Robust Affordable Alternative Building Systems Method in English
109
80
-
Upload
robuststructure -
Category
Technology
-
view
245 -
download
3
description
The Robust Affordable Alternative Construction Building Systems Method is an innovative monolithic structure that is stronger, faster, easier, more versatile & accredited and can be used in building almost any type of structure ranging from Multi-storey apartment buildings, Houses, Schools, Warehouses, Military camps, Swimming pools, Boundary walls, Retaining walls, High security perimeter walls, Suspended floor slabs, Staircases, Infill walls, Game Lodges, underground sewerage systems, water storage tanks both above and below ground and Silo’s up to 18,000 ton capacity to name but a few.
Transcript of Robust Affordable Alternative Building Systems Method in English
80
RO
BU
ST
THE BUILDING SYSTEM
The walls of the ROBUST Building System are constructed with factory-produced expanded metal panels to which mortar is
applied to both faces of the expanded metal panels to form the core structure of the wall.
Mortar is applied to the panels mechanically and can be applied wet (pumped with ROBUST mortar machine) or
dry (pumped with a gunite machine)
The core can then be scratched for a rough finish or plastered to both faces for a smoother finish to complete the system.
(Core can also be tiled or cladded for a preferred finish)
Stronger Up to 25Mpa
Faster 3 x faster than conventional construction methods
Easier 95% Local unskilled labour can be used including women
VersatileAny shape or design
Superstructure cost Robust compares to other building systems
Accredited Agrément South Africa Certified
Added living space Up to 12% more internal space
Monolithic walling structureContinuous single diaphragm wallR
OB
US
T
MpaStrongerROBUST walls provide a stronger structure
• The ROBUST wall is a steel reinforced mortared wall, exceeding the British structural engineering code of conduct specification requirements.
• ROBUST wall strength: 15 – 25 Mpa vs. Brick wall: 7 Mpa• Load bearing : 30 tons/lm for external wall (115mm)
• Monolithic continuous walling system (Single diaphragm) resulting in:o Resistant against structural cracks (Stability of structure)
o Far more resistant against forces of nature such as earthquakes, tornados and hurricanes.
• ROBUST walls are built to an engineer approved foundation
RO
BU
ST
BENEFITS OF ROBUST
BENEFITS OF ROBUSTFaster
•Because of the ROBUST technology, walls are assembled at a rate of
20m2/hour per jig.•Mortar and plaster is mechanically applied, speeding up the process even more.•No time is spent on beam filling due to trusses being recessed into wall structure.•A manpower team of 62 labourers can deliver 1 x 80m2 ROBUST house per day by manually mixing on site and creating a smooth plaster finish. (580 man hours)•A manpower team of 55 labourers can deliver 1 x 80m2 ROBUST
house per day utilizing a batch plant with a scratch plastered finish.(489 man hours)
RO
BU
ST
BENEFITS OF ROBUSTEasier
•The ROBUST core is a light weight structure. It weighs 3,5kg/m2 and is extremely easy to handle.
•The ROBUST jigs provide an easy hassle free assembly and erection process.
•Mortar is mechanically applied to structure.
•95% of the workforce utilized in the ROBUST structure are local unskilled labour, INCLUDING YOUTH & WOMEN.
RO
BU
ST
BENEFITS OF ROBUSTVersatile
•The ROBUST system can be adapted to meet any building design (Architects dream)
•Can incorporate any style of window, door, roof or finish.•Due to its flexibility, curved and any other shaped walls can be built.
•The system can be used to do building alterations to existing brick structures.
•ROBUST columns can be erected by hand in 30 minutes without the requirement of shuttering.
•Columns can be formed into any shape.
RO
BU
ST
BENEFITS OF ROBUSTAdded Internal Living Space
•The ROBUST external walls are 115mm and internal walls 90mm thick whereas conventional external walls are 260mm and 150mm for
internal walls. •In coastal areas within 15km from the sea, ROBUST external walls
are 130mm thick. Internal walls remain 90mm thick.
(On a standard 80m2 dwelling you gain an additional 7m2 of floor area)
RO
BU
ST
BENEFITS OF ROBUSTMore Secure
•The way the system fits together makes the ROBUST structure a monolithic system, something not possible with conventional building
systems.
•A ROBUST structure wall is far superior to conventional walling systems such as brick and block and alternative systems, as it is virtually
impossible to break in through the wall.
RO
BU
ST
ROBUST vs. BRICKRobust wall 115mm vs. Brick wall 260mm
RO
BU
ST
Performance AssessmentDurability
•More durable than conventional structuresCondensation
•Similar to brick. •Better than brick by applying waterproof sealer to external walls
Energy usage (Done with insulated ceilings)•Similar to brick in low humidity areas – Winter and Summer
•Better than brick in high humidity areas – Winter and SummerWater penetration
•Resistant to water penetration and rising damp•Better than brick by applying waterproof sealer to external walls
BENEFITS OF ROBUSTAspects of Performance
Acoustic performance•46db-49db airborne sound insulation between adjoining rooms on a
90mm thick internal wall.Fire performance
•Classified Type FR (non-combustible)•Fire resistance rating of 60 minutes
Thermal performance (Done with insulated ceilings)•Similar to brick in low humidity areas
•1°C Better than brick in high humidity areas.
RO
BU
ST
ROBUST Thermal Calculations
RO
BU
ST
Robust Standard wall Thermal CalculationsRobust Standard wall Thermal
CalculationsStandard Wall
Thickness m
K-Value Conductivity
W/m.K
R-Value Resistance
Km2/W
U-Value Transmitance
W/m2/KDensity Kg /
m3Weight/m2
Walling
Mortar 0.085 0.940 0.090 11.06 1900 161.5Plaster 0.030 0.570 0.053 19.00 1300 39Rsi 0.130 Rse 0.040 Core & Reinforcing 52 6Total 0.115 0.367 0.313 3.19 1796 206.5
Robust Insulated wall Thermal Calculations (Perlite added)Robust Insulated wall Thermal
Calculations Perlite addedStandard Wall
Thickness m
K-Value Conductivity
W/m.K
R-Value Resistance
Km2/W
U-Value Transmitance
W/m2/KDensity Kg/m3
Weight/m2 Walling
Mortar 0.085 0.940 0.090 11.06 1900 161.5Plaster 0.030 0.570 0.053 19.00 1300 39Rsi 0.130 Rse 0.040 Core & Reinforcing 46 6Perlite Plaster 0.015 0.080 0.188 5.33 500 7.5Total 0.130 0.260 0.501 2.00 1646 214
Thermal Comparisons (Brick, Block & Robust)
Thermal Comparisons Standard Wall
Thickness m
K-Value Conductivity
W/m.K
R-Value Resistance
Km2/W
U-Value Transmitance
W/m2/KDensity Kg/m3
Weight/m2 Walling
Clay Brickwork 220x110x75 0.220 0.900 0.244 4.09 2100 462Clay Brickwork 220x110x75 0.110 0.900 0.122 8.18 2100 231
Lightweight Hollow Block 390x140x190 0.140 0.540 0.259 3.86 600 84Normal Hollow Block 390x140x190 0.140 0.740 0.189 5.29 1700 238Robust 0.115 0.367 0.313 3.19 1796 206.5Robust with Perlite 0.130 0.260 0.501 2.00 1646 214
Masonry walls (Brick/Concrete/Robust) must achieve a minimum suggested R-value of 0.35 in South Africa, according to the National Building Regulation for Environmental sustainability SANS 10400 Part XA, when required.
BENEFITS OF ROBUSTIndirect cost savings:
More Affordable
•Due to ROBUST being a light weight structure, foundations can be designed to have less structural steel.
•The monolithic system is a structural ring beam and lends lateral strength to the structure, making it possible for almost any type of floor
slab to be placed on the walls with unsupported spans of up to 9,5m.•No requirement for structural columns needed with double storey
buildings•No shuttering required where ROBUST columns are used.•Due to no chasing of services, there is a saving in labour and
machinery costsRO
BU
ST
BENEFITS OF ROBUSTIndirect cost savings:
More Affordable (Continue)•Due to its speed there is a saving in overheads and finance costs.
•ROBUST is a compact system, therefore reducing transport costs dramatically.
•The storage for the Robust Core is minimal. 0.32m³ will suffice to store the core required for a 80m² house.
(5600m2 of Core can fit in a 6m container) 28 x 80m2 houses•Material wastage is kept to a minimum resulting in almost no rubble
removal. •Shrinkage of material is eliminated. There are no manufacturing batch
differences that could lead to a inconsistency in the quality of material supplied over a period of time.
•Unskilled local (sustainable) labour utilized to build the ROBUST structure..R
OB
US
T
BENEFITS OF ROBUSTBecause we Care
Social Awareness
•ROBUST creates job opportunities by employing and training local people. No skills are required to build with ROBUST .
•The utmost care is taken when planning a community because ROBUST wants to provide homes for happier
communities.
•Because the walls are resistant to structural cracks it will provide the community with a maintenance free house.
RO
BU
ST
BENEFITS OF ROBUSTGlobal Awareness
With extensive global market experience “ROBUST” offers added services:
•Training & Technology provisions•Provision of building materials from South Africa to other countries
•Market presence in:
AngolaZimbabweZambiaNamibiaMalawi
BotswanaMozambiqueU.S.A.South AfricaHondurasR
OB
US
T
BENEFITS OF ROBUSTAccredited
The ROBUST system has a proven track record. The system has been awarded Agrément South Africa, SABS accreditation and has also been
approved by NHBRC and the Dade County Building Code, Miami in the USA, which is recognized as one of the most
stringent building codes in the world.
RO
BU
ST
BENEFITS OF ROBUSTTests
Robust is approved by the Dade County Building Code, Miami in the USA, which is recognized as one of the most stringent building codes in the world.
Three different tests were conducted in order to certify compliance.
1. Impact field test2. Compressive strength of core test 3. Robust panel bending, shear and axial resistance test.
On the basis of these test results, the “Robust” panels are approved for general building purposes and for use in a structure classified as a“safe house structure” during events of disasters such ascyclones, tornado’s, hurricanes and earthquakes.
RO
BU
ST
BENEFITS OF ROBUSTTests
1. Field impact test
A 50mmx100mm Southern Yellow Pine plank, 2.27m long weighing 4.1kg was impacted three times in an area 460mm by 460mm in one wall of a model house built with Robust.
The results of this test were satisfactory and Robust houses are considered a “safe house” during disasters such as cyclones, tornado’s, hurricanes and earth quakes.
RO
BU
ST
BENEFITS OF ROBUSTTests
2. Compressive strength of core test
Using stone between 6mm to 13 mm maximum dimension the tests produced a high average compression strength, around 6342.64 psi which correspond to 43.7 MPa.
The above value is related to the compression test being undertaken on cylinders. In South Africa these tests are done on standard cubes. There is a difference in the results as follows: fcyl=1.2fcu and therefore the average compressive strength
obtained in the tests was 52.5MPa. RO
BU
ST
PROFESIONAL ENGINEERING andINSPECTION COMPANY, inc.
BENEFITS OF ROBUSTTests
3. Robust panel bending, shear and axial resistance test.
Test #1 is relative to the panel’s bending moment resistance being the panel simply supported at both ends. The load was applied to an area in the middle of the panel. Maximum stress of 15.8 kPa was measured at point of failure at a load of 334.3 kg.
Test #2 is relative to the panel’s bending moment resistance of a vertical wall fixed by the footing and free at the top. The load was applied to an area at top of the panel and perpendicular to the plane of the panel. The specimen failed at 1.92 kPa or kN/m2. The fail plane was approximately 51 mm.
Test #3 is relative to a similar panel as Test#2 but the objective of finding out the shear capacity of the panel. The load increment was 345 kPa or kN/m2. The specimen failed at 1724 kPa or kN/m2. The fail plane was approximately 51 mm. R
OB
US
T
BENEFITS OF ROBUSTTests
3. Robust panel bending, shear and axial resistance test.(Continue)
Test #4 is relative to the panel’s axial force resistance with panel placed vertically fixed by the footing at the bottom and free at the top. The load was applied to an area at top of the panel and pointing downwards. The load was applied in increments of 690 kPa up to 4137 kPa and thereafter in 345 kPa increments up to 7.6 MPa. No failure was observed at this point and the pressure of 7.6 MPa was sustained for 2 minutes.
RO
BU
ST
BENEFITS OF ROBUST
• Housing• Schools• Clinics• Hospitals• Community Centres• Apartment Blocks• Warehousing• Shopping Centres• Infill walls (High rise Buildings)• Staircases
• Columns• Swimming pools• Dams• Slabs• Boundary Walls• Retaining Walls• Silos• Water Reservoirs• Mining applications• Prisons
ApplicationsR
OB
US
T
ROBUST vs. BRICKWalling cost comparison for a 80m2 House
RO
BU
ST
Required Walling = 210m2
ROBUST Building SystemNo. of man hours = 580hThe above man hours includes the fitting of plumbing & water pipes, electrical conduits and plug boxes, window and door frames and the fitment of roof trusses.
Brick Building SystemNo. of man hours = 1,980hThe above man hours excludes thefitting of plumbing & water pipes, electrical conduits and plug boxes, window and door frames and the fitment of roof trusses.
Conclusion:A wall built with ROBUST will cost 30% less than with brick
& provides a saving of 70% in man hours.
HOW IT WORKSStep by Step
RO
BU
ST
1. Preparation of Raft Foundation
HOW IT WORKSStep by Step
RO
BU
ST
2. Casting of Raft Foundation
HOW IT WORKSStep by Step
RO
BU
ST
3. Demarcation on Slab
HOW IT WORKSStep by Step
RO
BU
ST
4. Assembling Wall Panels
HOW IT WORKSStep by Step (Continues)
RO
BU
ST
5. Erection of wall panels
HOW IT WORKSStep by Step (Continues)
RO
BU
ST
6. Fitment of door and window frames
HOW IT WORKSStep by Step (Continues)
RO
BU
ST
7. Fitment of plumbing reticulation
HOW IT WORKSStep by Step (Continues)
RO
BU
ST
8. Fitment of electrical services
HOW IT WORKSR
OB
US
T
9. Fitting of Ref 156 mesh to corners of all opening sections
Step by Step (Continues)
HOW IT WORKSR
OB
US
TStep by Step (Continues)
10. Applying mortar to walls mechanically
HOW IT WORKSR
OB
US
T
13. Final step by applying plaster finish to mortared walls
Step by Step (Continues)
Robust Vertical Binding Jig
Robust Supporting Jig System
Robust Mortar Pump & Trailer
Robust Mortar Pump & Trailer
Robust Mortar Pump Control Box
ROBUST BUILDING SYSTEM
Robust Housing Construction
Private Residence Thabazimbi
ROBUST BUILDING SYSTEM
Robust Boundary Wall Construction
Without Columns
Concrete Foundation Moulds
Concrete Strip Cast Foundations
Foundation Ready for Placement in Trench
Foundation Strip secured by Footings
Robust Erected Core Wall Panels
Panels secured and levelled by Jig Stays
Mortar Packing - Mechanically Applied
Final Plaster Application
Expansion Soft board Joints
Completed Boundary Wall
ROBUST BUILDING SYSTEM
Robust Track Record
Photo Albumn
Housing
Prince’s Grant – KZN – South Africa
Thabazimbi – Limpopo – South Africa
Housing
Clearwater Estates – Boksburg – South Africa
Housing
Bushwillow Estates – Greenstone – Edenvale - South Africa
Housing
Housing Development – Gaborone, Botswana
Housing
Housing Development – Blantyre – Malawi
Housing
Housing Development – Lilongwe – Malawi
Housing
Housing
Low Cost – Zonkisizwe – South Africa
Low Cost – Zonkisizwe – South Africa
Housing
Rondawel Huts – KZN – South Africa
Housing
Apartment Blocks
Warner Beach – KZN – South Africa
Apartment Blocks
Luanda – Angola
GDK Primary – Lucala – Angola
Schools
Unity Primary School – Tarlton – South Africa
Schools
St. Joseph Primary School – Soshanguve – South Africa
Schools
Pre - Primary Schools –Western Cape - South Africa
Schools
Swellendam, Wellington & Breda’sdorp
Game Lodges
Ladysmith – KZN – South Africa
Game Lodges
Kruger National Park – South Africa
Game Lodges
Pretoria – South Africa
Military Buildings
Military Barracks - Angola
African Game Zoo – Hartebeestpoort – South Africa
Zoo’s
Lisel Building Supplies – Benoni – South Africa
Warehouses & Factories
Dance Studio – Benoni – South Africa
Recreational Buildings
Game Lodge – Pretoria – South Africa
Swimming Pools
Angola
Reservoirs & Under Ground Storage
Tanks
VIP Toilets for DWERF – KZN – South Africa
Sanitation
Game Lodge – Pretoria – South Africa
Accommodation Suites
Game Lodge – Pretoria – South Africa
Decorative Screen Walls
Game Lodge – Pretoria - South Africa
Steps & Ramps
Hillcrest Golf Estate– KZN – South Africa
Boundary Walls
Private Residence– KZN – South Africa
Boundary Walls
NG Church - Umhlanga– KZN – South Africa
Boundary Walls
Boundary Walls
Westville– KZN – South Africa
Westville– KZN – South Africa
Boundary Walls
6,0m high wall – Retaining 4,5m
Goldfields Twin Shafts Mine – Westonaria – South Africa
Boundary Walls
Goldfields South Deep Mine – Westonaria – South Africa
Boundary Walls
Goldfields Beatrix Mine – Welkom – South Africa
Boundary Walls
Zuma Park – Kroonstad – South Africa
Boundary Walls
Benoni – Gauteng – South Africa
Boundary Walls
Witbank Colliery – South Africa
Boundary Walls
Robust Structures (Pty) LtdReg. No. 2005/043961/0737 Apex Road, Apex Industrial SitesBenoni 1540, South AfricaTel: +27 11 420 1470 Fax: +27 11 420 1463P.O.Box 634, Benoni 1500, South AfricaWeb: www.robuststructure.com E-mail: [email protected]
