GULFWALLING, a Dubai-based manufacturer of precast walling and partition systems, says its gypsum-based systems represent the new generation in precast walling. Called GulfWall, this versatile technology can achieve cost and labour efficiency as well as speed in quality construction projects, it says.

“With the current financial crisis impacting all areas of the economy, there’s an increasing need for constant innovation and new technological solutions that help attain cost-efficiency and high quality,” says Toby Cooke, general manager of the Jebel Ali Free Zone-based GulfWalling.
GulfWall is a factory-manufactured, environment-friendly, precast, pre-finished hollow panel made from gypsum plaster, glass rovings and other proprietary components.
“Offering the advantages such as speed of construction, light weight, cost benefits, environment-friendliness and a high quality finish, GulfWall represents the latest in gypsum-based precast walling systems,” he adds.
The technology can be applied to full-size load-bearing walls, segmented partitions, lost formwork/ceiling components as well as an excellent solution for boundary walls or fencing. The off-site prefabrication of walls reduces construction time while utilising just a fraction of the labour, according to Cooke. The multi-faceted technology allows the walls to be used both internally and externally. Compared to block work, the finish is of better quality being virtually ready for paint.
GulfWall systems have been installed in Australia for more than 12 years and in 2007, the company commissioned a new $7 million production facility in Dubai.
“We have subsequently completed a number of successful projects with some of the leading contractors and developers in the UAE, including the Motor City project with Al Futtaim Carillion,” says Cooke.
The company produces three main systems at its Jebel Ali facility. These include full-sized walls, partitions, and boundary walls and lost formwork/ceiling.

Full-sized walls
The system is based on 120-mm-thick GulfWall panels, which are factory-moulded from fibreglass reinforced plaster, creating two 14-mm-thick sheets, spaced apart by web members at 250 mm centres.
The walls are produced in 12-m lengths at heights of 2.4 m to 3.4m. They are then pre-cut with installed walls up to 8 m long. The walls arrive at site prefabricated to exact dimensions and with window and door cut-outs made.
“The vertically running voids can be used to run electrical and plumbing services, eliminating the need for chasing. Typically, voids are filled with grout or concrete to give a solid ‘feel’ and excellent fire and acoustic properties,” says Cooke.
GulfWall full-sized walls allow for fast installation and construction times, with low labour requirements. The systems are especially suited to all residential applications including labour camps, villas, apartment blocks and hotels.

Partitions
GulfWall non-load bearing partitions are said to be ideal for hotels and offices. The system is suitable for retrofits to standard concrete frame construction, typically replacing bricks, blocks or plasterboard. The partitions are 500 mm wide and between 2.4 m and 3.4 m high. A tongue-and-groove system, combined with plaster adhesive, ensures a flat wall.
Each partition weighs around 75 kg and is easily installed without the use of cranage. Here again, the vertically running voids can be used to run electrical and plumbing services, and the voids are filled with grout or concrete to give a solid “feel” and excellent fire and acoustic properties.
GulfWall partitions provide a fast and effective solution for inter-tenancy walls, Cooke points out.

Boundary walls & lost formwork
GulfWall also provides an “excellent solution” to boundary walls/fencing and lost formwork/ceiling systems with fast, simple and economic installations.
The panels can span between simple piers. The pilasters transfer all loads to these piers, eliminating the need for expensive excavation and footing construction and reducing the likelihood of cracking and other failures in the future, he explains.
The system allows for fast construction, with a prefinished plaster ceiling. A structural slab, designed to engineers’ requirements, can be formed, with pre-formed service ducts.

Installation
GulfWall may be installed manually for partitions and walls up to 1 m, by forklift for walls up to 5 m and by crane for walls up to 8 m.
The walls may then be filled with a grout mixture. Finishing consists of a light skim coat and sand prior to painting, producing a very high quality finish.
“GulfWall provides a significant cost advantage for the contractor while offering a quality finish,” says Cooke, adding that the technology is more economic compared to conventional building methods such as brickwork or block work.
Elaborating on the other benefits, he continues: “It helps the developer through time and cost savings, the contractor through lower manpower requirements, and occupants with improved amenities.
“The systems have good acoustic properties and fire resistance of two hours, thanks to its core-filled panel (400 kN/m working load) and low water absorption of less than 5 per cent. Off-site prefabrication provides a fast installation rate while using less labour than other similar systems.
“The technology is particularly environment-friendly having a relatively low level of embodied energy. It is non-toxic, inert and recyclable. It is also fire-proof, rot and termite-proof and has excellent sound modulation capabilities. Therefore it is tailor-made for residential construction.
“Finally, the construction method is clean and dry, eliminating the need for block-laying and limiting plastering requirements. This also cuts the level of mess on site and the subsequent cost of clean-up.”