fm QPANEL Lightweight Concrete Wall panel PRODUCT KNOWLEDGE Produced By Lisenced By PE.BUKAKA’ [BUILDING TECHNOLOGIES AUSTRALIA PTY LITED Bulaba Indust ‘Wabi: sew J. Raya Bekast Narogong 10M 195 Clune, Boga: 168201 INTRODUCTION Profile of 50mm ‘rapid construction’ Qpanel The raw Qpanel technology was invented and developed in Australia, WA in 1970's. It was subsequently purchased by Building Technologies Australia Pty Ltd in 1990, and taken to the Indian and Arab markets for extensive development and improvement. Since 2000, the technology has been marketed in selected regions around the world. Qpanel now has a presence in Australia, India, Yemen, Indonesia and other South East Asian countries. Markets are now being developed in the USA and South America as well as Pakistan and further Middle Eastern countries. Product Range (international) : Light Weight Wall, floor and roof panel construction systems, lightweight blocks, fibre cement sheet and manufacturing plant and machinery.1 INTRODUCTION Research & Development : Research & Development facility at Hyderabad Constructed Using QPanel Research & Development in India is housed in an ultra modem building equipped with state of art facilities and covering 3,300 m? area. It is manned with skilled & dedicated personnel engaged in product, plant and technology development, recognised by Department of Science and Technology, Government of India. All companies producing QPanel own their manufacturing facilities and carry out continual Research And Development on lightweight panels, blocks and other new and innovative building materials. Hyderabad Industries Limited have been conferred the DSIR National Award for R & D efforts in industry for the year 2000 in the area of new materials for “QPANEL INSTA WALL PANEL’. Hyderabad Industries operates in collaboration with Building Technologies Australia Pty Limited, an Australian company that owns right to Qpanel technology. The R & D activities of all companies involved are directed towards modernization, automation and technological innovation, development and commercialization of value added products and towards exploring new avenues for the utilization of waste materials like and flyash and EPS bead with an aim to reduce waste materials product cost.1 INTRODUCTION 1.1. What is Qpanel ? Qpanel Qpanel is a sandwich panel made up of two fibre reinforced cement facing sheets on either side of a lightweight conerete core. The lightweight concrete core consists of a mix of Portland cement, binders, siliceous and micaceous material aggregate suitably aerated, with non-toxit chemicals. Qpanel is designed so that it can be handled and erected QUICKLY by two men requiring no cranage or special mechanical equipment. Picture 1 Picture 2 Installation wall with Qpanel Installation lintel with Qpanel1 INTRODUCTION ADVANTAGES The advantages of Qpanel are : Economical FAST Track Construction, resulting in a strong high quality finish. + Tongue and groove joining system allows faster construction and high quality of finish. + Factory cured and quality controled panels eliminates on-site problems + Lightweight panels allow easy handling and erection. + Easy workability — no special tools required + Re-locatable-complete structure can be dismantled and re-erected «Safe and Resistant construction in cyclone and earthquake areas. Strong & Durable Panels are manufactured from high quality materials imparting strength and long life. Excellent water, termite and fire resistant Properties to withstand adverse conditions. Fire rating — 50 mm panel - 1 hour —75 mm panel — 2 hours Most suitable for seismic and cyclone prone zones Other Advantages = Excellent surface finish — takes all decorative treatments. * Excellent thermal and sound insulation properties. * Slim Qpanel provide extra usable floor space. = Usage of Fly ash and timber-free Qpanel makes it Eco-friendly. = Houses, school, hospitals and other building can be factory cut out and prepared then containerized and delivered to site ready for immediate erection. Qpanel — the product of new millennium, to cater to modern days construction needs.2 PRODUCT RANGE 2.1. Physical Dimensions : THICKNESS | WIDTH ‘LENGTH WEIGHT (b a (mm) (mm) (mm) (Kg/m?) 35 600 2400, 2700, 3000 29 50 600 2400, 2700, 3000 39 75 600 2400, 2700, 3000 48-54 100 600 2400,2700,3000 54-60 * Typical values on dry basis Diagonal difference (max) -3mm Edge straightness Deviation (max) +/-2mm These are available in two types for different applications : - Square edge panels for expressed joint finish. - Recess edge panels for smooth flushed joint finish. Low density panels can also be supplied if required on special order.PRODUCT RANGE 2.1. Technical Specification: Ignitability THICKNESS PROPERTY 35mm | 50mm | 75mm REMARKS. Axial load / meter width (KN/m) 50 | 583 | 83 | Factor of Safety—2.5 Bending test (4 point UDL) Uniform distributed load (Kg/Gm’) i 29nsren| 43. | a1 | 109. | Factorof Satety—2.5 1.5MSpan| 115 | 220 | 295 Flexural Strength / Modulus of a Berea 124 | 67 | 58 | Typical Test Results Compressive Strength (Kg/Cm*) 50 50 70 Typical Test Results isis Conductivity (Wimdeg. | 953 | o22 | 0.21 | BS4370-Part2 Sound Transmission Coefficient 1S : 9901 (Part Ill) — (db) 1981 Typical Test results of Praser 34 co 96 | Is: 11050 (Part !) — Bharati and NPL) 1981 Fire rating (minutes) i 2 As per test result of CBRI) 60 | 120 | BS 476 Part 20-22 Surface spread of flame CLASS | BS 476 Part 7 - 1971 Fire Propagation Index CLASS! BS 476 Part 8 — 1981 class P BS 476 Part 5 — 1968, * The above specifications are based on typical test results of Qpanel with Flex-O- Board and may vary subject to country of manufacture and materials used3 PRODUCT OVERVIEW Building Technologies Australia Pty Ltd (BTA), a private technology company based in Sydney, Australia is the owner of and holds rights to a number of panelised building technologies and other rapid construction systems manufactured and marketed throughout the world. BTA is presently in partnership with local companies manufacturing product in India, Yemen, South East Asia and Australia. Additionally, joint ventures are proposed for the European, New Zealand and various Middle Eastern markets. QPANEL TECHNOLOGY Variety of Applications Qpanel technology is capable of being used in a variety of applications: a) _ Loadbearing construction in single and two storey building. Panels can be economically used for loadbearing walls and permanent formwork for concrete columns and suspended concrete slabs in buildings of one and two storeys in height. By using Qpanel as loadbearing walls in place of traditional materials, the construction time cycle per floor is significantly reduced. Usable floor space is increased by virtue of a thinner walll doing the same job. The system is architecturally flexible and ideal for areas affected by seismic and cyclonic conditions. Panels can be specifically engineered and manufactured to suit conditions. b) _Non-loadbearing construction in multi-storey building. BTA's lightweight, prefabricated panel wall system for multi-storey buildings consists of various factory manufactured components that allow speedy erection and minimal finishing. Qpanel, when used for facades, fascias, sunscreens and_ building embellishment, can result in considerable cost savings in both material cost and cost of supporting structure due to its strength and lightweight . Used as a building facade or curtain wall, the fire-rated Qpanel can be erected | speedily from the inside of the building without the use of heavy equipment and scaffolding.To the surface of the panels may be applied a tough permanently coloured skin having very high impact resistance or a simulated stone finish (Styrostone) which is also particularly suitable for foyers, etc. Qpanel are fire and sound rated panels ideal for internal partitioning. Finished panels provide a solid, smooth surface an have the added advantage in that they can be demountable and reusable if erected accordingly. ¢) Agricultural and farm applications. Qpanel has been successfully use for pig pens, horse stables, dog kennels, aviaries, zoo enclosures, poultry sheds, dairies, grain rooms, temporary pens or shelters, animal races, fencing, retaining walls, offices and secure rooms within ‘open sheds or structures etc. Fire, Sound and Thermal Rating The surface of the Qpanel is very dense and inert. The panels are manufactures from non-combustible materials and consequently have good fire rating and thermal or acoustic properties with the Qpanel providing the structural element of the combined materials. The introductions of a sealed or vented air gap (to suit the particular requipments) between Qpanel and other material can be utilized to advantage. Insulating material can also be positioned in the gap to further improve thermal and/or acoustic performance of the composite wall. Walls can be engineered from test data and calculation, to suit any performance criteria required. Durability A structure built with Qpanel will last for generations. Panels are manufactured from strong, stable and high quality materials which are highly resistant to all types of weather conditions. The panels are non-combustible, dry rot resistant and safe from termite attack. Special surface treatments may also be applied to the face of panels. Many Qpanel buildings in the north of Western Australia have satisfactorily withstood cyclones. Recently built (1998) Qpanel buildings in India were the only undamaged buildings left standing after a recent cyclone (200kph winds) passed through the coastal town of Gujarat. Economy and Speed of Construction The Qpanel system involves fewer components than conventional construction, therefore it is easier to erect. Construction can be carried out by supervised unskilled workers. Qpane'’s fit into place quickly and easily, thus saving on construction time and development costs. Only two men are required to carry and erect a panel. Architectural Flexil ity Qpanel permits maximum design flexibility. Walls normally constructed out of masonry or reinforced concrete can be constructed with the Qpanel system. Design change are enabled on-site and panels may be applied to additional functions such as bookselves, bench tops and flooring.Experience shows that ‘closed systems’ which are designed with the object of providing interconnecting floors, walls and roofs are usually inflexible when encountering on-site discrepancies or the need for a design modification. The Qpanel is, on the other hand, a flexible ‘open system’ easily permitting on-site modifications and alterations. Qpanel Technology provides the flexibility of design that encourages the combination of traditional methods of building together with modern prefabricated innovation for economy and speed of erection. Appearance Because the panels are factory manufactured under quality controlled conditions, the walls produced are dimensionally accurate, strong and clean. Any type of surface finish may be applied including cementitious render, plaster, paint, wallpaper or tiles. Relocatable Qpanel was be recycled. Provided the building is so designed, Qpanel can be dismantled, transported and rebuilt on another site or re-used for other applications. Environmentally Friendly Qpanel was developed with the intention of a building system that was environmentally acceptable and which did not make use of any toxic material or diminishing natural resources. Cyclone and Expand Independent test and exposure to cyclone conditions in north-west Western Australia, India, Nigeria and the Pacific Islands have proven that Qpanel structures will withstand cyclones. These structures may be specifically designed to withstand varying levels of seismic activity and wind, and are therefore much more resistant to earth tremors and cyclone than those built from conventional materials. A recent cyclone that devastated the northern regions of India flattened almost every building structures whereas surrounding buildings were demolished. Since these natural disasters, Qpanel has become a preferred building material of the Indian government and private industry.4 COMPARABLE | STRENGTH TEST In order to compare the strength of the Stvrocon panel used in wall structures to that of other materials commonly used in simple single storey buildings, structural engineers. Wood & Grieve, who have been involved with Stvrocon since its inception, have examined these materials in a typical location under wind load. The bending stresses acting on the various wall types using the different materials have been calculated and these values divided into the ultimate loads in order to obtain a “relative strength factor” in order to allow comparison between Stvrocon and other wall types. The results set out hereunder are intended only as a guide to the strength of the Stvrocon panel as each particular wall structure requires independent analysis. Relative Strength Factor A. Styrocon Panel Wall 38 50 mm thick (unreinforced) (75 mm also available) B. Typical Timber Stud Wall Framing 35 (Australian pine stress grade F7 structural No. 3 studs 75 x 35 at 600 centres) Cc. Brick Veneer Wall 35 (To Masonry Code AS 3700 Section 5.9) D. Cavity Masonry Wall 19 (To Masonry Code AS 3700 — 1998) Cae SST ee ea 10D. 230 Clay Brick Solid Mansonry Wall FIRE TESTS 12 Styrocon panels were tested by the CSIRO Division of Building, Construction and Engineering in accordance with Australian Standard 1530, Methods of Fire Tests on Buikling Materials, Components and Structures, Part 4-1990; Fire Tests on Building Materials & Structures, Parts 20 & 22, 1987 on 25 July 1991. Certificates of these tests have been provided. These test results together with those for other commonly used buiding materials are set out hereunder. A Styrocon Panel Wall B. Brick Wall 110 Thick Plastered Cc. Cavity Brick Wall With 50 mm cavity D. 230 Clay Brick Solid Mansonry Wall Comparative Fire Ratings 50 mm thick 1 hr 75 mm thick 2 hr 100 mm thick 3 hr estimated 3hr 4hrSOUND INSULATION Airbone Sond Transmission Loss STC ( Sound Transmission Class) — STC figure is found by plotting the Sound Transmission Loss figures in 16-1/3 octave bands from 125 Hz to 4 KHz on graph fitting the STC contour over as detailed in ASTM E413-73. The rating is read at the 500 Hz intersection with the STC contour. Average Sound Reduction Index ( R ) Calculation R is the arithmetic mean to the nearest decibel of the values calculated in 16-1/3 octave bands from 100 Hz to 3.15 KHz. Sound insulation of panel walls may be easily increased by adding additional materials to wall surface internally of externally, doubling of panels or provision of a cavity in the wall composition. STC Rating (Decibels) A. Styrocon Panel Wall 30 50 mm thick (unreinforced) 38 (75 mm also available) 8. Typical Timber Stud Wall Framing 26 (Australian pine stress grade F7 structural No. 3 studs 75 x 35 at 600 centres) C. Brick Veneer Wall 45 (To Masonry Code AS 3700 Section 5.9) D. Cavity Masonry Wall 53 (To Masonry Code AS 3700 — 1998) E230 Clay Brick 48 Solid Masonry Wall| 5] APPLICATION External Cladding on Highrise1 External Cladding on Highrise2 4 Storey Styrocon Apartment buildings — PakistanB. RESIDENTIAL APPLICATIONS Finished House - Sydney Finished Interior House - Sydney Under Construction House - SydneyC. REMOTE AREAL APPLICATIONS Demountable Military Barracks Example Mining Camp Housing - India - Roofing fixed = Remote Area Construction - Rest Room 1