The CORLITE Home building System

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25 Νοε 2013 (πριν από 3 χρόνια και 7 μήνες)

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The
CORLITE
Home building System


Fast build, high quality, low cost,
affordable housing

1

Corlite Systems Limited (CS)

The
Corlite

system




The
Corlite
building system has been in use around the world for more than 35
years. It is fully endorsed by former US President Jimmy Carter’s Housing
Foundation and is frequently used in the Foundation’s building projects.


The
Corlite
system was designed to provide fast build, low cost, energy efficient
housing.


A 100 square meter house can be built within three days once the foundation is in
place.


If the houses are built in larger groups utilising specialist work teams the building
time is even less.


The
Corlite
system is based on the use of prefabricated reinforced expanded
polystyrene (EPS)panels.


Houses can be constructed using this system by a team of three people; one skilled
to the level of a carpenter and the other two as labourers.


Each house requires a pre
-
prepared concrete plinth.


The houses are termite proof; hurricane proof; earthquake proof and the EPS
materials are fire resistant for two to four hours.

2

Corlite Systems Limited (CS)

The
Corlite

System
-
Panel Attributes

Primary structural elements for walls, floors and roofs

Multi storey capabilities. Clear spans up to 5 metres

Axial loads to 7,500 kg/metre. Insulation values to R
-
30.

Sound ratings to STC
-
32. Fire ratings of 2 to 4 hours.

Meets Seismic Zone 4 requirements. Hurricane resistant
to 180 Knot wind speed. Termite and dry rot proof.

Lightweight Time
-
saving and easy to handle.

On site Applications for residential and

commercial markets.


MANUFACTURING VARIABLES


Width: 1200mm Length: 1800mm to 5000mm:

Thickness: 50mm, 75mm, 100mm, 125mm, 150mm
200mm,
Wire Gauge: 14g, 12g, 10g.

Core: Expanded polystyrene bead EPS board.

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Corlite Systems Limited (CS)

The
Corlite

System
-
Panel Attributes

4

The
Corlite

Panel has been Extensively Researched
and Tested over the Past 35 Years


in which time
more than 90,000 units have been built worldwide
using the system and there has not been a single
reported failure.

The
Corlite

Panel System is used in the construction
of External and Internal Walls, Roofs and Floors in
Single and Multi Level Structures. Its versatility has
many advantages in the construction industry. One of
the prime advantages is architectural design flexibility.
The Panel System can be engineered to meet any
architectural design.

Corlite Systems Limited (CS)

The
Corlite

System
-
Building attributes

The
Corlite

Panel consists of welded wire reinforcing,
foam core insulation, and Portland cement render on each
face. The panels incorporate a three dimensional welded
wire space frame utilizing a true truss design for strength
and rigidity. Each face of the panel is a welded mesh to a
50mm x 0mm configuration. Individually welded internal
truss wires extend through the panel core between each
face. These truss wires form a matrix within the panel
core. The foam insulation is recessed approximately
12mm from each wire face to permit the exposed wire to
be embedded in the cement render. All steel wire used
conforms to ASTM A185 and A82; steel wire fabric for
concrete reinforcement

5

Corlite Systems Limited (CS)

The
Corlite

System
-
Building attributes

The
Corlite

light weight panel structure is erected and
wire
-
tied to form the structure as designed by the
architect. The panels are very rigid and easy to handle
on site. They are easily cut to any shape required. After
the panels are erected the required plaster is applied.
This is normally a 20mm thickness of 2000 PSI Portland
cement Render. The Render surface may be applied by
hand, plaster gun or shotcrete.

The structures are designed in accordance with
American Concrete Institute Code Requirements for
Reinforced Concrete (ACI 318). Architects and
Engineers are not limited to one panel design. They
determine the wire diameter and panel

depth required by the structural design. Panels are
produced in 50mm to 200mm thickness by 1200mm in
width and in lengths from 1800mm to 5000mm.


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Corlite Systems Limited (CS)

The
Corlite

System
-
Building attributes

7

Foundations:

Corlite
buildings are erected on raft
foundations supplied by the customer. (Such
foundations are normally included as the final stage
of the ground works element of a housing
development project).

Once completed the raft foundation is used to store the initial
supply of
Corlite

Building Panels, and accessory items such
as panel anchors and jointing strips. (Note; here in
-
coming
utilities protruding through slab
-

photo left)

Corlite Systems Limited (CS)

The
Corlite

System
-
Building attributes

8

The erection of the walls is simple and fast. A 3 man
team can easily set up 100 square metres (plan area)of
single storey building
-

internal and external walls and
roof
-

in one/two days including fixing of all doors and
windows. There is sufficient inherent strength in a non
rendered panel structure up to two or three storeys for it
to be self supporting until rendered. While the building
shell is being erected, utility service and distribution runs
are installed in the form of conduits and plumbing fixed
to and behind the panel surface mesh. This is a further
major economy as no surface chases have to be cut in
brick, block work or concrete, and fine accuracy of the
position
ing of an outlet box or other fixtures is simply
obtained when attached to the wire mesh. All standard
M&E installations are more economically accomplished
in a
Corlit
e building including lighting, power, plumbing
and security.

Corlite Systems Limited (CS)

The
Corlite

System
-
Building attributes

Note the absence of temporary

support for walls and roof and

of lifting equipment and

scaffolding

Plumbing and electrical distribution is arranged by
in
serting water tubing
-

normally an approved
plastic plumbing system, and electrical conduits
into channels that have been formed in the panel
insulate using a butane blow lamp. These pipes and
conduits are then tied to the panel’s surface mesh
which ensures absolute accuracy of the inserted
circuitry, plumbing and associated fixture and
fittings, and avoids labour intensive ‘channelling
out’ for pipe
-
work and conduits. It also provides
substantial insulation in water pipes

Corlite Systems Limited (CS)

The
Corlite

System
-
Building attributes



10

The finishing of a
Corlite

building is as
with any other standard building
system.


Following the setting up of the building
shell and concurrent with the
installation of the service runs, the
panels are sand/cement rendered
externally. This is carried out using
mechanically applied sand
-
cement
render that incorporates appropriate
additives to handle plasticity and
setting time and other specified
physical requirements.

Corlite Systems Limited (CS)

The
Corlite

System
-
Building attributes Summary


11


Low cost


Design versatility


Long lasting


Extreme weather proof


Fast & easy build


Corlite Systems Limited (CS)

The
Corlite

System
-
The finished product

12

The
Corlite

system can
deliver fast build,
economical housing
solutions at every price
bracket; from low cost
housing right through to top
end executive housing. It is
also ideal for small hospitals
and administration buildings
up to four storeys high. At
every quality level the
Corlite

system will deliver
the fastest and most
effective solution
.

Corlite Systems Limited (CS)





13

The
Corlite

System
-
The finished product

Corlite Systems Limited (CS)





























14

These are pictures from Hurricane Andrew in Florida in 1992. The house
on the right was constructed under the

Corlite
system and suffered
virtually no damage. The house in the picture on the left and the houses
in the background of the picture on the right were constructed using
standard building materials.
Corlite

constructed houses also have similarly
high earthquake resistance.

Corlite Systems Limited (CS)

The

Corlite
System
-
Hurricane Proof


The
Corlite

System
-
Panel Supply


There are two ways of supplying panels:


For Immediate requirements
Corlite

Panels can be imported from existing
Corlite

panel factories
in other regions of the world. This is relatively expensive and time consuming but can be
appropriate where only small numbers of panels are required. Even after paying import duties
and freight, in most countries, the houses will still be substantially cheaper than conventional
building systems.


The more cost effective solution is to establish a panel factory in the region where the building
system will be utilised.


Corlite

homes constructed from panels made in the region, when compared with contemporary
traditional or manufactured houses are more than 30% cheaper than any other comparable
building system.


Houses built using the
Corlite
system can be produced more than 8 times faster than any other
comparable system.


A single panel production line can produce enough panels in one year of normal operation to
build more than 2,000 houses of one hundred square metres dimension.


From initial order it takes four to six months to establish a production line(s).





15

Corlite Systems Limited (CS)

The
Corlite

system
-
Panel production

16

There are 4 Main Elements to a Factory:


1. The Panel Making Equipment

2. The Foam Core Generator

3. The reinforced wire tying equipment

4. The Building to Put it in

Corlite Systems Limited (CS)

The
Corlite

system
-
p
anel making equipment


The
Corlite

Panel Equipment is produced by
specialist engineers to Corlite Building Systems
specifications.


In most cases factories are usually established with
a minimum of two lines.


The lines are modular, as with all the machinery
necessary to make the panels, and additional
equipment can be added as necessary to make
additional lines.


The panels can be supplied at a price which ensures
that the houses constructed with them are very
cost effective but which will ensure a very good
return for those who invest in the production lines.

17

Corlite Systems Limited (CS)

The
Corlite

system
-
EPS foam e
quipment


Foam generation is most easily carried out using
EPS


Expanded Polystyrene. EPS is treated to be
non
-
inflammable and self extinguishing and is
most easily adapted. (EPS can be locally supplied
from a suitable existing source if available).


Many other types of foam and certain waste
products can also used. However, whilst such
waste materials are usually cheaper they are
frequently more difficult to handle.


A proprietary foam generation unit is modified to
create a ‘bun’ or bulk volume block of the
particular specification of foam to be used for fill,
and acoustic and thermal insulation in the panel.


Blocks are then cut using a hot or a serrated wire
process into square section strips that are stored
ready to load into the
Corlite
panel assembly
frames.



18

Corlite Systems Limited (CS)

The
Corlite

system
-
Reinforced wire tying
machinery

19


A truss frame is added to the EPS panel.


Stock wire pre
-
coiled to specification is loaded onto ‘spiders’
and attached to the various demand points of the truss
fabrication equipment.


As with other raw material components, local materials can
be used if they are supplied to the correct specifications.


The panels pass through the finishing (or ‘strap and weld’)
unit, a wire is pulled down each side of the raw panel at
50mm intervals and spot welded to the trusses. (It is this part
of the manufacture process that forms the external square
mesh finish).


The frame passes through the finishing unit in approximately
2.8 minutes. On emergence from this unit the finished panel is
extracted from the assembly frame.


The last stage in the manufacture process is for the
Corlite

panel to be checked by the Quality Con
troller who looks for
general defects, and electronically tests the nearly 2,500
welds in each finished panel. Failures are repaired by hand
where necessary.


Corlite Systems Limited (CS)

The
Corlite

system
-
The building



A building of minimum 2,000 m
2

is needed to house the panel making and foam core
generation equipment


The essentials elements are:


A weatherproof structure


A Flat concrete floor


No cranes are necessary but an under beam height of 6 metres is an advantage


A reliable main 3 phase electricity supply of minimum 850 amps


Simple 3 room office


Domestic facilities for a labour force of approximately 45 (A three line system)



The building is not supplied by Corlite Building Systems.


It is quite possible to build the factory unit to house the

Corlite
equipment from imported
Corlite

panels. This is not only cost effective but it serves as a working advert for the
effectiveness and suitability of the
Corlite

system for industrial buildings.

20

Corlite Systems Limited (CS)

The
Corlite

system
-
The
Corlite

Management
Team

Mike Foster
-
Turner


Iain MacAulay C.A

Alan Ashby



Corlite Systems (CS) was established by Mike Foster
-
Turner.


Mike Foster Turner has more than 45 years high level building and design engineering
experience. Mike was previously a director of Taylor Woodrow and has been involved
in many large scale construction projects around the world.


Mike was one of the original designers of the
Corlite

system and has since added many
proprietary improvements to the panel manufacturing machinery and system.


Iain MacAulay is a Scottish Chartered Accountant with more than 25 years high level
international experience. Iain specialised in corporate management & restructuring and
is the C.E.O of Corlite Systems Ltd.


Alan Ashby is an experienced project developer in a variety of international businesses.


Corlite work closely with large building companies who are experienced in project
construction in developing countries.

21

Corlite Systems Limited (CS)

The
Corlite

system



CS are able to supply
Corlite

panels and/or establish
Corlite

panel manufacturing
units anywhere in the world.


CS will supply suitable management teams to run any manufacturing plant.


Where clients can demonstrate confirmed off
-
take for
Corlite

panels CS can also
organise suitable funding and investment packages for individual projects.


Contact Details:




C.E.O : Iain MacAulay











Email:


macaulayassociates@gmail.com



Telephone:

(44) (0) 7970 203 161

Corlite Systems Limited (CS)

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