Gypcrete wall panel is manufactured
from plaster - one of the world's oldest known construction materials.
Humankind has used this material for thousands of years. The pyramids
of Cheops, for example, were certainly built with plaster mortar
at least 4,000 years ago.
Plaster is manufactured from Gypsum which as
an inert, naturally occurring material available in vast quantities all over the
world. Gypsum is used extensively in horticulture and primary production.
Gypsum is also a by-product of other industrial
processes. For example, the burning of coal to produce steam for electricity generation (much
of the world's energy requirements are produced this way) produces
chemical or Sulphur-Gypsum that can, and should be, extracted from the boiler
GBIL produces all the plaster used in the Gypcrete wall panel manufacturing process. Using the Rapidflow Calcination Plant, chemical gypsum is calcined to produce high quality plaster for general use and for use in the production of Gypcrete wall panel.
Manufacturing and Materials Handling
Gypcrete wall panel is manufactured from Rapidflow Gypsum Plaster in an
automatic casting process. The production processes for both Rapidflow
Plaster and Gypcrete wall panel are low in energy use, they are fast, they
are very clean and they emit little or no carbon dioxide. The production,
transportation and installation of one square metre of clay brickwork
emits over 70kg of Carbon Dioxide. Comparatively one square metre of
Gypcrete wall panel emits less than 7 kg of Carbon Dioxide.
When compared to alternative products such as precast-concrete, a
single Gypcrete wall panel casting-table can produce in 24 hours atleast
20 times the quantity of precast concrete. It does this consuming a
fraction of the energy and a fraction of the water.
Over the last ten years building construction has been leaning towards
off-site or pre-manufacture of building elements. However the benefits can
often be eroded by high materials handling costs such from trucking and
Filling a Gypcrete wall panel on site
Gypcrete wall panel can be filled with concrete on site. The
transportation of liquid concrete is more efficient than transporting
concrete cast into flat panels. Furthermore, weighing only 45 kg/m2, up to
six times more Gypcrete wall panel can be transported to a building site
on a single semi-trailer.
When compared to precast concrete site cranage capacity and hook-time
requirements are considerably less when Gypcrete wall panel is employed on
a building project.
The high world demand
for housing parallels the high demand for electricity, much of
which is produced by burning coal.
Because of its low
cost and low energy demands and because it can be made from waste products
Gypcrete wall panel, we believe, presents as the most environmentally
responsible building product in the world.
In addition to having an embodied energy level [the
total energy consumed from the extraction of the raw materials through to the
final installation of the product on a building project] believed to be the lowest
of any walling product in the world, Gypcrete wall panel
can be manufactured from waste chemical-gypsum.
Gypcrete wall panel is 100% recyclable. By re-processing Gypcrete wall panel back through
a Rapidflow Calcination Plant the resulting plaster can be recast
into yet another Gypcrete wall panel.
Now being produced
in China as a replacement for bricks and soon to be produced in India
to construct several million homes in slum areas, Gypcrete wall
panel has become a world product.
The compelling attributes
of Gypcrete wall panel are: -
It is produced generally in a single
size as a production-line product and then cut to size [unlike precast concrete panels,
each of which is usually cast as a one-off detailed
panel with windows and doors etc.];
A single [up to a 36 square metres] Gypcrete wall panel
is manufactured in one hour as compared to an equivalent
precast-concrete wall panel's 24 hours minimum;
A 12 metre by 3 metre by 120 millimetre
concrete panel would weigh 10.5 tonne compared to 1.5 tonne
for the equivalent Gypcrete wall panel;
As a load-bearing
walling element Gypcrete wall panel has an installed cost of
about half that of precast concrete;
Depending on the wall layout, a Gypcrete wall panel when concrete filled on site
can support between twelve and twenty storeys thus eliminating the
need for columns and floor beams;
finish of Gypcrete wall panel is superior to an equivalent
off-form, precast-concrete or insitu wall panel;
Gypcrete wall panel can be made from naturally occurring
gypsum or from waste flue-gas gypsum;
Gypcrete wall has a lower embodied energy than all
other walling products [embodied energy is the total energy consumed by the product
from the point of extraction of the raw material to the manufacture of the
panel, to its transportation to a site and to its
final installation on a building project];
Gypcrete wall panels are 100%
recyclable wherein they can be re-processed through a calciner and
recast into new Gypcrete wall panels;
A single B-double truck can
transport over 900 square metres of Gypcrete wall panel compared to 125 square metres
for 120 millimetre thick precast-concrete and 190 square metres of
140 millimetre thick concrete hollow blockwork;
cottage construction utilising suspended timber floors, unfilled Gypcrete wall panel
is load-bearing up to three storeys;
cottage construction utilising suspended concrete floors, unfilled Gypcrete wall panel
is load-bearing up to two storeys;
When used as load-bearing shear walls
Gypcrete wall panel exhibits ductile qualities that make it safer
than masonry in earthquake prone structures;
A building system that employs load-bearing
Gypcrete wall panel as the walling elements
streamlines the construction process by removing the majority of on-site work. By the
factory production of large single-spanning lightweight wall elements that are easily and speedily erected
the Gypcrete wall panel system provides a revolutionary and cost
competitive alternative to conventional building methods.