing
kg per andcumconstruction and also as per IS: 875- sqm 831.30
1987, ISO 800-1984 and IS: 801- 1975. The wind load shall be as
26.38.3 75mm thick in Grade M 25 with cement content not less
per provisions of IS 875 (part -III). LGSFS frame shall be designed
than 330 kg per cum sqm 1217.60
as per IS: 801 using commercially available software such as Frame
26.39 Providing
CAD and inserting
Pro-11.7/ 12mm dia galvanised steel
STAAD PRO-V8i/ArchitekV2.5.16/ Revitinjection nipple
architecture-
in honey
2011 comb area and
or equivalent. Proper along crack
usage of line includingAccessories
Connection drilling of holes like
of required
Heavy Dutydiametre
Tension (20mm Ties, Lightto 30mm) up to depth
Duty Hold-ons, fromStraps
Twist 30mm(to to
80mm attruss
connect requiredwithspacing and making
wall frames), Strong theTie,
hole Tie& Rod,
crackH-Brackets,
dust free by
blowingSections,
Boxing compressed air, sealing
L-Shaped Anglesthe for distance between
better structural injection
stability.
nipple with adhesive chemical of approved make and allow it to cure
The framing section shall be cold form C-type having minimum web
complete as per direction of Engineer-In-Charge. each 147.50
depth 89 mm x 39mm flange x 11mm lip in required length as per
26.40 Providing and
structural designfixing hard drawn duly
requirement steel punched
wire fabricwith of size 75 x25 mm
dimple/slot at
mesh or other
required locationssuitable
as per size wire mesh
approved to be fixed
drawings. The & firmly
slots willanchored
be along
to the line
centre concrete
of webs surface
and shall by bemeans spaced of minimum
"L" shaped mild away
250mm steel
Code Description Unit Rate
shearboth
from key welded
ends ofwith theexisting
member. reinforcement
The frame can including the cost of
be supplied in
No.
materials, labour,
panelized or knock tooldown
& plants as approved
condition by engineer-in-charge.
in specific dimensions and sqm 601.60
fastened
NEW with screws extending
TECHNOLOGY ITEMS through the steel beyond by minimum
of three exposed threads. All self drilling tapping screws for joining
26.41
SUB HEAD : Designing,
the
26.0 members providing,
shall have
NEW TECHNOLOGIES installing
a Type
AND IIand fixinginfactory
coating
MATERIALS finished
accordance withcustom
ASTM
designed
B633(13) or cold form Light
equivalent Gaugeprotection
corrosion Steel 426Framed
of gauge super 10 &structure
12, TPI
comprising
16 & 8 of length of steel
20mm. wallThepanel,
frames trusses,
shall be purlins
fixed toetcRCCmanufactured
slab or Tie
out
beam over Neoprene rubber using self expanding carbonper
of minimum 0.75 mm thick steel sheet as steeldesign
anchor
requirements.
bolt of dia as per Theapproved
steel sheet shall be
drawings. galvanized
design subject(AZ-150
to minimum gms
Aluminium
12mm diameter Zinc andAlloy121mm
coatedlength
steel having
conforming minimum
to AISIyield
304 strength
and 316
300- 550 Mpa)
at 500mm c/c withconforming
minimumtoembedment
AISI specificationsof 100mm andinIBC RCC 2009(RCC for
cold
to beformed steel framing
paid separately) and construction
and located not more than and300mm
also asfrom per IS: 875-
corners
1987, ISO 800-1984
or termination of bottom andtracks
IS: 801- 1975. The
complete wind
in all load shall
respects. Thebe itemas
alsoprovisions
per includes the submission
of IS 875 (part of stability
-III). LGSFS reports
framedulyshall examined
be designed and
issued
as by 801
per IS: any NIT/IIT.The
using commercially rate includes the concept
available softwaredesign,
such asdetailed
Frame
design,
CAD fabrication
Pro-11.7/ STAAD of sections, transportation, installation
PRO-V8i/ArchitekV2.5.16/ and all
Revit architecture-
required
2011 fixing arrangement
or equivalent. Proper at site as
usage of described
Connection above.
Accessories like Kg 174.10
26.42 Heavy Duty Tension Ties, Light Duty
Providing and fixing of external wall system on Light Hold-ons, TwistgaugeStraps (to
steel
connect truss with wall frames), Strong
frame work with . Outer face having 6mm thick heavy duty fiberTie, Tie Rod, H-Brackets,
Boxing
cementSections,
board fixed L-Shaped
on 9mmAngles for better
thick heavy dutystructural
fiber cement stability.
board
confirming to IS 14862:2000, category
The framing section shall be cold form C-type having minimum IV type A (High pressure
web
steam 89
depth cured)
mm xas39mm per standard
flange xsizes11mmfixed lip inwith self-drilling
required length/ astaping
per
screws / fasteners
structural @ 60cm c/c ofduly
design requirement approved
punched make.withA grove of 2 mm
dimple/slot at
to 3mm shall
required be maintained
locations as per approvedand groves shall The
drawings. be sealed
slots willwith
besilicon
along
based sealant.
centre line of websThe board and shall
shallbe befixed in a staggered
spaced minimumpattern.Screws
250mm away
shall be of counter sunk rib
from both ends of the member. The frame head of 1.60mm to can
4 mm bethick of 8 to 10
supplied in
gauge of length varying from 25 to 45 mm and internal face 12.5mm
panelized or knock down condition in specific dimensions and
thick gypsum plaster board fixed on 8mm thick fiber cement board 173
confirming to IS 14862:2000 of category III type B (High pressure
SUB HEAD : steam
26.0 NEW cured) as per standard
TECHNOLOGIES sizes fixed with self-drilling / taping
AND MATERIALS
screws / fasteners @ 60cm c/c of approved make, proper taping
and jointing to be done using fiber mesh tape 426 and epoxy and acrylic
 issued by any NIT/IIT.The rate includes the concept design, detailed
design, fabrication of sections, transportation, installation and all
required fixing arrangement at site as described above. Kg 174.10
26.42 Providing and fixing of external wall system on Light gauge steel
frame work with . Outer face having 6mm thick heavy duty fiber
cement
Building board
Materials fixed on
& Technology 9mm Council,
Promotion thick heavy
Ministry duty fiber
of Housing cement
& Urban board
Affairs
confirming to IS 14862:2000, category IV type A (High pressure
steam cured) as per standard sizes fixed with self-drilling / taping
Code screws / fasteners @ 60cm c/c of approved make. A grove of 2 mm
Description Unit Rate
No. to 3mm shall be maintained and groves shall be sealed with silicon
based sealant. The board shall be fixed in a staggered pattern.Screws
shall beRates
Note: shall sunk
of counter include the providing
rib head of 1.60mm necessary
to 4 mm thick ground
of 8wires
to 10
etc. The levelling gauges, if used, shall be
gauge of length varying from 25 to 45 mm and internal face 12.5mm paid for separately.
Payment
thick gypsumunder this item
plaster boardshall
fixedbe made
on 8mm only after
thick proper
fiber wet curing
cement board
has been done
confirming to IS and surface has
14862:2000 been satisfactorily
of category III type B (High evaluated
pressure by
sounding/tapping
steam cured) as per withstandard
a blunt metalsizes instrument.
fixed with self-drilling / taping
screws / fasteners
26.38.1 25mm thick @ 60cmin Gradec/c of M approved
25 with cement make, propernot
content taping
less
and jointing thanto be330done using
kg per cum fiber mesh tape and epoxy and acrylic sqm 498.45
based jointing compound for seamless finish.(cost of frame work to
26.38.2 50mm thick in Grade M 25 with cement content not less
be paid for separately). Sqm 2783.65
than 330 kg per cum sqm 831.30
26.43 Providing and fixing internal wall panels on Light gauge steel frame
26.38.3
work with 12.5mm 75mm thick in Grade
thick gypsum M 25 with cement
plaster board content not less
conforming IS
2095:2011 fixed than on330 8mmkg per cum
thick fiber cement board conforming to IS sqm 1217.60
14862:2000 of category III type B (High pressure steam cured) as
26.39 Providing and inserting 12mm dia galvanised steel injection nipple
per standard sizes fixed with self-drilling / taping screws / fasteners
in honey comb area and along crack line including drilling of holes
@ 60cm c/c of approved make, Screws shall be of counter sunk rib
of required diametre (20mm to 30mm) up to depth from 30mm to
head of 1.60mm to 4 mm thick of 8 to 10 gauge of length varying
80mm at required spacing and making the hole & crack dust free by
from 25 to 45 mm. Proper taping and jointing to be done using
blowing
fiber mesh compressed
tape and epoxy air, sealing
and acrylic the based
distance between
jointing injection
compound for
nipple
seamlesswithfinish.(cost
adhesive chemical
of frameof approved
work to be paidmake forand allow it to cure
separately) Sqm 1738.45
complete as per direction of Engineer-In-Charge. each 147.50
26.44 Providing and fixing in all exterior face panels breathable vapour
26.40 Providing and fixingthe
barrier underneath hard drawnfiber
cement steelboard
wire fabric
as perof size 75Building
National x25 mm
mesh or other suitable size wire mesh to
Code 2009 complete as per direction of Engineer-in-charge. be fixed & firmly anchored Sqm 238.05
to the concrete surface by means of "L" shaped mild steel
26.45 Supplying
shear and installation
key welded of moisture
with existing resistant/fire
reinforcement includingresistant 6 mm
the cost of
thick Heavy duty fiber cement board (High pressure
materials, labour, tool & plants as approved by engineer-in-charge. steam cured) sqm 601.60
conforming to IS 14862:2000 of category III type B as per standard
sizes TECHNOLOGY
NEW fixed with self-drillingITEMS / taping screws. Screws shall be of
Code
26.41 counter sunk rib head
Designing, providing, installing of 1.60mm to 4fixing
Description
and mm thick
factory of 8finished
to 10 gauge
custom of Unit Rate
No. length varying from 25 to 45 mm.
designed cold form Light Gauge Steel Framed super structure Sqm 869.15

26.46 comprising
Providing offixing
and steelinwall panel,
position, 200trusses,
mm thick purlins etcmade
factory manufactured
Expanded
SUB HEAD : out of
26.0 NEW minimum
TECHNOLOGIES 0.75 mm
AND thick
MATERIALS steel sheet as per design
Polystyrene Core (EPS Core) wall panels consisting of EPS core
requirements. The steel sheet shall be galvanized
427
sandwiched between two Engineered sheets of welded wire fabric (AZ-150 gms
Aluminium Zinc Alloy coated steel having minimum
mesh duly finished with shortcrete materials on outer faces. The yield strength
300-
fabric550
mesh Mpa) conforming
shall be made to of AISI
3 mmspecifications and IBC
dia G.I. wire mesh with2009
50 mmfor
cold formed steel framing and construction and also
pitch in both the directions and on both faces of the wall, kept at as per IS: 875-
1987,
120-135 ISO 800-1984
mm gap andand IS: 801- by
connected 1975.
the The windG.I.
zig zag load
wireshall
of 3bemmas
per provisions of IS 875 (part -III). LGSFS frame
dia at alternate row by welding (at an angle ranging from 50-70 shall be designed
as per IS:. The
degree) 801 EPS
usingcorecommercially
shall consist available
of 100 mm software
thick such
EPS of asdensity
Frame
CAD Pro-11.7/ STAAD PRO-V8i/ArchitekV2.5.16/ Revit
not less than 20 kg/ per cum. Both the outer faces of the panel shall architecture-
2011 or equivalent.
be finished by applying Proper usage
the layer ofof
50Connection
mm thick cementAccessories
mortar like
1:3
Heavy Duty
{1 cement: Tensionsand
3 coarse Ties, Light
(not havingDuty Hold-ons,
more than 40% Twist
stoneStraps
chips(to
of
connect
size uptotruss
6 mm)}withÀ wall frames),
with the help of Strong Tie, Tie Rod, H-Brackets,
shotcreting/guniting equipment
Boxing
etc at a Sections,
pressure not L-Shaped
less than Angles
1 bar for better structural
(100Kn/m2) and both stability.
surfaces
finished
The framing with trowel.
section shallFixing
be coldoperations
form C-typeofhaving wall minimum
panels shallweb
be completed
depth 89 mm xin39mm all respect
flange as xper
11mmdrawings
lip in and specifications
required length as andper
under the overall
structural designdirection
requirementof the Engineer-in-charge.
duly punched with dimple/slot at sqm 3246.15
26.47 required
Providinglocations
and fixingasinper approved
position, 230mm drawings. The slots
thick factory made willExpanded
be along
centre line ofCore
Polystyrene webs andCore)
(EPS shall be spacedpanels
roof/floor minimum made 250mm
of 3 mm away
dia
from both
G.I. wire endswith
mesh of 50themm member.
pitch inThebothframe can be and
the directions supplied
on bothin
panelized or knock
faces of panel, kept at down
120-135condition
mm gap in and
specific dimensions
connected by theand
zig
zag G.I. wire of 3 mm dia at alternate row by welding (at an angle
ranging from 50-70 degree). The EPS core shall consist of 100 mm
SUB HEAD : thick EPSTECHNOLOGIES
26.0 NEW of density notAND lessMATERIALS
than 20kg/ per cum. The bottom side
of the panel shall be finished by applying426 a layer of 60-65 mm thick
cement mortar 1: 3 {1 cement: 3 coarse sand (not having more than
40% stone chips of size upto 6 mm)} À with the help of shotcreting
equipment etc at a pressure of not less than 1 bar (100Kn/m2) and
surface finished with trowel. The top face of the panel shall be
174 provided and finished by applying 70-75 mm thick layer of cement
concrete 1:1.5: 3 (1 cement :1.5 coarse sand : 3 graded stone
aggregate 20 mm nominal size). Fixing operations of roof/floor panels
shall be completed in all respect as per drawings and specifications
26.47 Providing and fixing in position, 230mm thick factory made Expanded
Polystyrene Core (EPS Core) roof/floor panels made of 3 mm dia
G.I. wire mesh with 50 mm pitch in both the directions and on both
faces of panel, kept at 120-135 mm gap and connected by the zig
zag G.I. wire of 3 mm dia at alternate row by welding (at an angle
Compendium of Prospective Emerging Technologies for Mass Housing – Third Edition
ranging from 50-70 degree). The EPS core shall consist of 100 mm
thick EPS of density not less than 20kg/ per cum. The bottom side
Code of the panel shall be finishedDescription
by applying a layer of 60-65 mm thick Unit Rate
No. cement mortar 1: 3 {1 cement: 3 coarse sand (not having more than
40% stone chips of size upto 6 mm)} À with the help of shotcreting
Rates
equipment
Note: etcshall include the
at a pressure providing
of not necessary
less than ground wires
1 bar (100Kn/m2) and
etc. The levelling gauges, if used, shall be
surface finished with trowel. The top face of the panel paid for separately.
shall be
Payment under
provided and this item
finished byshall
applyingbe made
70-75only
mmafter proper
thick layer wet curing
of cement
has been1:1.5:
concrete done and3 (1 surface
cement has :1.5 been
coarsesatisfactorily evaluated
sand : 3 graded by
stone
sounding/tapping with a blunt
aggregate 20 mm nominal size).metal
Fixinginstrument.
operations of roof/floor panels
shall be completed
26.38.1 25mm thickin all in
respect
Gradeas M per drawings
25 with cementand specifications
content not less
and under the overall direction
than 330 kg per cum of the Engineer-in-charge. sqm
sqm 3436.35
498.45
26.48 Providing and
26.38.2 fixingthick
50mm of costomized
in Grade M Aluminium formwork
25 with cement for monolithic
content not less
constructionthanRCC members
330 kg per cum with a repetitive usage of 100 times sqm 831.30
using grade 5052 aluminium for panel sheets of minimum 4 mm
26.38.3 75mm6061
thick and grade thick(Type-6)
in Grade aluminium
M 25 with cement contentsections.
for extruded not less
The form work than 330 kg
includes ofper
beamcum components i.e.beam side panel,prop sqm 1217.60
26.39 head for soffit
Providing and beam,beams
inserting 12mm soffit
dia panel,beam
galvanised steel soffitinjection
bulk head and
nipple
deck componets i.e. deck panel, deck prop, prop length,
in honey comb area and along crack line including drilling of holes deck mid,
soffit
of length,diametre
required deck beam (20mmbar and wall components
to 30mm) up to depth i.e. from wall
30mm panel,
to
rocker, kiker and internal soffit corner, external soffit
80mm at required spacing and making the hole & crack dust free by corner,external
corner,internal
blowing corner etc.,The
compressed panels
air, sealing theare held in position
distance between byinjection
a simple
pin andwith
nipple wedge system
adhesive that passes
chemical throughmake
of approved holesand in the outitside
allow rib
to cure
of each panel.The tolerance of finished
complete as per direction of Engineer-In-Charge. panels to be (-1 mm), and each 147.50
shall conform to IS 14687-1999. Pins and wedges to be made of
26.40 Providing
high gradeand mildfixing hardcomplete
steel,all drawn steel as wire fabric of size
per direction 75 x25 mm
of Engineer-in-
mesh or other suitable size wire mesh
charge.(Cost of RCC work shall be paid seperately)to be fixed & firmly anchored sqm 149.45
to the concrete surface by means of "L" shaped mild steel
shear key welded with existing reinforcement including the cost of
materials, labour, tool & plants as approved by engineer-in-charge. sqm 601.60
SUB HEAD : NEW
26.0 NEW TECHNOLOGIES
TECHNOLOGY AND MATERIALS
ITEMS
26.41 428
Designing, providing, installing and fixing factory finished custom
designed cold form Light Gauge Steel Framed super structure
comprising of steel wall panel, trusses, purlins etc manufactured
out of minimum 0.75 mm thick steel sheet as per design
requirements. The steel sheet shall be galvanized (AZ-150 gms
Aluminium Zinc Alloy coated steel having minimum yield strength
300- 550 Mpa) conforming to AISI specifications and IBC 2009 for
cold formed steel framing and construction and also as per IS: 875-
1987, ISO 800-1984 and IS: 801- 1975. The wind load shall be as
per provisions of IS 875 (part -III). LGSFS frame shall be designed
as per IS: 801 using commercially available software such as Frame
CAD Pro-11.7/ STAAD PRO-V8i/ArchitekV2.5.16/ Revit architecture-
2011 or equivalent. Proper usage of Connection Accessories like
Heavy Duty Tension Ties, Light Duty Hold-ons, Twist Straps (to
connect truss with wall frames), Strong Tie, Tie Rod, H-Brackets,
Boxing Sections, L-Shaped Angles for better structural stability.
The framing section shall be cold form C-type having minimum web
depth 89 mm x 39mm flange x 11mm lip in required length as per
structural design requirement duly punched with dimple/slot at
required locations as per approved drawings. The slots will be along
centre line of webs and shall be spaced minimum 250mm away
from both ends of the member. The frame can be supplied in
panelized or knock down condition in specific dimensions and

SUB HEAD : 26.0 NEW TECHNOLOGIES AND MATERIALS

426

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 Compendium of Prospective Emerging Technologies for Mass Housing
Compendium
of Prospective Emerging
Technologies for Mass Housing
Third Edition

Building Materials & Technology Promotion Council

Ministry of Housing & Urban Affairs
Government of India

The Executive Director The Joint Secretary & Mission Director (Housing for All)
Building Materials & Technology Promotion Council Ministry of Housing & Urban Affairs, Government of India,
Core-5A, 1st Floor, India Habitat Centre Room No.116, G-Wing, Nirman Bhawan,
Lodhi Road, New Delhi New Delhi-110011
Tel: 011-24636705; Fax: 011-24642849 Tel: 011-23061419; Fax: 011-23061420
E-mail: info@bmtpc.org E-mail: jshfa-mhupa@gov.in
Website: http://www.bmtpc.org Website: http://mhua.gov.in