Contacts
Head Office & Rapidwall ¨
Licensing
Rapid Building Systems Pty Ltd.
1590 main North Road
Brahma Lodge
South Australia 5109 Australia
P: +61 8 8281 1319
F: +61 8 8281 7416
Rapidwall ¨ Distribution
Queensland
Rapidwall Technologies Queensland Pty Ltd.
91 Harts Road
Indooroopilly
Queensland 4068
P: +61 7 3871 0200
F: +61 7 3871 3835
Rapidwall ¨
Products
Rapidwall Australia
Manufacturing Pty Ltd.
35 Willomavin Road
Kilmore Victoria 3764
P: +61 3 5782 2111
F: +61 3 5782 0531
Plaster
Products
RFC Plaster Pty Ltd.
35 Willowmavin Road
Kilmore Victoria 3764
P: +61 3 5782 0534
F: +61 3 5782 0531
New South Wales
ACS Walling Pty Ltd.
5/1 Burroway Street
Neutral Bay
NSW 2089
P: +61 2 9953 8739
F: +61 2 9907 8665
Victoria
Rapidwall Technologies Victoria Pty Ltd.
35 Willomavin Road
Kilmore Victoria 3764
P: + 61 3 5782 0534
F: + 61 3 578 20531
For more product and technical
information for industry and
consumers please visit our
website at www.rapidwall.com.au
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Load-bearing Pre-fabricated Walling
Rapidwall ¨ Product Information
Light weight and accurate
Environmentally positive
Good sound attenuation
High quality finish
Fire proof
Cyclone resistant
Economical
Earthquake resistant
Space saving
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Load-bearing
Water and rot resistant
100% recyclable
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Fast
Termite resistant
Pre-fabricated (12m X 3m X 120mm)
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Lightweight ( 42kg/m 2 )
Fast
manufacturing rate 72 m 2 /hr
installation rate (two man crew) up to 45 m 2 /hr
Fully engineered structural walling
Environmentally sustainable
100% recyclable
low embodied energy
manufactured from natural and/or waste raw materials
13 mm
13 mm
94 mm
Rapidwall¨ is a revolutionary, low
structural
cost, prefabricated, load bearing
Rapidwall ¨
panels
loadbearing
walling product suitable for use in
and
suited
for
high-rise residential, c o m m e r c i a l
earthquake-prone areas.
attributes
well
that
make
use
in
and industrial building construction .
230 mm
glass fibre reinforcements
20 mm
All panels are 12 metres long and
250 mm
Rapidwall ¨
is
manufactured
in
120
millimetres
and
can
be produced in heights ranging
using glass-fibre reinforced water
from
resistant
Construction
Gypsum
plaster.
After
2.5
metres
using
to
3
the
metres .
precise
removal from the casting table the
Rapidwall ¨ panels is very fast, low
flat, single sized panels are oven
in cost and elimnates the need for
cured. The technically advanced
brick, blocks, wall framing and
manufacturing process provides
wall-board. It can also be used as
a durable walling product w i t h
suspended floor formwork.
12 metres
3 metres
1/ www.rapidwall.com.au
thick
an automated moulding process
20 mm
>
superior building material
CROSS SECTION DIMENSIONS
light weight and accurate
economical
load-bearing
A 12 m x 3 m x 120 mm reinforced
Rapidwall ¨ has an installed cost
The unique cellular structure of the
concrete wall panel weighs
considerably less than that of
Rapidwall ¨ panels enables it to be
over 10 tonne. A similarly sized
an equivalent standard precast
used as left-in-place formwork and
Rapidwall ¨ panel weighs only
concrete wall. Rapidwall ¨ costs
site-filled with concrete to provide
1.5 tonne.
less than equivalent strength
sufficient axial strength and lateral
masonry walling over which it also
rigidity to support buildings up to
enjoys a 15% space saving.
15 storeys. When used structurally
At only 42 kg per square metre ,
a
single
B-double
truck
can
Rapidwall ¨ eliminates the need for
transport over 900 square metres
Because Rapidwall ¨ is quicker and
of Rapidwall¨ compared to
easier to erect, projects are finished
125 square metres of 120 mm
faster and development funds
When filled with insulation only ,
thick precast thick concrete
a r e t i e d u p f o r s h o r t e r periods .
Rapidwall ¨ can be used as load
hollow
Precision
Rapidwall ¨ can eliminate the
bearing walling for timber floored
manufactured Rapidwall ¨ panels
need for bricks, blocks, timber wall
residential construction up to
provide certainty in calculations
frames and plasterboard linings .
three storeys.
blockwork.
beam and column framework.
a n d i n c o n s t r u c t i o n t o l e r a n c e s.
www.rapidwall.com.au /2
INDUSTRIAL CONSTRUCTION
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>
>>
MARINE CONSTRUCTION
>
CUT RAPIDWALL PANELS DELIVERED TO
SITE IN STILLAGES
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>>
CUT RAPIDWALL PANELS DELIVERED TO SITE
IN STILLAGES
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>
POURING CONCRETE INTO RAPIDWALL FROM
WALLS PLACED AND PROPPED BEFORE
PLACEMENT OF FLOOR FORMWORK
superior finish
The finish of Rapidwall ¨ is smoother
and flatter than an equivalent
precast concrete, insitu-concrete or
rendered masonry walls. Rapidwall ¨
provides the ideal ÒgreenÓ structural
walling material for contemporary
architectural designs. Rapidwall ¨
panels can be finished in a range
of decorative texture finishes
and can include bands, quoins and
rendered finishes.
Rapidwall ¨ is a strong, crack free ,
clean and sharp structural grade
wall panel requiring less jointing and
less finishing.
earthquake resistant
water and rot resistant
When used as load-bearing shear
In an unsealed and uncoated
walls Rapidwall ¨ exhibits superior
state and after full immersion
ductile
it
in water for 24 hours, the moisture
safer a n d e f f e c t i v e l y s t r o n g e r
uptake of Rapidwall ¨ is less than
than
qualities
that
make
u n - r e i n f o r c e d m a s o n r y.
5% [by weight].
Its mechanical properties make
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Rapidwall ¨ a superior earthquake
R a p i d w a l l ¨ is approved for use
resistant structural walling product
in wet areas requiring only
for both vertical and lateral loads .
the application of the nor mal
m a n d a t o r y wet-area
3/ www.rapidwall.com.au
mebrane.
Detail 24/ Contrete Filled
internal wall to suspended floor
non-continuous reinforcement
APARTMENT COMPLEX, SYDNEY.
>>
>> refer to the Rapidwall web site www.rapidwall.com.au
for a full range of construction details
HOTEL CONSTRUCTION
>
>>
>>>
fire resistant
termite resistant
speedy installation
Rapidwall ¨ panels are machine
Rapidwall ¨ panels are made of
fire-resistant properties making it
made
gypsum
an ideal building material for
generally manufactured in one
use in dwellings in bushfire prone
size then cut to dimension for
vermin and termites. Rapidwall ¨
areas as well as in apartment
height and length complete with
construction is devoid of any timber
construction
door and window cut-outs.
products eliminating any risk of
Rapidwall ¨
has
outstanding
where
fire-rated
in
one
hour.
They
are
plaster
and
fibreglass .
They are immune to attack from
termite infestation for which there
party walls are required.
In a single day a small crane
Rapidwall¨ is rated at one, two and
and two trained installers can
four hours when empty, insulated
erect all the wall sections for
and concrete filled respectivly.
a
medium
sized
are no safe prevention methods .
350\square
metre house. The large size of
the Rapidwall ¨ panels also means
fewer fully sealed construction and
contraction joints.
www.rapidwall.com.au /4
>
APARTMENT COMPLEX, BRISBANE.
Thermal Insulation
The thermal transmission properties have been determined for a number
of Rapidwall ¨ construction options. The thermal resistance (R-rating)
from laboratory tests on 120mm thick panels are provided in Table 8.1.
Theoretical opinions for some other types of constructions are also
available on request from Rapidwall Australia Manufacturing Pty Ltd.
Ta b l e 8 . 1 T h e r m a l r e s i s t a n c e f o r v a r i o u s f o r m s o f R a p i d w a l l ¨ c o n s t r u c t i o n
Construction
Additional
coat
or lining
To t a l
thickness
(mm)
R
(m2K/W)
NA
120
0.36
NA
120
0.25
NA
120
0.6
Single leaf Rapidwall¨
With standard
120
1.63
filled with 35kg/m3 and
texture finishing
R2.5 Rockwool batts
coats (ASTEC) on
Single leaf Rapidwall¨
unfilled
Single leaf Rapidwall¨ filled
with 20MPa normal concrete
Single leaf Rapidwall¨ filled
w i t h l i g h t w e i g h t c o n c re t e
both exter nal faces
Environmentally Positive
Rapidwall ¨ is made using plaster manufactured
b y t h e product
from either naturally occurring gypsum or waste
of
flu-gas gypsum. Gypsum is readily available and
processing and delivery to its final installation and
is low in cost. The gypsum is processed by our
finishing on a building project.)
the
raw
from the point of extraction
material
through
manufacture,
company in our own Rapidflow Calcination Plant
Rapidwall ¨ panels are 100% recyclble. They can be
located in Kilmore Victoria.
re-processed through our Rapidflow Calcination
Rapidwall ¨ has one of the lowest levels of embodied
Plant and recast into new Rapidwall¨ panels.
energy of all manufactured walling products.
(ÒEmbodied e n e r g y Ó is the total energy consumed
good noise resistance
accomodates building services
Whether insulated or concrete
plasterboard on resilient mounts .
The cellular panels can be used to
filled Rapidwall ¨ has excellent
A rating of RW 55 can be
accommodate
sound attenuating characteristics .
achieved using plasterboard lining
such as plumbing and electrical
Rapidwall¨ can be used as
on isolated studs on one side of
conduits. They can be left empty or
structural party walls providing
t h e loadbearing Rapidwall ¨ .
filled with insulation for increased
building
services
the basis for an effective 55 STC
thermal performance or they can
sound barrier when lined with
be
filled
with
structural
grade
concrete for increased axial strength .
5/ www.rapidwall.com.au
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Fire Resistance
The fire resistance levels (FRL) of Rapidwall ¨ are listed in Table 6.1.
Copies of the test certificates are available by request from Rapidwall
Australia Manufacturing Pty Ltd. (RAM).
Description
FRL
Single leaf unfilled Rapidwall¨
180/120/60*
180/90/90*
30/30/30*
Rockwool batts
loadbearing
walls
Single leaf panel filled with
>>>>
Single leaf panel filled with
A SINGLE THREE-TABLE RAPIDWALL PLANT CAN
PRODUCE UP TO 650,000 SQUARE METRES / YR
>>>
panel
TRANSPORTATION OF UP TO 570 SQUARE
METRES/TRUCK
>>
non-loadbearing
walls
Fire Resistance Levels
INSTALLATION OF FLOOR FORM-WORK,
REINFORCEMENT AND SERVICES BETWEEN
RAPIDWALL PANELS
>
Table 6.1
MULTI-STOREY CONSTRUCTION UP TO 15 STOREYS
12mm scoria aggregate
Single leaf panel filled with no
120/120/120*
fines scoria
Single leaf panel filled with
240/240/240*
32 MPa concrete
Double leaf panel filled with
180/180/180*
c e l l u l o s e f i b re i n s i d e t h e c o re s
The three figures in the right hand column refer to
fire resistance periods for satisfying structural adequacy,
integrity and insulation, respectively. Note: 2. FRL ratings with
an asterisk Ò*Ó are test results from previous 100 mm thick
Rapidwall¨ panels. These results are deemed be applicable to
120 mm thick Rapidwall¨.
Note: 1.
www.rapidwall.com.au /6
specific applications
Mechanical Properties of Rapidwall ¨
Table 5.1 provides the various mechanical properties
of Rapidwall ¨ panels when used empty and when
concrete filled.
Load-bearing walls in
multi-storey apartments
Ta b l e 5 . 1 M e c h a n i c a l P ro p e r t i e s o f R a p i d w a l l ¨
Firewalls
Description
Property
Value
Note
Non-load
Uni-axial
100 kN/m
S t r e n g t h o b t a i n e d f ro m
bearing walls
compressive
l o n g i t u d i n a l c o m p re s s i o n /
strength fRu
tension tests with ribs vertical
Roof panels
Lost formwork and
ceilings for
suspended slabs
Fencing
Domestic housing
construction, single
and double storey
Uni-axial
tensile
s t re n g t h φ R u
28.8 kN/m
Out-of-plane
flexural rigidity
EI, rib parallel
to span
3 . 5 x 1 0 11
N m m 2/ m
Out-of-plane
1 . 7 x 1 0 11
flexural rigidity
N m m 2/ m
Townhouses
Shops
EI, rib
perpendicular
Offices
to span
Resorts
Unit weight
40 kg/m2
Thermal
1 2 x 1 0 -6 m m /
expansion
m m / oC
Hospitals
Factory buildings
coefficient
Cinemas and
Wa t e r
absorption
<5%
mohr hardness
1.6
Rapidwall¨ panels
Uni-axial
890 kN/m
filled with 25 MPa
compressive
concrete in all
strength fRu
sound studios
Wa t e r a b s o r p t i o n b y w e i g h t %
after 24 hours of immersion
Obtained from longitudinal
compression tests with ribs
in the longitudinal direction
the cores
cyclone resistant
Rapidwall ¨ when concrete or
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sand-filled is resistant to penetration
by flying objects so common in
cyclones Additionally a simple
Rapidwall¨ is an Australian
tie-down system passing through
invention now being used in
the Rapidwall ¨ cells and into
construction under license in
the foundation secures the roof
China, India and Malaysia as
against severe uplift forces
well as throughout Australia.
experienced in cyclones.
7/ www.rapidwall.com.au
space saving
At only 120mm wide, when
compared to brick-veneer
construction Rapidwall ¨ provides
up to 10% more usable internal
floor space of a building of
.
comparable
external dimensions.
Sound Transmission
Sound Transmission Coefficients [STC] have been deter mined for a number of
Rapidwall ¨ construction options. The coef ficients from tests on 120mm thick
panels are provided in Table 7.1.
Other types of constructions have been investigated and the acoustic
opinions are available on request from Rapid Building Systems Pty Ltd. STC
test results on for mer 100mm thick panels, including double leaf walls, ar e
also available onrequest from Rapid Building Systems Pty Ltd.
Ta b l e 7 . 1
STC values for various for ms of Rapidwall¨ construction.
Construction
Main element of wall
Additional lining
Attachment method
To t a l
thickness
(mm)
STC
Single leaf Rapidwall¨ unfilled
-
-
120
28
Single leaf Rapidwall¨ filled
-
-
120
31
-
-
120
33
120
45
133
36
161
45
171
54
173
55
194
55
with 60kg/m3 cellulose
fibre insulation
Single leaf Rapidwall¨ filled
w i t h 9 0 k g / m 3 c e l l u l o s e f i b re
insulation
S i n g l e l e a f c o n c re t e f i l l e d
-
-
Rapidwall¨
Single leaf Rapidwall¨ filled
13mm Gyprock¨
Direct-fixed
with 90kg/m3 cellulose
with screws and
fibre insulation
thin glue daubs
Single leaf Rapidwall¨ filled
13mm Gyprock¨ and
Standard 28mm
with 90kg/m3 cellulose
To n t i n e T S B 3 ¨
Rondo 129 furring
fibre insulation
polyester insulation
channels
S i n g l e l e a f c o n c re t e f i l l e d
13mm Gyprock¨ and
Heavy gauge (1.2mm)
Rapidwall¨
To n t i n e T S B 3 ¨
Rondo 38mm
polyester insulation
top hat sections
S i n g l e l e a f c o n c re t e f i l l e d
13mm Gyprock¨ and
Standard 28mm Rondo
Rapidwall¨
To n t i n e T S B 3 ¨
129 furring channels
polyester insulation
and CSR Gyprock¨
resilient mounts
S i n g l e l e a f c o n c re t e f i l l e d
13mm Gyprock¨ and
Separate row of
Rapidwall¨
To n t i n e T S B 3 ¨
51mm steel studs
polyester insulation
spaced 10mm
from Rapidwall¨
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rapidflow calcination plant
and plaster products
the Rapidwall¨ products
In addition to selling Rapidwall ¨
RFC Plaster Ltd Pty, a subsidiary of
panels we license the Rapidwall ¨
Rapid Building Systems Pty Ltd
technology
RBS],
sell
and
and
manufacture ,
distribute
owns
the
latest
and
most advanced technology for
Rapidwall ¨
manufacturing plant.
producing high quality plaster using
The parent company, Rapid Building
a fluidised bed calcination process .
Systems Pty Ltd [RBS], developed
and owns the intellectual property
The first calcination plant using
associated with the patented.
this technology was manufatured
Rapidwall¨ manufacturing process
by RBS adjacent to the groupÕs
RBS licenses the manufacture of
Rapidwal l¨ manufacturing plant in
Rapidwall ¨ worldwide.
Kilmore, Victoria.
RBS also
manufactures, exports and installs
Rapidflow Calcination Plants are
the equipment necessary for
producing Rapidwall ¨ .
sold as a package with the sale
RAPIDWALL PRODUCT PLANT, KILMORE, VICTORIA.
>
>
This equipment includes:
RAPIDFLOW CALCINATION PLANT, KILMORE VICTORIA.
Fully automated casting beds
Fully automated travelling
mixer/dispensers
Rapidryer curing ovens
Handling equipment
Rapidwall ¨ numerically
controlled cutting beds
Rapidflow calcination plant
see back page for RBS
contact details
>
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SYDNEY PARK VILLIAGE, NSW
Detail 6/
concrete fille
>> refer to the
www.rapidwa
for a full range
9/ www.rapidwall.com.au
Detail 10/ External 45
concrete filled
or insulated
of the Rapidwall¨ manufacturing Rapidflow plaster is also available for
plants or they can be purchased purchase by construction contractors ,
individually
in
sizes
able
to retailers and manufacturers.
manufacture from 5 tonne per hour
up to 50 tonne per hour. Compared The full range of Rapidflow plaster and
to normal wall-board plasters the associated products includes:
Rapidflow plaster produced from
the Rapidflow Calcination Plant Rapidwall ¨ Casting Plaster
is superior in quality and is used
exclusively in the manufacture of Rapidwall ¨ White Cornice Adhesive
Rapidwall ¨ structural wall panels.
Rapidwall ¨ White Base Coat Plaster
Rapidwall ¨ Mining Plaster
Rapidwall ¨ Glass-fibre Rovings
Rapidwall ¨ Plaster Release Agent
see back page for RFC
contact details
>
RAPIDFLOW CALCINATION PLANT, KILMORE VICTORIA.
SYDNEY PARK VILLIAGE, NSW
>> refer to the Rapidwall web site www.rapidwall.com.au
for a full range of construction details
Detail 6/
Detail 10/ External 45o Corner
concrete filled
concrete filled
or insulated
ed
e Rapidwall web site
all.com.au
e of construction details
5o Corner
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