Cement is considered as the most significant substance used in construction which acts as a binder which can adheres the materials together. Cement is a hydraulic binder when mixed with water and sand transforms into mortar and when mixed with water and aggregates converts to concrete which can be used for a number of applications. As per World cement association concrete comes second only to water as the most used resource. China is the largest producer of cement with 53% and India follows with 8% with this production likely to be doubled in next ten years.
The basic raw materials used for cement manufacturing is lime stone or chalk and shale or clay. Cement clinkerisation plants are normally located near the raw materials areas and most of the the times the plants are equipped with conveyors which can directly feed the raw materials from the mines
Based on the technic adopted for mixing raw materials the manufacturing process is divided into wet process and dry process. Wet process is normally used now a days. But dry process is also gaining popularity due to their energy efficiency and when the ingredients are hard.
WET PROCESS OF CEMENT MANUFACTURING
The wet process of cement manufacturing is divided into a number of stages
a) Raw material extraction
b) Grinding
c) Proportioning and mixing and preparing composition based on the raw material purity.
e) Preheating the composition
f) Burning the composition in a kiln to form clinkers
g) Clinker cooling with gypsum addition and grounding to fine powder.
h) Storing in silos and packing and loading for conveying.
The raw materials needed for cement manufacturing are
a) CALCAREOUS (i.e. chalk consists of limestone.) b) ARGILLACEOUS (i.e. clay consists of silicates of alumina.)
a) RAW MATERIAL EXTRACTION
Major raw material involved in the cement manufacturing process is limestone. Cement manufacturing plants are located near the limestone sources for easy access to the raw materials or else it turnout to be expensive to transport the materials from outside. The next major ingredient is clay which have to be located around 25-30 km within the plant premises to minimise the cost incurred in transportation.
Lime stone obtained from open cast mines are transported and feeded to a limestone crusher and clay is placed in a clay crushers. Other raw material like sand which controls the kiln temperature and iron ore etc can be transported or supplied from outside sources.
b) RAW MATERIAL GRINDING
The raw materials calcareous (lime) extracted are crushed to make a size of 6 inch and further crushed to make it 3 inch in secondary crushers. The argillaceous materials (clay) are washed to remove the organic contents and stored in basins and limestone is stored in silos.
c) PROPORTIONING MIXING AND PREPARATION OF COMPOSITION
The washed Clay and crushed lime stone are conveyed and mixed in desired proportion and further grinded in a wet grinding mill where both the materials are closely mixed in the presence of water to form a slurry .The slurry is stored in storage tanks where minor corrections in the compositions are carried out. The slurry which constitutes around 35-40% water is constantly kept in agitation to prevent the settling of limestone and clay.
The preheaters are used to heat the raw mix and drive off carbon dioxide and water before it is fed into the kiln.The raw meal passes down the preheater tower while hot gases rise up, heating the raw meal. At the entry point of kiln the raw meal largely decarbonates .
e) BURNING OF COMPOSITION IN KILNS
The decarbonated slurry is fed directly to an inclined steel cylinder which is called rotary kiln .In the rotary kiln through a series of reactions clinker is produced. The kiln is made of a steel casing lined with refractory bricks which have to withstand the reactions happening inside the kiln. The kiln is divided into three zones depending on the process happening in each zone and the temperature at each zone. The kiln is heated from the bottom using coal, oil or gases.
In the first zone water and moisture from the decarbonated slurry is evaporated at a temperature of 400C and the process is known as drying zone.
In the second part which is the calcination zone temperature is around 1000 degree and carbon dioxide is removed and is immediately converted into flakes after loosing the moisture. These flakes or modules are taken into the third stage with the help of rotary movement of the kiln.
In the third stage which is called the burning zone or clinkering zone and the temperature their will be around 1300-1500 degree . In this zone the lime and clay reacts to produce calcium aluminates and calcium silicates. Immediately on entering the burning zone aluminates and calcium silicates get fused and the modules are converted into a dark greenish balls and is called clinker. The size of the clinker ranges from 5 mm to 20 mm. These are the chemical reactions happening in the kiln.
F) CLINKER COOLING WITH GYPSUM ADDITION AND GROUNDING TO FINE POWDER
The cooled clinkers are finally grinded in ball mills. At this stage gypsum(2-4%) is added which functions to reduce the setting time of cement. The grinded powder is take to the cement silos for storage. The particle distribution is also done in a graded manner. The stored grinded powder is taken to the packing plant and packed for distribution
ALSO READ : DRY PROCESS OF MANUFACTURING OF CEMENT
ALSO READ : DIFFERENCE BETWEEN DRY PROCESS AND WET PROCESS OF MANUFACTURING.
Eco friendly materials for building are the talk of the hour. We have gone so far that it is almost difficult to make a return to the idea of nature in our lives now. But what if I told you the building in which you spend the main part of your life will help you get there? Yeah, let me share with you some secrets about eco friendly materials that can support you on a journey of new construction.
What wonders eco friendly materials for building can do?
Eco friendly material can solve the issue of building waste that often includes concrete, metals, glass, plastics, wood, asphalt, bricks and more. Not only does this pollute the land and the air, but the transportation required to remove such waste has a major impact on the environment as well.
It cuts down on energy consumption, leading to less use of natural resources that cause climate change warming, such as oil and gas
Use of recycled building materials reduces cost
The good practice can attract clients
Pretty interesting. But having the pros known is not all. The challenge that hindrance us from incorporating them in construction is that environmentally friendly materials might compete with less expensive alternatives. After all, what’s perfect in all facets in the world?
So, shall we get into our business now?
Let’s take an easy trip from the top to bottom of a building and meet significant faces in eco friendly materials for buildings.
1. How to use eco friendly materials for building in foundation
Everything starts here- At the foundation. You can incorporate recycled fly ash in concrete. This reduces the amount of cement needed, thereby decreasing the overall environmental impacts of cement production.
2. How to incorporate eco friendly materials fro building in super structure
Having colored the foundation of green, next we are going to deal with the part that is visible to the world; The Super structure. It has a lot of possibilities to be explored. Using pozzolona materials like fly ash and blast furnace slag in OPC cement can consume the industry wastes and protect the quality of concrete. The inner walls can utilize fly ash bricks, or GFRG or GRFG panels or AAC panels, bricks etc. which are amiable green building products. For false ceiling, Mineral fibre boards or gypsum boards can be used. And remember, MDF and exterior grade formaldehyde free plywood when it comes to the interiors.
Bonus: There is a recent innovation by Nexii Building solutions which is a proprietary material named Nexiite, that is capable of replacing concrete enabling rapid construction of sustainable buildings.
i. Flooring
Being a very fascinating facet in a structure, we often tend to forget about the environmental effects caused by the flooring feature. Here is the chance to vindicate. Rapidly renewable floors like bamboo and cork flooring are good alternatives to hardwood flooring. Recycled-content ceramic tiles are also sustainable materials for flooring.
Recycled-content carpet with Low-VOCs made from recycled plastic bottles, recycled cotton, agricultural by-products such as corn silk saves resources and diverts waste from landfills.
ii. Exterior finish
Now for exterior finish, use sustainable content decking materials like recycled-content decking made from plastic lumber and composite lumber.
In the journey so far, you might have started getting an idea of how vast and needy is the concept of eco friendly materials for building. Let’s go forth…
iii. Walls and ceilings
It’s time we talk about the most attention seeking part of the structure; the walls and ceilings. Cellulose is a highly effective insulation made out of recycled newspaper. Using cellulose insulation reduces air leakage and contributes to a more comfortable and energy-efficient home. Another available option is advanced insulation materials such as recycled cotton that have no added formaldehyde which is harmful to nature.
iv. Windows
Moving on to windows, the eyes of the building, install Low Solar Heat Gain Coefficient (SHGC) Window Film on Single-Glazing that can significantly lower the need for additional cooling
v. Heating, Ventilation and Air Conditioning (HVAC)
So, how do we make HVAC a good fellow? Solar attic fan is good that removes much of the hot air and reduces the burden on the air conditioning system. A whole house fan uses one-tenth the electricity of an air conditioning unit. Moving large volumes of air achieves indoor comfort at higher temperatures without air conditioning.
Then, another choice is a wall heat pump that has an exterior compressor and an interior air handler that blows conditioned air throughout the home. With this, you can eliminate wall-mounted electric and gas heaters results in greater safety and more energy savings. And the Installation of air conditioning with Non-HCFC Refrigerants is a clever thing to do because it reduces depletion of the ozone layer in case of leakage during replacement.
2. How to add eco friendly building materials in renewable Energy and Roofing
Nature left us an option for all our energy needs. Renewable energy. We can leverage it through a variety of techniques. One of the best methods to incorporate it is through installing Photovoltaic (PV) System. PV panels can be used as a means to decrease reliance on conventional power plants that contribute to air pollution.
3. Eco friendly building materials in Indoor Finishes
Let’s bid bye with the final finishes. Low/No-VOC paint reduces the emissions of VOCs into the home, improving indoor air quality and reducing the formation of urban smog.
Also, use law VOC, Water-Based Wood Finishes. Using low VOC wood finishes that improves indoor air quality, and reduces the formation of urban smog.
Just think about how beautiful it is to live with the lullaby of nature. You would naturally have the mind to opt for eco friendly materials for building, which is the perfect way to create a green home.
Concept of green building is a buzz word at present, right? Because it has been a now or never situation to save nature. Therefore, you will come to understand the concept of green building and complete details in the blog.
Why concept of green building is important?
i. Protect occupant health
ii. Optimal environmental and economic performance
iii. Reduce overall impact to the environment
iv. Quality indoor spaces
v. Improve employee productivity
vi. Use energy, water and other resources more efficiently
vii. Increased market value of the building
Now that you have the answer to the big y, shall we move on to the main elements to incorporate the concept of green building in your home?
Let’s dig in systematically and find out what exactly each concept of green building implies.
a.)First Concept of green building- Powerful sites
Site selection
A canvas is as important as the drawing brush. So is a site of construction in concept of green building. The following points are to be considered diligently.
Set preliminary environmental performance targets
A well revised plan is the ablest key. The plan should take into account the inevitable like water, energy, materials, waste, the mode of construction, indoor environmental quality, and economic performance.
Select appropriate land
We have two options in handy during a hunt for a building. Either we can renovate existing structures or select a land. If you are going for later, make sure that is a short walk from public transit, pedestrian and bicycle routes, exists in an already-urbanized area, is walking distance from amenities, is already serviced by the requisite urban infrastructure (roads, utilities, etc.), is a brownfields site and remediate it, allows infill development and allows mixed-use development. And the important point to be noted is that the land shouldn’t come under any restricted zones such as farmlands, the natural habitat of wildlife, wetlands, waterways.
2. Site design
This is a vital facet of the concept of green building and opens up wide possibilities to embed creativity of a civil engineer for the purpose. It includes,
A. Protect or enhance site’s ecological integrity and biodiversity
The color green itself highlights the importance of this aspect. The construction should be such that it preserves the site’s natural areas, re-establishes damaged native ecosystems and makes connections between the natural ecology of the site and natural systems both within and beyond the site.
B. Reduce or eliminate disturbance to water system
You can celebrate your life with the natural water conservation methods by making them into attractive landscape elements. Also increase site infiltration where soil conditions allow by maintaining the natural pervious landscape or designing a pervious landscape. Use pervious surfaces for as much as possible of the surfaces that are usually paved where soil conditions permit. capturing rainwater for site or building use is also a simple act to contribute to this.
C. Reduce urban heat islands
Maximize green space through the clever designing techniques including native gardens, trellises, roof gardens, green walls etc. and provide shade on impervious surfaces where high-albedo materials cannot be used.
D. Design infrastructure to support alternative transportation
In between the continuous run to balance work and life, there is no way you can compromise on this aspect. Location of the building should be such that it has access to public transit, bike routes, and pedestrian routes. And the feature should encourage walking, bicycling and battery operated vehicles, by designing attractive, safe pedestrian and cycling infrastructure.
3. Building orientation& configuration
The orientation of the building and the configuration of each element is significant to make a strong connection with nature. Use existing and proposed trees & plantings to reduce heating, cooling, and lighting loads and utilize the site resources to reduce building loads and enhance indoor environmental quality. Finally, orient the building to optimize prevailing winds and solar opportunities.
b.) Second concept of Green building- Wizardry in construction
After setting up the site, the next concept of green building is obviously construction. Here, we have the opportunity to take out the technical skills to weave the green blanket for our building.
i. Design stage
Choose environmental friendly materials
Try to use recycled and efficient materials, Use locally harvested or manufactured materials and materials that cause very less damage to nature as much as possible. You can find more elaborate details in A JOURNEY TO ECO- FRIENDLY MATERIALS
Design for reuse
Design a structure that allows for changes in use over time.Select building systems that can be deconstructed at the end of the building’s useful life.This is where the importance of a good design team arises.
Design envelope
Design envelope to reduce heating, cooling, lighting, and ventilation loads. Also it should incorporate all possibilities that make it energy efficient and allows for maximum natural light without glare and pollution and maximum wind intake. Remember to consider individual control for all the features because that is a determining factor of the comfort of the residents.
Reduce or prevent the use of potable water to treat human waste
Installation of water-efficient toilet fixtures and alternative wastewater technologies like constructed wetlands and monitoring the usage with something like water meters is very efficient to make sure that we protect each drop of water and ourselves.
Reducing impact of environment
While ozon depletion is growing on a daily bases, let’s do our bit to reduce it.Use HVAC systems, refrigerants and fire-suppressant equipment that do not contain CFCs, HCFCs or Halons.
ii. Building stage
Prevent erosion during construction
The prevention of erosion is important because properly done, it will also prevent the accompanying air pollution, and sedimentation of streams and storm sewers. Different strategies like maintaining or providing vegetated ground cover and controlling erosion with mulch or grass can be done.
Minimize the disposal of construction waste
A formal waste management plan can be adopted for minimizing the construction waste envisaging reuse, recycle or salvage the waste for later reuses.
c.) Third Concept of green building -Showering aura through energy & water efficiency
This is the highlight of the concept of green building. First, let’s close the deal with energy efficiency.
Thanks to technology and the human quest for innovation, new techniques and strategies are emerging every day. Smart home technology is one of the blessings in which interesting products like highly programmable thermostats reduce your heating and cooling bills and saves the environment by reducing energy production. Furthermore, your heating, ventilation, and air conditioning (HVAC) system works more efficiently, meaning less wear-and-tear on the system and longer life.
Another remarkable trend is energy star windows that reduce heating and cooling costs and thereby rise in home values. To boost the windows’ insulating effect, you can draw blinds in both summer and winter. Also, seal all air leaks in the house with caulk or weather stripping and clean and change furnace filters frequently. Having all the new lessons taken, don’t forget your roots. Aid renewable energy as much as possible.
So, you have set up your home for better energy treatment.
Now let’s see the practices for methodical water management.
Use rainwater collected for suitable domestic purposes and Install tank less water heaters, which heat up water at the source that avoids having to run the tap to bring hot water from a remote water heater. See more details about rainwater harvesting at RAINWATER HARVESTING; EVERYTHING YOU NEED TO KNOW. Consider fixtures and appliances that conserve water such as low flow faucet aerators. And home automation can help you too in monitoring, measuring, and controlling water usage. Another thing worth doing is systematic wastewater management. Wastewater can be recycled using recharging pits and used for landscape watering. Moving onto another concept of green building,
d.) Fourth Concept of green building- Rating tools to standardize
Congrats! You have the whole concept of green building ready to receive you now. Next you need to know how to market it with verification. Here is the significance of rating tools. These tools can even help you gain incentives for clients. Building rating and certification systems are in a state of change and evolution and continue to be refined to reflect new standards and goals. So it is essential to investigate the most current versions of these programs to gain an understanding of particular requirements that must be met in order to achieve the best results.
There are a number of green building rating tools that exist but are not administered by a World Green Building Council. Let’s look at some of the tools which are administered by them.
1. BREEAM or Building Research Establishment Environmental Assessment Method started in the UK where it is now a voluntary initiative in the private sector and compulsory in the public sector. Points are awarded in line with sustainable approaches to energy and water use, internal environment, pollution, transport, materials, waste, ecology, management processes and the life-cycle of buildings.
2. LEED or Leadership in Energy and Environmental Design started in the US and is now popular worldwide as well as in North America. It covers new, existing, commercial and residential property and is concerned with energy, atmosphere, water efficiency, materials, resources and indoor environmental quality.
3. HQE (High Quality Standard) is a French initiative. Not as widely adopted as LEED or BREEAM, HQE is still committed to common aims including reducing energy and water use, minimal environmental impact on surroundings, a healthy internal environment and the full life-cycle of a building. It covers new and existing buildings from commercial properties to multi-family housing.
4. DGNB (German Sustainable Building Council) focuses on around 50 criteria ranging from environmental, economic, technological and work process aspects to sociocultural and functional dimensions. “A holistic approach is taken” meaning the system assesses the entire lifecycle of the building. Buildings are awarded DGNB certificates in bronze, silver or gold. In addition, there is the option of simple precertification in the planning phase.
5. WELL focus on “advancing health and well-being in buildings” through issues such as thermal and acoustic comfort and good air quality.
Drop a message in the comment section to reach out to us for Green Building Consultancy Services. Let’s make the bond for a lifetime of prosperity by sharing the joy with green.
The past decade has been a witness to a lot of path breaking ideas and tremendous technological advancements. But a building at zero cost??
“The people crazy enough to think they can change the world are the ones who do”. So at one point hopefully mankind would do that. For now, let’s dive into the key aspects that are nearly ideal for a low cost building.
1.INTAKE OF NATURAL LIGHT
Natural light has a lot of proven benefits over productivity and well being of people who reside/ work there. It has a positive effect on you life too.
Positioning of windows and doors, mirrors that can reflect light to maximum space can contribute greatly for maximizing natural light to indoor areas. A light intake medium to be available on the roof top also contributes for this.
The real success in constructing a building is in its utility.
Open plan living which are popular recently is very much close to the feature. The columns or structural walls will need to be carefully placed to ensure they have minimal impact on the flow of spaces/views. Also the passages inside the building should be an optimized design considering the position of doors that utilizes the floor space cleverly.
2. CHERRY- PICK THE STRUCTURAL COMPONENTS
A home is an emotion…
The windows that give you view to the outer world from your cozy personal space, the doors that welcome you to your universe of comfort and boundless freedom, the walls and corners of the house who have been with you in your thick and thin…
These different structural components where the housing material plays a significant role are one the quintessential factors that contribute to the cost of erection of a building. A proper care towards the different elements will help us save a lion’s share of the amount spent for the construction. These are,
i. Foundation
Foundations need to be as per available local materials and soil.
ii. Super structure
a.) Flooring material
b.) Walls
Environmental degradation in the top soil used for brick walls, the environmental pollution and enormous cost while making the bricks compel us to consider another alternatives for bricks Brick walls. GFRG Panels and AAC Blocks are best fits for this that highlight the significance of low cost construction materials.
GFRG Panels
Glass fibre reinforced gypsum(GFRG) panels have emerged as a recent trend in low cost buildings. It has the potential to reduce the cost of construction of a building by 30 percent.
The lucky charm of the low cost material is that it doesn’t require cement plastering of the walls and there by a considerable amount of money can be saved. Well, this not all. There are some amazing qualities of the material that can pull you towards it.
Autoclaved aerated concrete blocks (AAC) is one of the best low cost building materials suitable for producing concrete masonry unit like blocks. The whole building can be built and no plastering is required in internal and external areas.
AAC Blocks have a clear upper hand over bricks thanks to its characteristics. They are easy to transport and handle leading to less labour charges. They eliminate the need for applying costly fire proof material and ensures fast construction owing to its physical characteristics. And less wastage reduces the extra expenses for removal of debris in the construction site.
How can you not be biased towards this cutipie?
EXTRA BOUT: AAC blocks have an overall saving of 30% on the total construction cost.
c.) Roof:
When Khaled Hussein said “One could not count the moons that shimmer on her roofs…” he might not have thought that it could have a meaning from civil engineering point of view. When we have filler in concrete that is capable of reducing the amount of cement in concrete without loss of strength, there is no doubt that it will catch our attention and mental presence.
Polyurethane Foam Infill (PUF) is a commercially attractive filler material which is reusable or disposable mold systems.
GRFG Panels can also be use and affordable and cost effective alternative for roofing system
GREEN WALLS
Another category which we shall miss at no cost is green walls. A green wall is comprised of plants grown in supported vertical systems that are generally attached to an internal or external wall. They illustrate the back to nature concept with several healing benefits that can vent you from the hustle and bustle of urbanization.
3. INCORPORATING TECHNIQUES OF VASTU
There is a prevailing myth pertaining to Vastu that it is a blind belief. But there is also a sound claim that draws a fair line of pragmatic concepts that rely on logical reasoning that talk about techniques to save money. For example Vastu advocates the position of kitchen windows in the eastern direction which helps to trap sunlight rays that can disinfect kitchen.
4. SHIFT IN THE PERSPECTIVE
“I’m so happy that I could build my home at low cost”- When was the last time you heard this from someone?
Very rare, I tell you. That’s because cheap buildings are never stylized. Because of the persuasion of some people who involve in between an engineer and the client, a low cost buildings is always looked down upon. Think over it the next time you hear the boasting of an expensive building.
5. LAURIE BAKER CONCEPTS
Figure shows Laurie Baker and the building designed by him
How is it possible to close the chapter without reaching it through the wizard of the realm?
Laurie Baker made a variety of practical suggestions, including the use of rat trap bonding for brick walls, providing wall bends that increased strength and offered ready-made shelves, thin concrete roofs and even basic precautions, such as moving the dug up to the built-up area rather than out of it.
Now that we have taken a wonderful journey through all the possible factors for a low cost building, you may also think about other aspects like installing solar panels for energy efficiency. Remember a penny saved is a penny earned.
Money has its value when used for the right purpose. Low cost for a building can imply an empty belly filled. So liberate yourself from living in others thoughts and construct an independent mind as a perfect start.
<p class="has-text-align-justify" style="font-size:18px" value="<amp-fit-text layout="fixed-height" min-font-size="6" max-font-size="72" height="80">When you look from outside a house is a building of brick and cement but from inside it is a soul's dream. For affording a house an individual is ready to spend his hard-earned money without a second thought. The increase in housing demand is exhausting the raw materials/sources and keeping the dream of affording a house, to be more of a dream rather than a reality.When you look from outside a house is a building of brick and cement but from inside it is a soul’s dream. For affording a house an individual is ready to spend his hard-earned money without a second thought. The increase in housing demand is exhausting the raw materials/sources and keeping the dream of affording a house, to be more of a dream rather than a reality.
In the urban sector, there is a huge requirement of affordable housing as people migrate and make their settlements for their jobs.
While chasing the dream of affording a house, everyone thinks of innovative, highly efficient, and cost-effective sustainable options. This search terminates in GFRG ( Glass Fibre reinforced gypsum ) which addresses all these concerns and presents us with one of the most affordable walling and roofing system which have the qualities of a perfect innovation. GFRG privileges in using a superior and sustainable material that can reduce the overall cost by 40% and ensure a speedy construction when implemented professionally.
CONCEPT OF GFRG
GFRG PANEL VIDEO
GFRG is an innovative Australian technology gaining footage in the construction sector. The conventional system of using country burnt bricks is creating massive environmental degradation like excessive removal of topsoil and converting the fields into barren lands. In an initiative to protect the environment, the authorities are forced to restrict the manufacturing of red bricks which in turn increased the cost of bricks drastically. This method is used in China, the middle east, India, etc, and is one of the most trending building materials. GFRG panels are also called rapid wall system.
FRG PANELS
The concept of the rapid wall system can eliminate the most time-consuming construction activities like brickwork, shuttering, casting, removal of RCC slabs, plastering, curing, etc. These activities generate a lot of debris lead to environmental degradation to some extent. Rapid walls in turn are fast and easy, consume less time, and creates negligible wastage. The construction time is reduced to 20-25% and painting can be applied to the wall directly after the application of special primers and putty.
MANUFACTURING PROCESS OF GFRG
MANUFACTURING STAGES
GFRG is a calcined gypsum plaster spread with glass fibre reinforcement for imparting tensile strength. Raw gypsum an industrial waste from the fertilizer plants is heated at a temperature of 140-150 degrees centigrade and is stored in tanks for later use. The slurry is mixed with water and other chemicals (retarders and water repellents ) and spread over a table and is interspersed with glass fibres. Aluminum plugs are used for creating hollow cavities. The glass fibres are added to induce tensile strength to the panels. Aluminum plugs are removed in around 30 minutes and panels are dried to a temperature of around 275 degrees for 1 hr before being cut to the required size. The transporting shall be done by keeping the panels vertical in stillages.
DIMENSIONS AND PROPERTIES
TYPICAL MODULAR HOLES
The panel sizes are 12 mtr x 3 mtr and have a thickness of 124 mm. These panels are used for walls as well as roofs and applications like staircases, boundary walls, etc. These panels are factory cut as per the design requirements. Cutouts for doors and window openings, air conditioners, etc are done in the factory before conveying to the site.
TYPICAL PANEL
Each panel constitutes 48 modular holes of 230 mm x 94 mm x 3000 mm dimension. The weight of one panel is around 1440 kg. The load-bearing capacity of the panels can be increased by using concrete infills embedded with rebar.
APPLICATION OF GFRG PANELS
The applications of GFRG panels are as follows: GFRG panels are used as lightweight load-bearing walling & roofing in single-storeyed and multi-storeyed buildings. The panel can be used with or without filling the core with concrete. The core can also be filled with nonstructural materials like sand, sawdust, quarry dust, etc.
When used in a multi-storeyed building the panel core is filled with concrete and embedded rebar as per the design to resist the lateral as well as gravity loads..
ERECTED PANELS
GFRG panels can be used as intermediate flooring and roofing elements for flat as well as the sloped roof. This will function as a composite member with RCC Microbeams and slabs making it a T beam structure.
GFRG can also be used in sunshades , facades , boundary walls etc.
Rapid wall buildings are resistant to earthquakes, cyclones, and fire. The panels are fixed on the foundation with a unique locking system . GFRG panels do not require any plastering on the internal and external sides of the wall and roof.
The foundation can be decided as per the site conditions. It can either be a spread footing, continuous footing, column footing structure, or rubble masonry /brick masonry with a plinth beam where the panels can rest. The plinth beam shall be embedded with reinforcement steel 12 mm dia 75 mm protruding over the beams.
GFRG PANEL ERECTION GOING ON
b) DIMENSIONING OF PANELS
The panels are cut into required sizes as per the drawings. The cut-outs for door, window, and Air conditioner, etc shall be factory cut. Panels are marked and conveyed in stillages from the factory to the concerned sites.
b)ERECTION OF PANELS FOR WALLING
The GFRG walls are designed to resist axial force from gravity loads, lateral in-plane shear force, and in-plane bending moment from wind and seismic loads. The cavities inside the GFRG panels are filled with concrete, to enhance the compressive strength of the panels and reinforced to enhance lateral load-bearing capacity. This option is essential for multi-storied buildings.
The unloaded panels have to be erected using a crane with the requisite boom length. The panels are lifted and placed over the plinth beam with the protruded rebar going inside the infills and concrete is filled from the top after plumbing it. Door and window frames can be fixed at this stage for better stability with anchorages in the infills properly filled with concrete. Sunshades over windows and door openings to be provided with conventional shuttering by cutting the external part of the rapid wall.
WALL ANGLE JOINT AND WALL T- JOINT
The wall corners and T junctions has to be provided with the rebar as shown in the figure. The concrete shall be done with 12 mm aggregate and filled in a layers of 1 mtr height.
RCC tie beam running on the full length of the wall has to be provided as per national building code for protection against earth quake. The web of the infills are removed upto the beam depth for this purpose and reinforcement shall be placed and casted
For up to 3 storeyed high low rise GFRG buildings there is no need to infill all cavities with reinforced concrete. We recommend concrete infill for every third cavity
FIXING ROOF PANEL
After casting of tie beam shuttering for fixing roof panels shall be done with 1 foot width wooden planks or any acrow spans . Support shall be provide in areas where the micro beams are coming. The panels are lifted and placed over the supports and care should be taken to maintain a gap of 40 mm. These gaps are provided to take up the rods from the floor below to maintain continuity. For providing mirco beams the flanges are cut with 25 mm offset as shown in the figure. Weld mesh is placed over the rapid panels and casted for 50 mm thick . The micro beam and the weld mesh slab provides a T beam action
The panels of the first floor are provided in the same way as done in the ground floor over the plinth beams. The internal of the rooms are applied with putty and painted . Electrical conduit has to be done through the cavities Plumbing fixtures shall be provided as per design .
WHY GFRG CAN BE PREFERRED OVER CONVENTIONAL WALLING AND ROOFING SYSTEMS
The panels possess high flexural strength, shearing strength, compressive strength etc. It is an approved and accepted construction material by the Building Material and Technology Promotion Council of India (BMTPCI).Concrete filled with vertical reinforcement rods improves it’s vertical and lateral load capacities and improves the earth quake resistant properties.
a) THERMAL CONDUCTIVITY
Rapid walls posses very low thermal conductivity and high resistance to heat. GFRG panels can make the indoors cooler by 6-7% than conventional buildings.The high resistance to heat can keep interiors cooler in summer and warmer in winter which in turn can drastically reduces the air conditioning loads and energy bills.
b) GREEN TECHNOLOGY
The manufacturing process involves using very advanced and green technology in recycling the raw materials. This process consumes less energy and reduces carbon emission making GFRG an environmental friendly material.
c) COST EFFECTIVE AND AFFORDABLE
As the demand increased there was a drastic increase in the in cost of labour, energy, bricks, cement, river sand, water, labour and hire charges for scaffolding etc. . The introduction of rapid walls which is much cheaper construction material and has the potential to reduce the cost drastically and can make the housing an affordable one for all .
d) FAST CONSTRUCTION
The construction speed can be drastically increased by elimination of time consuming brick work, shuttering, concrete, deshuttering , plastering etc. The time taken for construction will will be reduced to 25%. A conventional G+1 house with takes 6-8 months for completion and with GFRG the same shall be constructed in a span of 2-2.5 months.
e) FIRE RESISTANT, WATER RESISTANT, EARTHQUAKE AND TERMITE RESISTANCE
ROOF ERECTION GOING ON
GFRG panels are fire resistant, water resistant, earth quake resistant, heat resistant , rodent and termite resistant which can be used for any type of atmosphere. GFRG panels can resist upto 1000 degree and have a fire rating of 140 minutes
f) STRENGTH,DURABILITY & SERVICEABILITY
Strength and durability of GFRG is not behind any other building material but in turn is is more superior to them . This makes GFRG houses much stronger than conventional houses and have a life of more than 100 years.
g) INCREASE IN CARPET AREA
As we are using 124 mm walls in place of conventional 230 mm walls there is an increase in the carpet area which amount to about 4% of the overall area.
h) USAGE OF INDUSTRIAL WASTE AND ELIMINATE SITE DERBIES
GFRG Technology uses fertiliser industry waste which is abundantly available .The system is very easy to erect and can be done effectively and fast with the help of experienced people. It can eliminate lot of wastages accumulating at site.
i) OPTIONS AVAILABLE FOR USING GFRG
GFRG panels can be used without filling for single storied houses . For G+1 houses and above it is safer to fill concrete in one out of three cavities with embedded rebar . Multi storied houses can be constructed upto 10 floors as load bearing walls. For multi storied building we can even go with a conventional beam column structure with slabs and walls of GFRG . The system has to be designed accordingly.
GFRG panels can be utilised for the construction of staircase waist slabs. All the top flanges of panels shall be cut open and concreted with reinforcement. Steps for the stair can be done with any building material.
The panels have to be handled with extreme care and specific machinery is needed for their erection. Spaces have to be allocated for crane movement all around the building.
The panels cant be used for walls with circular or higher curvature.
The panels need to be neatly stacked in order to avoid breakage and scratches.
The clear span is limited to 5m in the case of residential buildings.
A specially skilled team is required for erection and supervision. The panels are cut as per requirement and transported to the site and hence onsite changes are difficult.
When the little kiddo was caged out from her mother’s care to explore the widened garden in the lobby of the home, she yelled in the curious voice “mummy, see the Corona flower, it even got kids with it!” “That’s football flower baby!”
While all of us are living with the humming and chanting of the notorious COVID-19, it’s high time we spoke about its impact on the lifeline of the world, Construction and civil engineering.
Let’s look at the important aspects to reboot ourselves to face the situation gracefully.
Economic uncertainty
Being the second largest provider of blue and white collar jobs, construction sector is the industry that has the worst impact from COVID- 19, after agriculture. According to the COVID- 19 impact and Implementation survey 2020 of ASCE, as of May 26, half of the responding organizations have experienced corona virus related delays in receiving materials from suppliers owing to the disruption in the global supply chains. It’s alarming to note that two large airlines, Delta and United, announced plans to reduce capital investment by $2 billion each as a result of the pandemic’s economic impact.
These shed light into the fact that companies are revising their plans about their capital investment and they are focusing on implementing cost cutting measures into the form of layoffs, increase in working hours which is about a tiresome 12 hours a day and pay cuts.
In the light of the gruesome provisions, government has issued a number of notices and instructions to companies in India not to deduct workers ‘ wages or to refrain from lay-offs or withdrawals during the lock-down period. But we know how unsure when the lock down extension is uncertain.
So how are you going to tackle these?
If a tiny virus that can’t even be seen by eyes can transform the entire universe in its working, then our brains should be given a chance to prove its part. By doing the calculations with investment reduction and changing the business plan and strategies accordingly, we can be robustly prepared to confront that.
Pro-tip: You should also bear in mind the scope of the business insurance policies and if you deserve it, you should get yourself to claim it!
Managing remote work force
This aspect could be a phoenix to rise from all that hinders you from visiting the construction site. But remember we have comprehensive software tools and technical support systems. Let the building site be anywhere in the world. You can use 360 cameras to digitally capture site conditions. This effectively creates a street view of your construction site. All that is required is a mechanism to carry out the survey, so all stakeholders will have access to the site tour staying at home itself. Also, the advent of robotics which offers wide possibilities in 3D printing a building, brick laying and masonry,can even change the fate of the sector. They’re all an asset to the future. Only that, thanks to Corona, it all happened in the blink of an eye.
3. Overall management of safety requirements / regulation
Employee safety is of paramount importance no matter the company’s business status. They should be provided with mandatory safety equipment in good time and should be treated gently to make them comfortable amid the prevailing pandemic. Major government instructions must be strictly applied to construction sites and offices which include:
1. Keeping a safe distance between workers
2. Mandatory hand washing for at least 20 seconds before work begins, after workers remove gloves, before and after the use of shared items such as tools, before and after any restroom breaks, and after shifts end.
3.Temperature checks when the workers arrive on site and when they leave for home
4. Limiting crossover of subcontractors
Customers going out of business
The sustaining epidemic conditions can change the mind of your customer anytime. So you better keep in touch with them through the virtual communications and strengthen the bond by testifying other customer’s success with your service.
Employee morale
It’s not at all worth a big bet that employee morale is directly connected to their productivity. Construction economists say construction loses 975,000 Jobs in April, Because of COVID-19 Impacts. The results of the April 9 survey of ASCE showed a similar statistics. One-quarter of the organizations have furloughed/ laid off/ terminated employees since March 1, 2020. These statistics tell us that boss to the caregiver is a must-have shift in this intense time. There’s no better feeling than that when you feel your job is secure.
6. Troubles in contract period
The reports say that two-thirds of the responding organizations have experienced cancellation or delay of contracts. One out of seven organizations are facing potential contract penalties due to project delays. It implies that you should be well versed in our law to keep your client in peace.
The extra bout: Section 55 of the Indian Contract Act, 1872 (‘Contract Act’) provides for the effect of failure to meet the specified timeline. However, the intention of the parties must be examined, not the letter of the clause.
7. Expectations from government
Though government has taken required measures, it needs to think innovatively to save the sector that has been growing tremendously and contributing considerably to the economy. Even if banks have given moratorium options, they are still adding interest for the months we are not paying. Banks can avoid charging interest for these months when we are not able to pay EMIs. Also, some exemptions in GST will be a great relief. There shall be measures to mitigate impact on micro, small and medium enterprises (MSME) workforce, defer utility and social security payments, enhance access to credit and specific measures for self-employed. There is no better time to usher the commitment and care of the government to the people of the country.
8. Work from home challenges
Every difficulty is an opportunity. The pandemic era is an opportunity to improve digital infrastructure, communication skills, automation and mechanized construction methods that can potentially replace manual intensive labour by machinery. Moving away from the difficulties, you’d better make it a rocking platform to improve all these things about your company.
9. Work- life balance
Suddenly, when your home desk says hi and your office desk misses you, it’s not easy to work normally and then move on to your personal life all of a sudden. A thick line is always to be drawn. A dedicated workspace and schedule can make a perfect balance.
IN NUTSHELL:
Being the second largest provider of blue and white collar jobs, construction sector is the industry that has the worst impact from COVID- 19, after agriculture.
Companies are revising their plans about their capital investment and they are focusing on implementing cost cutting measures into the form of layoffs, increase in working hours which is about a tiresome 12 hours a day and pay cuts.
The pandemic era is an opportunity to improve digital infrastructure, communication skills, automation and mechanized construction techniques.
By embedding navel technologies like 360 cameras, robotic assistance for brick laying , masonry and virtual communication systems, the challenges can be confronted gracefully.
Boss to the caregiver is a must-have shift in this intense time. There’s no better feeling than that when you feel your job is secure. Also employee safety is of paramount importance no matter the company’s business status.
One out of seven organizations are facing potential contract penalties due to project delays. But section 55 of the Indian Contract Act clearly states the relaxations during unpredictable situations.
There shall be measures to mitigate impact on micro, small and medium enterprises workforce, defer utility and social security payments, enhance access to credit and specific measures for self-employed. Some exemptions in GST will be a great relief.
Bonus: Which the following do you find an advantage of COVID- 19, that helped the growth of your company/your work life?
1. It led digital transformation of your company
2. It helped you show gratitude and care to your employees
3. It helped you to explore the world of productivity
vin civilworld 