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

Reinventing Construction
www.rapidwall.com.au

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

Reinventing Construction

Load-bearing

Water and rot resistant

100% recyclable

www.rapidwall.com.au

Fast

Termite resistant

Pre-fabricated (12m X 3m X 120mm)

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www.rapidwall.com.au

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

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

>

>

>>

MARINE CONSTRUCTION

>

CUT RAPIDWALL PANELS DELIVERED TO

SITE IN STILLAGES

>>

>>

CUT RAPIDWALL PANELS DELIVERED TO SITE

IN STILLAGES

>

>

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 green 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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www.rapidwall.com.au

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.

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.

(Embodied e n e r g y 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

Reinventing Construction
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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 * 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 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

www.rapidwall.com.au /8

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 groups

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

>

Reinventing Construction
www.rapidwall.com.au
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

www.rapidwall.com.au /10