MAN €€ NATURE €€€ TECHNOLOGYimages.mofcom.gov.cn/ua/201505/20150515163549031.pdf · 2015....

«RAPID» PLANT

MAN NATURE

TECHNOLOGY

СОNTENTS

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Сontents 03

INTRODUCTION

TYPICAL PROJECTS

HISTORY OF ORIGINATION

APPLICATION

ADVANTAGES

MANUFACTURE

STRUCTURES AND MATERIALS

ENERGY EFFICIENCY

INTRODUCTION

Introduction 05

MULTIFUNCTIONAL

INNOVATIVE

ENVIRONMENT-FRIENDLY

ENERGY-EFFICIENT

HIGH-QUALITATY

FAST

Only high quality technological and environmental-friendly materials are used inproduction. Quality and health safety are approved by Russian and Europeancertificates.

Fully automated process, productivity and high level of readiness of all buildingassembly components guarantee uniquely short term of the facility construction.

Centuries of experience in frame-built construction, technological progress,industrial production of all building structures guarantee long-term operation life ofthe facility. Full production cycle, system of automated and program qualitycontrol keep all specifications stated during the whole lifetime.

Engineering solutions of constructive proposals, complete technology compliance,progressive materials provide buildings with the best thermal specifications. It helpssignificantly reduce operational expenses on facility maintenance and increase itspayback period.

The suggested construction technology helps build objects of any difficulty andpurpose. Construction is performed on aggregate soils, in any climatic and evenearthquake endangered areas.

Frame building is a new, progressive principle of construction of buildings ofdifferent type and purpose. High speed of manufacture, all-time low installationperiod, the lowest operational expenses is a warranty of efficiency of yourinvestments.

HISTORY OFORIGINATION

History of origination 07

Frame building has centuries of history. This technology originated in Europe.Scandinavian countries started active construction of frame-built houses in theMiddle Ages - these are the first frame houses known in the history. They appearedbecause of ambition to find a substitution to massive timber and brick houses, sincethere was deficiency of timber and qualitative brick. This house is based on timberframe, which consists of the system of ledgers, pillars, braces. These elements wereperforming both bearing and decorative functions. Straw, lime, brick etc. could playthe role of insulation. Such technology turned out to be very effective, since ithelped to build qualitatively, fast and, consequently, a lot. If necessary, insulationcould be substituted, that increased working life of such houses up to severalcenturies.

Technology gained its further active development in Canada and the USA with flowof emigrants after the Second World War. Only frame technology could providequalitative housing to a big amount of population in a record-breaking short time.That’s how projects of medieval constructors obtained their continuation on theother continent. Indeed, technology itself suffered significant changes - bearing,insulation and enclosing functions were distributed among different materials.Nowadays, you can see a lot of houses in suburbs of Europe, America and Canada,which have been standing there for more than one century.

Principles of frame industrial technology, in the form they exist now, started activedevelopment in the 60th of the previous century with the participation of Europeanconstructors. Practical Germans decided to improve quality and term for buildingtimber frame houses. That’s how the main principle originated - to make itQUALITATIVELY and FAST, maximum work must be performed at a place it can besuccessfully controlled, in other words, AT THE PLACE OF PRODUCTION. Rapiddevelopment of machine building in Germany led to immersion of the secondprinciple - maximal amount of work on building houses must be AUTOMATED. Sincethen the area of building houses according to German technology was successfullydeveloping and growing, moreover, at all continents.

APPLICATION

Application 09

Frame building - is 100% ready for installation set of necessary elementsmanufactured under plant conditions: panel of wall (external, dividing walls), floorslabs, roof panels, roof and any additional elements - terrace, open shed.

Panels are designed for construction of buildings and structures erected and usedin the areas:

- with earthquake activity less than 9 scores;- in all climatic zones;- with wind loading up to 80 kilogram-force/square meter;- with soils of any complexity.

Construction of frame buildings doesn’t require raising complex footings, sincecomposite panels are several times lighter than brick or timber walls. Due to thisreason shallow foundations can be used for timber frame buildings, which make itpossible to significantly save financial assets.

All supporting parts of the frame are assembled in preliminary state of stress,which makes the frame exclusively robust and further releases from differenttemporary deformations, hence guaranteeing construction durability. Afterconstruction there are no cracks in the building, since the frame house is notshrinkable.

Construction of frame building can be performed in any time of the year and atsubfreezing temperature - this is related to lack of «wet» processes duringinstallation of frame structures. Such all- season works gives opportunity of anurgent construction of frame building in winter without loss of quality.

ADVANTAGES

Advantages 11

Construction of frame buildings - good investment due to many reasons:

- high accuracy and quality of constructions is associated with absence ofhuman factor effect and maximum process automation;- construction is performed in minimal terms;- frame buildings are lighter than traditional equivalents, which helpssignificantly reduce cost of foundation, using shallow foundations;- frame building is the most resistant to seasonal footing movementscaused by soil expansion; - construction can be performed in winter time without a slight loss ofquality; - frame buildings have the highest power-saving features;- don‘t require permanent necessary heating in winter time;- cost of operational expenses is significantly lower than in brick, reinforced-concrete and bearing-wall houses;- construction doesn‘t need to use heavy lifting machines, which helpssignificantly reduce work effort and save surrounding landscape.

In terms of many characteristics, frame buildings considerably surpassbuildings of other materials, and they are reliable and long-lasting.

Walls of frame buildings erected in compliance with manufacturingprocesses have the lowest thermal conduction. Reliability of a frame housecan be proved by the fact that its walls can withstand unlimited number ofcycles of freezing and thawing.

High thermal insulation properties at a small wall thickness are reachedusing mineral cotton together with modern vapor- and water-proofmaterials as multilayer heating system. Thermally insulating layer in panelwalls of a frame building ensures comfortable living in it all year round,thermal characteristics of the walls surpass brick laying of much greaterthickness.

An integrated heating system can be successfully applied in framebuildings because of low heating capacity of walls. It needs much lessenergy to heat the same houses made of brick. Eventually, these expensescan be reduced twice or thrice.

MANUFACTURE

Manufacture 13

An important advantage of manufacture of these sets of houses is automation ofall processes and usage of CNC machines. This guarantees exact staticscompliance when making frame and mounting slabby material.

«RAPID» plant is an modern automated manufacture of rapidly erected framebuildings by means of German manufacturing process for industrial, social andcivil construction. It was built in 2014. According to opinion of equipmentmanufacturers, plant «RAPID» is now one of the largest, up-to-date and the mostautomated ones within the whole territory of Eastern Europe. Capacity of the plantis 250 000 sq. m. a year.

Manufacture is based on the latest advanced technology solutions, innovationideas and tendency to increase efficiency of construction processes. Due to thisreason the main part of processes is made not on the construction site, but underplant conditions, where there manufactured not separate details, but completelyready for installation elements of construction.

14 Manufacture

Frame buildings manufactured in our plant - is time proved quality. We useproducts of the leading European manufacturers, complying and controlling fullcycle of manufacture. Our engineers thoroughly monitor and examineappearance of new technological processes, materials, offering most up-to-dateand environmentally effective solutions at construction market in the form offinished product.

The process of house manufacture on «RAPID» plant involves all stages ofdesigning, construction and consists of the following operations:

- preparation of base materials: wood is sorted and comes to bucking, which isfollowed by technologic stage of drying wood. There selected an individualprogram for each type of wood and section of crude product in kilns. All wood isdried in automatic mode. Programming provides wood steaming, stress relievingand equal distribution of humidity 8-10%. Final temperature of the cycle of kilnshelps get rid of mycotic lesion of wood.

- automated wood processing: this stage includes optimization, removal ofdefects and lengthening of timber for further crosscutting of converted timber,cutting grooves and tenons, sawing out coggings of all kinds, boring holes,shaping. All these help reach perfect quality of shaping converted timber fordimension within the accuracy of 0.01 mm.

- structure fabrication: rectangular frame structures (frame of external, internal anddividing walls) are manufactured on a cross-beam station in automatic mode. Allsupporting parts of the frame are assembled in prestress (8 atm.), which makes thestructure exclusively robust and further releases from different temporarydeformations, hence ensuring durability of the structure.

Manufacture 15

Strict quality control and selection of up-to-date materials, which are safe forhuman health, guarantee comfortable microclimate and perfect sound insulationof the building.

Quality Engineer (Quality Control Dept) checks compliance of a fabricated partwith the sketch (dimensions of elements, quality of execution) and marks withQuality Control Dept.

Panel package is made of water-proof polyethylene bubble and stretch wraps.

- installation of structures: a house assembled with split-hair accuracy under plantconditions can be installed in any time of the year by means of special purposebrigades.

STRUCTURES ANDMATERIALS

Structures and materials 17

Planed timber frameCertified products of the biggest wood processing companies of normalized humidity are applied. This isa necessary condition for construction of a high quality house.

Gypsum plasterboard "Knauf"Up-to-date, firer-proof, environmentally friendly material - its acidity more or less equals to acidity ofhuman skin, it neither contains nor evolves into environment harmful for people chemical compounds. 93% of a standard plate is calcium sulfate dihydrate, 6% - cardboard and 1% - surface acting agents, starchand humidity. Gypsum plasterboard - is an ideal means for fast leveling of surfaces without using "wet"construction work. This significantly reduces term of construction work. Besides, gypsum plasterboardsurfaces don’t need any additional treatment before finishing.

OSB-3OSB - (oriented strand board) is three-layer boards compressed out of oriented directed shred atmachines of wet press (ultra-thin veneer) and soaked with synthetic resin. OSB manufacture usesdisbarked softwood, wax emulsion, polyurethane resin and water. This material is characterized by goodshape stability and optimal technical properties because of using special shape shred (length of chip - upto 160 mm) and high level of chip orientation of coating layers. Examinations of independentorganizations prove that boards contain the same amount of formaldehyde as natural wood. OSB ischaracterized as a construction material that has access to being used based upon examinations ofoutside organizations and marked with CE sign in accordance with the norms of EN 13986.

Mineral wool heat insulator ISOVERThis is heat insulation in rolls and slabs out of mineral wool based on fiberglass and stone fiber of thehighest quality. Heat protection level of material is one of the best at the market of mineral wool heatinsulation. Product group of the company presents materials that ensure maximal level of heat protection.ISOVER effectively protects from noise, make a house comfortable and quiet. It is the only manufacturerof fiberglass rigid slabs in CIS. They have high strength properties, which ensures high operationalcharacteristics. ISOVER products are safe for protection of human and environment. In 2012 ISOVERmaterials obtained Eco-label - decision on conformity with the standard "EcoMaterial" - Eco-standard.ISOVER products refer to nonflammability group NG and don‘t have effect on fire hazard class of thesystem they are installed in. Material life in climatic conditions of Russia is over 50 years. It is examined andapproved by the Scientific-Research Institute of structural physics, Institute of biochemical physics ofRussian Academy of Sciences and JSC "Teploproekt".

Vapor barrier membraneHigh technology roll material, which is designed for waterproofing, windshield and vapor-proofing of wallsand pitched roofs. The material consists of millions of microfibers ensuring correct and equal distribution ofcompounding materials for protection against ultraviolet and heat impact, which guarantees durability ofproperties within the whole thickness of material. That’s why materials have great experience of effectiveusage in the area of frame house-building.

Foam polystyreneExternal insulation of an exterior wall. Due to its physical properties it is a very good heat and sound-insulating material. Plastic foam is a material, which is not sensitive to moisture, doesn’t evolve anyhazardous compounds. It refers to so called "monomaterials" (consisting of one type materials). Foampolystyrene is absolutely non-toxic, it can be used without any worries.

Decorative plaster "rustic-textured" Ceresit CT 35Polymer-cement mortar mix for making thin layer textured coverings. Resistant to weather impact, impactloads, frost-proof, permeable to vapor, water-proof, environmentally safe. Provides the following paintingwith acrylic, silicate, silicone and other paints both water and organic base.

Facing panelsPS-panels - up-to-date aesthetic, reliable and durable materials, which are used for installation ofventilated facades. They make façade surface distinctive and attractive. An advantage of this system isfast and easy assembly, shift away from "wet" constructing operations. It also lets use additional facadeheat insulation.

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18 Structures and materials

Applications: for the construction of residential houses and civil buildings

The structure of exterior wall panel for buildings of increased level of fire-resistance (finishing with ventilated facade)

1.Ventilated facade (PS-panels).2. Wind barrier. 3. Magnesium oxide board - 10 mm. 4.Oriented strand board OSB-3 - 12 mm.

5.Mineral wool heat insulator - 150 mm. 6.Frame out of planed timber of softwood - 45х145 mm.7.Vapor barrier membrane. 8.Fire-resistant gypsum plasterboard - 12,5 mm

12 145 12 12,520 10 12,5224

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The structure of exterior wall panel for buildings of increased level of fire-resistance (finishing with ventilated facade)

1.Ventilated facade (PS-panels).2. Wind barrier. 3. Magnesium oxide board - 10 mm. 4.Oriented strand board OSB-3 - 12 mm.

5.Mineral wool heat insulator - 150 mm. 6.Frame out of planed timber of softwood - 45х145 mm.7.Vapor barrier membrane. 8.Fire-resistant gypsum plasterboard - 12,5 mm

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1. Fire-resistant gypsum plasterboard - 12,5 mm. 2. Oriented strand board OSB-3 - 12 mm.3. Mineral wool heat insulator - 150 mm.

4. Frame out of planed timber of softwood - 45х145 mm.


The structure of interior load bearing wall panel for buildings of increased level offire-resistance


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1.Fire-resistant gypsum plasterboard - 12,5 mm. 2. Oriented strand board OSB-3 - 12 mm.3. Mineral wool heat insulator - 150 mm.

4. Frame out of planed timber of softwood - 45х145 mm.

The structure of interior load bearing wall panel for buildings of increased level offire-resistance

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1. Fire-resistant gypsum plasterboard - 12,5 mm. 2. Batten out of planed timber of softwood - 30х50 mm.3. Vapor barrier membrane. 4. Frame out of planed timber of softwood - 45х195 mm.

5. Mineral wool heat insulator - 100 mm. 6. Oriented strand board OSB-3 - 24 mm.7. Reinforced sand cement screed - 50 mm



Interfloor overlapping panel structure for buildings of increased level of fire-resistance

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Interfloor overlapping panel structure for buildings of increased level of fire-resistance

1. Fire-resistant gypsum plasterboard - 12,5 mm. 2. Batten out of planed timber of softwood - 30х50 mm.3. Vapor barrier membrane. 4. Frame out of planed timber of softwood - 45х195 mm.

5. Mineral wool heat insulator - 100 mm. 6. Oriented strand board OSB-3 - 24 mm.7. Reinforced sand cement screed - 50 mm

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Roof panel structure for buildings of increased level of fire-resistance(in buildings with an attic floor)

1. Gypsum plasterboard - 12,5 mm. 2. Batten out of planed timber of softwood - 30х50 mm.3. Vapor barrier membrane. 4. Planed timber frame - 45х195 mm.

5. Mineral wool heat insulator - 200 mm. 6. Waterproof membrane. 7.Planed timber counter batten - 45х25 mm.8.Roof boarding out of planed timber of softwood- 100х25 mm. 9.Metal tile roofing. 10. Planceer piece - 15х90 mm.

11. Wall plate.


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Roof panel structure for buildings of increased level of fire-resistance(in buildings with an attic floor)

1. Gypsum plasterboard - 12,5 mm. 2. Batten out of planed timber of softwood - 30х50 mm.3. Vapor barrier membrane. 4. Planed timber frame - 45х195 mm.

5. Mineral wool heat insulator - 200 mm. 6. Waterproof membrane. 7.Planed timber counter batten - 45х25 mm.8.Roof boarding out of planed timber of softwood- 100х25 mm. 9.Metal tile roofing

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The structure of exterior wall panel(finishing with decorative plaster)

1.Decorative facade plaster. 2. Foam polystyrene - 50 mm. 3. Oriented strand boardOSB-3 - 12 mm. 4. Mineral wool heat insulator - 150 mm. 5.Frame out of planed timber of softwood - 45х145 mm.

6. Oriented strand board OSB-3 - 8 mm. 7. Vapor barrier membrane. 8. Gypsum plasterboard - 12,5 mm

Applications: for the construction of residential houses

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The structure of exterior wall panel(finishing with decorative plaster)


1.Decorative facade plaster. 2. Foam polystyrene - 50 mm. 3. Oriented strand boardOSB-3 - 12 mm. 4. Mineral wool heat insulator - 150 mm. 5.Frame out of planed timber of softwood - 45х145 mm.

6. Oriented strand board OSB-3 - 8 mm. 7. Vapor barrier membrane. 8. Gypsum plasterboard - 12,5 mm

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1. Gypsum plasterboard - 12,5 mm. 2. Oriented strand board OSB-3 - 12 mm.3. Mineral wool heat insulator - 150 mm. 4. Frame out of planed timber of softwood - 45х145 mm

The structure of interior load bearing wall panel

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1. Gypsum plasterboard - 12,5 mm. 2. Oriented strand board OSB-3 - 12 mm.3. Mineral wool heat insulator - 150 mm. 4. Frame out of planed timber of softwood - 45х145 mm


The structure of interior load bearing wall panel

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1. Gypsum plasterboard - 12,5 mm. 2. Mineral wool heat insulator - 100 mm.3. Frame out of planed timber of softwood - 45х95 mm

Internal partition panel structure


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1. Gypsum plasterboard - 12,5 mm. 2. Mineral wool heat insulator - 100 mm.3. Frame out of planed timber of softwood - 45х95 mm


Internal partition panel structure

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Attic floor panel structure(in buildings with cold attic)

1. Gypsum plasterboard - 12,5 mm. 2. Batten out of planed timber of softwood - 30х50 mm.3. Vapor barrier membrane. 4. Frame out of planed timber of softwood - 45х195 mm.

5. Mineral wool heat insulator - 200 mm. 6. Oriented strand board OSB-3 - 12 mm

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Attic floor panel structure(in buildings with cold attic)


1. Gypsum plasterboard - 12,5 mm. 2. Batten out of planed timber of softwood - 30х50 mm.3. Vapor barrier membrane. 4. Frame out of planed timber of softwood - 45х195 mm.

5. Mineral wool heat insulator - 200 mm. 6. Oriented strand board OSB-3 - 12 mm

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Roof panel structure(in buildings with cold attic)

1. Planed timber frame - 45х195 mm. 2.Planed timber counter batten - 45х25 mm. 3.Roof boarding out of planedtimber of softwood - 100х25 mm. 4. Waterproof membrane. 5.Metal tile roofing. 6. Planceer piece - 15х90 mm.

7. Wall plate


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Roof panel structure(in buildings with cold attic)

1. Planed timber frame - 45х195 mm. 2.Planed timber counter batten - 45х25 mm. 3.Roof boarding out of planedtimber of softwood - 100х25 mm. 4. Waterproof membrane. 5.Metal tile roofing

ENERGY EFFICIENCY

Energy efficiency 37

There is no a single official definition for energy efficient building in internationalexperience. Generally, energy efficiency - is technological processes and way oflife, which help us reduce energy consumption by means of its sustainableutilization.

The notion of energy efficiency includes different design, structural andengineering solutions, which make it possible during the process of operation ofthe building from «RAPID» plant to significantly reduce expenses on itsmaintenance, in other words, reduce expenses on heating. For example, framebuildings of «RAPID» plant surpass stone ones in economical efficiency twofold -that‘s exactly the amount annual expenses on heating are reduce. This factsignificantly increases liquidity of houses of «RAPID» plant, such house can alwaysbe sold at a profit (since the idea of energy efficiency is becoming a standard forqualitative housing).

Energy efficiency of the building consists of internal heat insulation, air tightness ofbuilding envelope and «warm» windows.

We can easily state that heat and power indexes of external walls of the house of«RAPID» plant surpass existing norms applicable to residential and civil buildings.

According to its heat transmission, frame building wall, which is 0.24 m thick isassociated with:

- 2 meter brick wall,- 1.2 m of gas concrete wall;- 0.9 m of timber;- 0.75 m of beam

TYPICAL PROJECTS

Typical projects 39

Nursery school with 180 seatsOverall area is 2400 m2

40 Typical projects

Rural medical outpatient department for 30 visits a dayOverall area is 175 m2

Individual residential houseOverall area is 150 m2

Typical projects 41

42 Typical projects

Individual residential houseOverall area is 180 m2

Partners:

Contact Information:LLC "Plant" RAPID "

61030Kharkiv

ul.Grekovskaya, 79tel / fax: +38 (057) 733 42 43

+38 (057) 733 42 36e-mail: ооо[email protected]

MAN €€ NATURE €€€ TECHNOLOGYimages.mofcom.gov.cn/ua/201505/20150515163549031.pdf · 2015....

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