PROJECT REPORT ON DESIGN OF

PREFABRICATED SLAB USING (GFRG) PANEL

submitted in the partial fulfillment of the requirements

for the award of the degree in

BACHELOR OF TECHNOLOGY

By

R.AKILAN 161051101006
A.MOHAN 161051101055
M.GAYATHRI 161051101027
R.DANIEL SANTHOSH 161051101019
 DEPARTMENT OF CIVIL ENGINEERING
DECLARATION
I affirm that the project work titled “Design Of Prefabricated Slab Using
(Gfrg) Panel” being submitted in the partial fulfillment for the award of
the degree in BACHELOR OF TECHNOLOGY in Civil Engineering
is the original work carried out by us. It has not formed the any part of
any other project submitted for award of any other diploma,either in this
or any other university.

Name of the Candidate Register number Signature

R.AKILAN 161051101006
A.MOHAN 161051101055
M.GAYATHRI 161051101027
R.DANIEL SANTHOSH 161051101019

I certify that the declaration made above by the candidates is true.

Project Coordinators Signature of Guide

Dr.T.Kavitha , A.Hemamalinie Dr.T.Kavitha
Assistant Professors, Assistant Professor,
Dept. of Civil Engineering, Dept. of Civil Engineering,
Dr. M.G.R Educational and Dr. M.G.R. Educational and
Research Institute. Research Institute.
 DEPARTMENT OF CIVIL ENGINEERING
BONAFIDE CERTIFICATE
This is to certify that this Project entitled “Design Of Prefabricated Slab
Using (Gfrg) Panel” is the bonafide report of project work done by,

R.AKILAN 161051101006
A.MOHAN 161051101055
M.GAYATHRI 161051101027
R.DANIEL SANTHOSH 161051101019

Bachelor of Technology in Civil Engineering during the year 2019-20.

Internal Guide Head of the Department

Dr.T.KAVITHA DR.S. ARIVALAGAN

Assistant Professor, Head of the department,

Department of Civil Engineering, Department of Civil Engineering

Dr. M.G.R. Educational and Dr. M.G.R. Educational and

Research Institute. Research Institute.

Submitted for Viva Voce Examination held on_________________

Internal Examiner External Examiner

 ACKNOWLEDGEMENT

We express our sincere thanks to our Chancellor Thiru.

A.C. SHANMUGAM, B.A.,B.L., President Er. A.C.S. ARUNKUMAR,
B.E., and our Secretary Thiru. A. RAVIKUMAR for giving us the
oppourtunity to do the final year project.

We express our gratitude to our Vice Chancellor

Dr. PADMANABAN , for allowing to carry out our project in our campus.

We express our sincere thanks to Dr.T.FELIXKALA , professor for

her continuous support.

We express our indebtedness and gratitude to Dr. S. ARIVALAGAN,

Head of the Department, Civil Engineering for encouraging us throughout
the project work.

We express our deep gratitude to Dr.T.KAVITHA &

A.HEMAMALINIE, Assistant professors, project coordinators, for their
support.

We express our heartfelt thanks to the project guide Dr.T.KAVITHA,

Assistant professor, for helping us and for their guidance.
 ABSTRACT

This review paper compiles and retrospect the developments in the field of
prefabricated building systems using GFRG construction technology also
known as Rapid wall construction technology in India. Glass fiber reinforced
gypsum panels, manufactured in standardized parts are sections prepared for
rapid erection of buildings, as they are ready-made gypsum structural panels
with hollow cavities. GFRG walls can be used both for esthetical as well as
structural component as walls and slabs, with no external columns and
beams needed. It has currently found great utilization, even without
exercising complicated codes of structural design, largely for the reason that
they are environmental friendly.
CHAPTER No. TABLE OF CONTENT PAGE.NO

1 INTRODUCTION
1.1 GENERAL
1.2 OBJECTIVE
1.3 SCOPE

2 METHODOLOGY
2.1 GENERAL
2.2 DESIGN METHODOLOGY

3 DRAWINGS
3.1 PLAN
3.2 CROSS SECTION

4 CALCULATION
4.1 DESIGN OF GFRG SLAB
4.2 DESIGN OF SLAB

5 MODEL DETAILS AND

PRESENTATION

6 CONCLUSION

7 REFERENCE
 INTRODUCTION

1.1 GENERAL

1. The design manual provides guidelines and recommendations for the

design of GFRG/Rapid wall building panels as structural walling and
flooring system in buildings.

2. Prefabrication is the practice of assembling components of a

structure in a factory or other manufacturing site, and transporting
complete assemblies or sub-assemblies to the construction site where
the structure is to be located.

3. Housing is one of the basic needs of society and is an essential

component of the built environment.

4. Buildings using Glass Fiber Reinforced Gypsum (GFRG) panels hold

promise as a rapid, affordable and sustainable mass housing solution.

5. GFRG system over conventional buildings are: high speed of

construction involving less labor, increased carpet area for the same
built-up area, reduction in the use of cement, sand, steel and water,
excellent finish of the panels with no need for plastering, lesser
building weight contributing to reduction in earthquake forces, etc.

6. GLASS FIBER REINFORCED GYPSUM

(GFRG) PANEL OR RAPID WALL is a modern building element
devised by the GFRG Building System Australia for mass-scale
construction of houses in a very short span of time. A GFRG panel is
basically claimed gypsum plaster, reinforced with glass fibers which
when filled with reinforced concrete in an appropriate proportion
becomes strong enough to act as a load bearing and shear wall
1.2 OBJECTIVE:

The purpose of this paper focuses on views of the construction

industry about the difference of the two building methods such as GFRG
wall panel system and conventional building construction system of RCC
framedstructure and load bearing wall structure based on the estimation
value and we have to generate some construction management results. We
have to accumulate properties and cost details of the building materials.
Comparing the methods, details were taken of cost and time duration for
finishing each construction activity.

1.3 SCOPE:

 GFRG panels are a composite material consisting of

calcined gypsum plaster and glass fibre. The panel contains
cavities that may be filled with concrete and reinforced with
steel bars to impart additional strength and provide ductility and
also it can be used for the construction of walls, floor and roof
slabs.

 A GFRG panel is basically calcined gypsum plaster, reinforced

with glass fibres which when filled with reinforced concrete in
an appropriate proportion becomes strong enough to act as a
load bearing and shear wall. GFRG panels can even resist the
lateral loads due to earthquakes and wind.
 METHODOLOGY

2.1 GENERAL

 The major element of this work is estimating the total cost of the
construction work for a residential house based on the Quotation
gathered from five different zones for each part of work.

 The compilation of quotation contains Cost for each construction

Material like Cement, Sand, Aggregate, bricks, etc and every activity
like Excavation, Centering work, Flooring, Plastering, Labor charges,
etc.

 The estimation work is carried out for both types of building system
of wall panel system and conventional building system.

 The approximate time requirement and time difference for every work
of Prefabrication system and conventional Building system was also
taken into account to calculate the cost due to time elapsed as time
also plays an important role in determining the cost of the
construction

 Glass fiber reinforced gypsum (GFRG) panel or Rapid wall is a

modern building element devised by the GFRG Building System
Australia for mass-scale construction of houses in a very short span of
time. A GFRG panel is basically claimed gypsum plaster, reinforced
with glass fibers which when filled with reinforced concrete in an
appropriate proportion becomes strong enough to act as a load bearing
and shear wall.
2.2 DESIGN METHODOLOGY

OVERVIEW OF (GFRG) WALL PANEL SYSTEM:

1. Glass fiber reinforced gypsum, or GFRG is the name of a new
building panel, made of gypsum plaster, reinforced with glass fibers.

2. GFRG is of exceptional relevance to India, where there is a massive

need for cost-effective mass-scale affordable housing, and here
gypsum is available in plentiful amount as an industrial by-product
waste.

3. The product not only proves to be environmental friendly or green,

but also resistant to damage by water and fire.

4. GFRG panels are currently manufactured in a panel size of length of

12m, a height of 3m and a thickness of 124 mm.

5. The panel contains cavities that can be filled with concrete and
reinforced with steel bars to provide additional strength and ductility,
if required. Experimental researches and studies have shown that
GFRG panels, when properly filled with reinforced concrete, acquires
significant strength to act not only as load-bearing elements, but also
as shear walls, able of resisting lateral forces due to earthquake and
wind.

6. GFRG panels are originally white in color (due to gypsum) and have a
smooth finished surface. They can be whitewashed or painted without
cement plastering the walls, therefore, providing some scope of
creativity for the client.

7. The typical dimension of a GFRG building panel is 12 x 3 x

0.127m which weighs around 1.6 tons. It is provided with 4 cavities
within 1 meter of the pane
STRENGTH OF RW PANEL
 DRAWINGS

3.1 PLAN

Construction of GFRG slab

3.2 CROSS SECTION
(a)

(b)
 FLOWCHART

LITERATURE REVIEW

PLAN

DESIGN

STAAD PRO ANALYSIS

MODEL PREPARATION

COST ANALYSIS
 DESIGN CALCULATION

4.1 DESIGN FOR PREFABRICATED [GFRG] SLAB

[span4.0m]
The floor slab is designed for a room of interior dimensions 4.0m × 5.0m
using gfrg building panel supported on gfrg building panels as a wall for
residential building. also it is a part of residential building and floor finish to
be 1.0KN/m2. M25 concrete and Fe415 concrete are used.Reinforced
concrete micro beam are provided at every 750mm in shorter direction
together with 50mm screed concrete at the top of the panel. Ribs are placed
along the shorter span and also the floor slab is assumed to be simply even
though floor/roof slab is integrated with the wall panels by starter bars and
infilling.

EFFECTIVE SPAN:
The distance between the centers of support, or the clear
distance between supports plus the effective depth of the beam or
slab, the lesser value being taken
.
Effective depth assuming 12mm diameter bars,

d=(124+50-15-8-12/2)=145mm

Effective span as per clause 22.2 of is:456-2000:

Effective span (l) is the minimum of

(1) clear span +effective span =4.00+0.145

=4.145m
(2) c/c of support = 4.00+0.124
=4.124m

Accordingly,
Effective span =4.124m

LOADING:

The application of a mechanical load or force to,

weight of empty slab panel =0.44kN/m2

weight of unfilled concrete plus the 50mm screed concrete
=0.05×25+(0.094×0.23×25/0.75)
=1.97KN/m2

floor finish =1.0 kN/m2

live load as per IS:875 1987 =2.00kn/m2

total service load =5.4KN/m2

Including a load factor of 1.5,

Design bending moment,

Mud =(1.5×5.4×4.1242/8)
=17.22KN-m/m.

Design bending moment/rib

Mud = 0,75×17.22
=12.92KN-m
Mud/bd ={12.92×102} / {230×(145)2}
2

= 2.6/mm2

Design aids to IS: 456,

pt = 0.876
Ast =(0.876/100)×230×145=292mm2

provide 2Y12 + 1Y10,giving an area of 305mm2

Shear force, Vu= 1.5×5.4×0.75×(2-0.145) =11.27kN

tu =(11.27×103)/[230×145] =0.34N/mm2

From table 19of IS:456,

For pt=0.914, tc=0.62N/mm2>0.32N/mm,

Hence, only nominal stirrup steel is required.

Minimum stirrup steel ,ASV = (0.4bsv)/{0.87fy}

Maximum spacing Sv,max =0.75×145=108mm=100mm

Asv min =(0.4×230×100)/(0.87×250)
=42.3mm

Provide 6mm two legged mild steel stirrups @ 100c/c.

Nominal steel for screed concrete = (0.12/100) ×50×10

=61.2mm/m

Provide 10 gauge weided mesh @100mm c/c on top.

4.2 DESIGN OF PREFABRICATED SLAB

Designing a two way slab for a room of size 4m by 5m with

discontinuous and simply supported edges on all the sides with
corners prevented from lifting to support a live load of 4kn/M2.
Adopting M-20 grade concrete & Fe-415 HYSD bars.

A) DATA
LX = 4 m
LY = 5 m
FCK =20 N/mm2
FY =415 N/mm2
Two way slab simply supported on all the sides with provision for
at corners
B) DEPTH OF SLAB

As the span is more than 35m, adopt a a span ratio of 25

Depth (span/25)-(4000/25)-160 mm
Adopt effective depth, d = 145 mm
Overall depth, D = 170 mm

C) EFFECTIVE SPAN

Effective span = (Clear span + effective depth)

= (4 +0.145)
=4.145 m

D) LOADS

Self weight of slab = (0.17 x 25) -4.25 kN/m2

Live load on slab 4.00m,
Floor finish = 0.60
Total working load = w = 8.85 kN/m2
Design ultimate load = wU =(15x8.85) = 13.275 kN/m2

E) ULTIMATE DESIGN MOMENT AND SHEAR FORCES

Refer Table-9.2 and read out the moment coefficients

for,
(LY/LX) = 1.25
Ax = 0.076 and
A =0.056
Max=(axwuLX2) = (0.076×13.275× 4.1452)
= 17.37 kN.m

M.-(ay wu LY2 )(0.056 x 13.275 x 4145212)

= 80 kN.m

V(0.5 Wu Lx) (05 x 13.275 x 4.145)

= 27.6 KN

F) CHECK FOR DEPTH

MMAX =0138 FCK b d2

D = 1737x 10Y 0.138 x 20x109
=79.33 mm< 145 mm

Hence, the effective depth selected is sufficient to resist the design

ultimate moment

(A) (0.0012x 1000 x 170)=204 mm

G) REINFORCEMENT (SHORT AND LONG SPAN)

Mu =( 0.87x415 A, x 145)(10'x145x20)

Solving, Au = 302 mm2

Adopt 10 mm diameter bars at 255 mm centers in short span

direction

Using 10 mm diameter bars in the long span direction

Effective depth = (145-10)
= 135 mm.

Hence reinforcements in the long span direction is computed using

the relation,

41SA(12.8x10-10'x 135 x 20

Solving A-237 mm2.

Hence provide 10 mm diameter bars at 300 mm centres in the long

span direction (Au = 262 mm2)

H) CHECK FOR SHEAR STRESS

Considering the short span 4 and unit width of slab, the shear stress
is given by,

10'x145100A100x 3020.20 N/mm10'x145

Refer Table-19 (IS: 456) and read out the permissible shear stress
as,

KTC = (1 26 x0 32) = 0.40 N/mm2

Hence the slab is safe against shear forces.

I) CHECK FOR DEFLECTION

Considering unit width of slab in the short span direction LX

and for A=0.20 From read out k = 1.720x1.7 =>145 28.6<34

Hence deflection control is satisfied

J) CHECK FOR CRACKING

i) Steel provided is more than the minimum percentage of 0.12

percent.

ii) Spacing of main steel < 3d< (3 x 145) = 435 mm

iii) Diameter of reinforcement <(D/8)= (175/8)= 21.8 mm

Hence cracks will be within permissible limits as per the

specifications ofIS:456 code.

ADVANTAGES OF USING GFRG PANELS:

1) Quicker Construction
Conventional buildings with G+1 that are usually constructed in a
span of 6-8 months can be constructed in a month with GFRG
panels.

2) Economical
GFRG reduces the consumption of cement by almost 50%, steel by
35% and sand by an astonishing 76%.

3) Fire Resistant
In an event of fire, GFRG panels release 15-20% moisture of its
own weight which largely reduces the surface temperature and fire
damage.
4) Earthquake Resistant
GFRG panels have been found to be successful at resisting the
impacts of earthquakes in the fifth seismic zone as their panels can
be turned into shear walls as well.

5) Cooler than a Conventional building

When compared with the conventional building materials, GFRG
panels can keep your building cooler by up to 4 degrees.

6) Strength and Durability

The strength and durability of GFRG panels is five times that of
the conventional construction materials. Besides, gypsum is known
for its strength and offers excellent dimensional stability and
durability.

7) Water Resistant
Certain chemicals are added to the mix during the manufacture of
GFRG panels which make them impervious to the attack of water.

8) More Carpet Area

Since the thickness of the walls made with GFRG panels is less (5
inches) when compared with the conventional walls (9 inches), a
greater carpet area is accessible in a GFRG building.

DISADVANTAGES:

1. The panels are required to be handled with extreme care and

specific
2. machinery is needed for their movements.
3. The panels cannot be used for wall with circular or higher
curvature.
 4. The panels need to be neatly stacked in order to avoid
abrasion.
5. The clear span is limited to 5m for residential buildings.

COST ANALYSIS:

Difference between conventional and GRFG slab,

CONCLUSION:

Construction projects are bound by time constraints. It is

up to the contractor to innovate and come up with new material
designs to overcome this restriction while staying true to the
specifications of the plans. GFRG system has proved to very
effective in all the aspects of construction especially in time and
cost.
 REFERENCE:

1. RAPID WALL[2002] Engineering guidelines, compiled by

Ms Dare Sutton clarkeEngineers,Adelaid,Australia.

2. IS:456[2000],Code of particle for plain and reinforced

concrete for general building construction, Bureau of Indian
standard, New Delhi.

3. IS:1905[1987],Code of practice for structural use of

unreinforced masonry, Bureau of Indian standard, New Delhi
.
4. SCRC[2002],Evaluation of seismic performance of gypcrete
building panels,srtuctural Engineering Research
centre,chennai,India;August 2002.Project no.CPN 053241/2.

5. SERC [2002], Investigation on behaviour of gyrate panel and

blocks under static loading, structural engineering research
centre, Chennai, India; august 2002. project number. CNP
053241/1.