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The CORLITE Home building System


Each house requires a pre-prepared concrete plinth. ... The Corlite System-Building attributes The Corlite light weight panel ... Blocks are then cut using a ... – PowerPoint PPT presentation

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Title: The CORLITE Home building System

The CORLITE Home building System
  • Fast build, high quality, low cost, affordable

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
    Carters Housing Foundation and is frequently
    used in the Foundations 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
  • 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
  • The houses are termite proof hurricane proof
    earthquake proof and the EPS materials are fire
    resistant for two to four hours.

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.
The Corlite System-Panel Attributes
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.
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
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.
The Corlite System-Building attributes
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)
The Corlite System-Building attributes
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 positioning of an outlet box or other
fixtures is simply obtained when attached to the
wire mesh. All standard ME installations are
more economically accomplished in a Corlite
building including lighting, power, plumbing and
The Corlite System-Building attributes
Plumbing and electrical distribution is arranged
by inserting 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 panels 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

The Corlite System-Building attributes
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.
The Corlite System-Building attributes Summary
  • Low cost
  • Design versatility
  • Long lasting
  • Extreme weather proof
  • Fast easy build

The Corlite System-The finished product
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.

The Corlite System-The finished product

The Corlite System-Hurricane Proof
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
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
  • 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).

The Corlite system-Panel production
There are 4 Main Elements to a Factory 1. The
Panel Making Equipment2. The Foam Core
Generator 3. The reinforced wire tying
equipment4. The Building to Put it in
The Corlite system-panel making equipment
  • The Corlite Panel Equipment is produced by
    specialist engineers to Corlite Building Systems
  • 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.

The Corlite system-EPS foam equipment
  • 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
  • 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
  • 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.

The Corlite system-Reinforced wire tying machinery
  • 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
    Controller who looks for general defects, and
    electronically tests the nearly 2,500 welds in
    each finished panel. Failures are repaired by
    hand where necessary.

The Corlite system-The building
  • A building of minimum 2,000 m2 is needed to house
    the panel making and foam core generation
  • 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
  • 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.

The Corlite system-The Corlite Management Team
  • Mike Foster-Turner Iain MacAulay C.A Alan Ashby
  • Corlite Systems (CS) was established by Mike
  • 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.

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
  • Contact Details
  • C.E.O Iain MacAulay
  • Email
  • Telephone (44) (0) 7970 203 161