Introduction

GFRG stands for Glass Fibre Reinforced Gypsum panels. The panels are manufactured in sizes of 12 m long,3m height and 124 mm (5 inch) thick thus providing more carpet area. The hollow cavities inside the panel is filled with concrete to provide more strength to the panel. Below is an image showing GFRG panel and its internal structure.

RBL PREFAB GYPWALL is a revolutionary low-cost load bearing pre-fabricated walling system with broad construction application. Glass fibre reinforced gypsum (GFRG) wall a new composite wall product is made of gypsum plaster reinforced with glass fibre. The glass fibres are random distributed inside the panel skin and ribs in the manufacturing process. Panels are hollow and manufactured in 124 mm thick by 12 metre length and 3 metre width and are cut in the sophisticated wall cutting plant to suit the customers requirement. The wall panels can be reinforced with concrete during construction as per requirement of the structure.

FACT – RCF Building products Ltd (FRBL) is a joint venture of M/s FERTILISERS & CHEMICALS TRAVANCORE LTD, Kochi (FACT) and M/s RASHTRIYA CHEMICALS AND FERTILIZERS LTD, Mumbai (RCF)(Both public sector undertakings under the Department of Fertilizers ,GOVT: of India).

FRBL has set up a 150crore state of art plant at Kochi for manufacturing and sales of Gypsum based building products like load bearing walls and wall plaster. FRBL utilises the experience and expertise of FACT & RCF for the manufacturing of Gypsum based building products with the technical support of Australian technology.

The unique cellular structure of PREFAB GYPWALL enables it to be used as formwork and side filled concrete to provide enough axial strength and lateral rigidity. Our panels are strong, crack free and provide crack free surface with less joints. The finish of our panels is smoother than equivalent precast concrete/masonry walls and hence does not require putty application. The light weight characteristic of our panel helps to reduce the structural element cost including foundation. The durability of the buildings with GFRG panels is time tested and the water absorption rate is less than 5%. The resistance to moisture can be increased by providing a thin membrane coating.

The FRBL Wall panels can be accommodated in any type of Architectural designs. To aid the builder/ designer, FRBL has come up with a detailed construction manual. The panels and its construction methodology help to reduce the construction time substantially and save in labour cost

Recognitions For GFRG Wall Panels

FRBL PREFAB GYPWALL is approved by Building Material and Technology Promotion Council (BMTPC- under Ministry of Housing and Urban poverty Alleviation, Govt of India).

IIT Madras has come out with a design manual for GFRG panels published by BMTPC. IIT Madras has been testing and conducting various studies on GFRG wall panels for the past 10 years.

IIT Madras has constructed a 2 storied 4 apartment building at their campus using GFRG Panels for the entire construction including slab. The Structural Engineering Research Centre (CSIR-SERC) has tested GFRG panels in the construction in earthquake prone areas.

Why is GFRG superior than conventional construction?

Gypsum which is a by product of fertilizer industry is used to make the panels economical and Eco-friendly. Glass fibre is used as reinforcing agent which enhances the strength of the panels. Eventually the usage of cement is reduced.

One cement industry alone accounts for 5% increase in CO2 emission. By using GFRG panels cement usage is reduced and thereby reducing environmental pollution.

In site they are just erected using cranes. Those hollow cavities inside the panels are filled with concrete and steel. Concrete is poured in every third cavity of the panel and other cavities can be filled with waste materials like quarry dust hence it becomes more economical than conventional construction methods.

Comparison of GFRG over conventional building

GFRG is an eco-friendly material:

GFRG iss a GEP (Green Environmental Protection) material has no odour and its Radioactive Nuclide Limit is accord with A-style decoration material standard of GB6566-2001, which can be used for recycling.

Factories manufacturing this GFRG panels:

FRBL-FACT RCF Cochin, Kerala

RCF Mumbai

These panels are precast in factories, transported to construction site and erected with the help of crane.

Test Results of GFRG:

Cons:

More space needed for crane movement

Complicated design will make it less economical

Skilled labours needed

GFRG panels should be handled with care while transportation and erection

Need specific machinery for cutting GFRG panels at site

Erection and placing of GFRG panels are a bit difficult.

Uses of GFRG:

The GFRG Wall panels can be accommodated in any type of Architectural designs. The panels and its construction methodology help to reduce the construction time substantially and save in labour cost.

Our GFRG panels can be used as light weight load bearing wall

As partition wall

As compound wall

Cladding in industrial structures

Pitched roofing

Horizontal roofs/slabs

All load bearing and non-load bearing walls

Over all, GFRG Wall panels can replace total normal construction activity.

Main advantage of using GFRG pre-fabricated panels is, it is 25% less cost than normal conventional constructions. What we need 180 days to construct a normal residential building, can be constructed with in 45 days using our product. Also get more carpet area by using GFRG Panels.

How much you can save with GFRG:

GRFG Wall Joints:

Panel lifting procedures:

Panel lifting jaw:

Panel lifting using Jaw:

Positioning of panels:

GFRG is a viable and tested method to construct economical homes: This technology has been used by Australian’s since 1990’s only as walls.

Professors from IIT Madras made research and found out this technology can be used for all structural elements such as walls, floors and roofs in a building. They have built a 2 storeyed model house in IIT campus 2013 which was completed in 30 days for 6.5 lakhs/flat.

APPLICATIONS OF GFRG PANEL

  • LOAD BEARING WALLING

  • PARTITION INFILL WALLS

  • MASS HOUSING

  • MULTI STORIED BUILDINGS

Frequently Asked Questions

What is GFRG construction?

Construction of homes using Glass Fibre Reinforcement Gypsum panels.

What is GFRG Panel made of?

It’s a mixture of gypsum and glass fibre put together

Is it an approved building construction material?

Yes it is recognized and approved by BMTPC – Building Material & Technology Promotion Council, India (Approved)

IITM has dedicated over a decade in R&D and now it has come to the stage of technology transfer.

How Strong is GFRG Panel?

GFRG panel is world s largest load bearing lightweight panels. The panels are manufactured with size 12 m length, 3m height and 124 mm thickness. Each panel has 48 modular cavities of 230 mm x 94 mm x 3m dimension. The weight of one panel is 1440 kg or 40 kg/sqm. The density is 1.14g/cm3, being only 10-12% of the weight of comparable concrete /brick masonry. Light weighted Rapid wall has high comprehensive strength, shearing strength, flexural strength and ductility. It has very high level of resistance to fire, heat, water, termites, rot and corrosion. Concrete infill with vertical reinforcement rods enhances its vertical and lateral load capabilities. GFRG buildings reduce burdening of the environment and help to reduce global warming. GFRG use also protect the lives and properties of people as these buildings will be resistant to natural disasters like earthquakes, cyclone, fire etc.

How fast is the construction?

Less than 35 days for 600 sq. ft home

What is the wall thickness?

Standard 5 inch

What are the disadvantages of GFRG construction?

Need space for crane to operate & cannot make curvy walls, however curvy walls can be made by concrete.

Need trained labours and storage space to store the panels

What are the Benefits of GFRG construction?

Eco-Friendly & Safe

All Climate & Weather proof

20% + Overall cost saving

Fire, Sound, Flood proof

Earthquake Resistance

No Air Cracks & Water Patches

Rapid Construction

8% More Carpet Area

Keeps The Building 4 Degrees Cooler

2/3 Labour & Water Saving

Less Usage of Sand

Build up to 10 Floors +

Very Neat & Modular Finishing

Structural life over 75 years

Cost per Sq. ft for construction?

Please send us the floor plan and we will provide you with estimated Quote

Can it be constructed over a conventional building?

Yes, it can be built after analysing the structure

Are there any long term effects or health hazards in a GFRG house?

No, GFRG houses are completely safe. They do not aggravate or create any health hazards when exposed to it. GFRG is a GEP (Green Environmental Protection) material has no odour, and its Radioactive Nuclide Limit is accord with A-style decoration material standard of GB6566-2001, which can be used for recycling.