Robust Affordable Alternative Building Systems Method in English

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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

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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

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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)

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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.

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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.

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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)

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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.

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ROBUST vs. BRICKRobust wall 115mm vs. Brick wall 260mm

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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.

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ROBUST Thermal Calculations

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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

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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

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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.

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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

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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.

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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.

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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.

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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

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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

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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.

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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

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ROBUST vs. BRICKWalling cost comparison for a 80m2 House

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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

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1. Preparation of Raft Foundation

HOW IT WORKSStep by Step

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2. Casting of Raft Foundation

HOW IT WORKSStep by Step

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3. Demarcation on Slab

HOW IT WORKSStep by Step

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4. Assembling Wall Panels

HOW IT WORKSStep by Step (Continues)

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5. Erection of wall panels

HOW IT WORKSStep by Step (Continues)

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6. Fitment of door and window frames

HOW IT WORKSStep by Step (Continues)

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7. Fitment of plumbing reticulation

HOW IT WORKSStep by Step (Continues)

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8. Fitment of electrical services

HOW IT WORKSR

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9. Fitting of Ref 156 mesh to corners of all opening sections

Step by Step (Continues)

HOW IT WORKSR

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10. Applying mortar to walls mechanically

HOW IT WORKSR

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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: Info@robuststructure.com