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Erection Process

Ther Overall Process

The overall process from the manufacture of the Gypcrete wall panels to their final erection to form load-bearing walls for a building project is generally as follows:-

  • Using the Gypcrete wall panel design guidelines the walls are analysed by a suitably qualified structural engineer and the Architectural and Engineering drawings prepared indicating plan layouts, cross-sections, reinforcements, setdowns and edge details;
  • Whole Gypcrete wall panels are manufactured in the factory in a single panel twelve metres long by three metres high [12,020 mm X 3050 mm] and delivered to the licensed Gypcrete wall panel distributor in bulk quantities up to 900 square metres per load; 
  • Based upon the contractual design drawings the distributor prepares full cutting schedules including panel elevations and transportation- stillage load sheets; 
  • Using a numerically-controlled table-mounted saw the distributor cuts the panels to dimension including openings for doors and windows; 
  • The distributor installs galvanised steel metal closures to the panel ends and openings where required; 
  • Between five and eight such 'processed' Gypcrete wall panels are loaded on to a transport-stillage in which they are held vertically to maximise the transportable volume;
  • Several full stillages, often containing up to 500 square metres of ready-to-install Gypcrete wall panels, are loaded onto a semi-trailer for transportation to the building site; 
  • The stillages are unloaded, positioned and stabilised on prepared flat ground near the construction face in readiness for erection.

The Erection Process

  • After completion of the foundation or the concrete suspended floor onto which the Gypcrete wall panel is to be positioned, the builder's surveyors establish and mark all main grid lines; 
  • Using the Architectural layout drawings the trained Gypcrete wall panel erection crew marks out the walling positions in reference to these grid lines; 
  • For the first floor the concrete foundation is drilled and starter bars epoxied into place in the positions and to the spacings indicated on the engineering drawings [for subsequent floors starter bars extend from the panel below; 
  • Weighing up to five tonnes the laden stillage containing the cut Gypcrete wall panels selected for erection is then lifted by crane onto the concrete floor or foundation prepared to receive the panels; 
  • One by one, and by crane, the cut Gypcrete wall panels are decanted from the stillage and placed into their final position, propped and then connected in accordance with the installation guidelines; 
  • To construct the next suspended floor spanning between the load-bearing Gypcrete wall panel, formwork is installed and propped after which it is used as staging to pump the concrete into the cells of the Gypcrete wall panel; 
  • Whilst still plastic, starter bars are placed in the concreted cells in readiness for the next floor of Gypcrete wall panels; 
  • Slab reinforcement is placed on the formwork and the concrete poured for the next suspended floor.
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