A comprehensive guide to readymade wall panels
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Readymade Wall Panels

A Comprehensive Guide

The construction industry has constantly been witnessing a paradigm shift with the advent of innovative technologies; one of which is the use of readymade wall panels. These panels are also known as sandwich panels for walls or pre-fabricated wall panels, have gained significant traction due to the efficiency they lend to construction, cost-effectiveness due to reduced wastage and time lag, and their versatility to suit the requirement. In this article, we will try to understand these prefabricated wall panels, explore their definition, trace their evolution, try to catch a glimpse of their manufacturing processes, understand their structural benefits, and their diverse applications in residential, commercial, and industrial settings.
What are Readymade Wall Panels?

Readymade wall panels, often referred to as sandwich panels for walls or pre-fabricated wall panels, are innovative building components designed to streamline the construction process of any building. These panels consist of multiple layers, typically an insulating core sandwiched between two outer layers known also known as wythes, creating a robust and energy-efficient structure. The materials used in these panels vary, including but not limited to concrete, steel, gypsum boards and insulation materials such as foam or mineral wool.

These panels are precisely manufactured off-site, ensuring superb quality control and precision. The term ‘readymade’ implies that these panels are ready for installation upon delivery to the construction site. This off-site fabrication not only accelerates the construction timeline but also minimizes on-site disruptions and wastage, making Prefabricated buildings an eco-friendly option.

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A brief history of readymade wall panels
The concept of readymade wall panels can be traced back to the mid-20th century when the then building construction technology was seeking more efficient and cost-effective methods. Early prototypes of prefabricated wall panels, emerged as a response to the ever-increasing demand for faster construction without compromising quality.
Over the decades, advancements in materials and manufacturing technologies further refined the concept of readymade wall panels. The integration of computer-aided design (CAD) and other cutting-edge technologies have significantly enhanced precision and customisation options. Today, the wall blocks are a staple in the modern construction industry, embodying decades of evolution and technological progress.
A brief description of the manufacturing process
The manufacturing process of readymade wall panels involves several key steps, each contributing towards enhancing the panels' structural integrity and performance. First and foremost, detailed design and engineering are conducted using advanced software to ensure precise specifications.
The core materials, which often include insulation materials for enhanced energy efficiency, are carefully selected and assembled. The outer layers, commonly made of concrete or steel, are then added so as to encase the insulating core in a rigid stout structure. This process takes place in a controlled factory environment, allowing for optimal curing and quality control.
Once assembled, the panels are subjected to rigorous testing to ensure they meet industry standards and project- specific requirements. The completed readymade wall panels are then transported to the construction site, ready for an efficient installation.
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A brief description of the manufacturing process

The manufacturing process of readymade wall panels involves several key steps, each contributing towards enhancing the eps panels structural integrity and performance. First and foremost, detailed design and engineering are conducted using advanced software to ensure precise specifications.

The core materials, which often include insulation materials for enhanced energy efficiency, are carefully selected and assembled. The outer layers, commonly made of concrete or steel, are then added so as to encase the insulating core in a rigid stout structure. This process takes place in a controlled factory environment, allowing for optimal curing and quality control.

Once assembled, the eps panels are subjected to rigorous testing to ensure they meet industry standards and project- specific requirements. The completed readymade wall panels are then transported to the construction site, ready for an efficient installation.

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Structural estimations, calculations and allocations

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Selecting insulation materials

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Manufacturing in different sizes and volumes

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Selecting appropriate re-enforcements

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Making each unit with insulation material and re-enforcements

How readymade wall panels ensure structural stability
Prefabricated wall panels offer unparalleled structural stability due to their precise manufacturing and composite nature. The combination of sturdy outer layers and insulating cores enhances the panels' load-bearing capacity while providing superior thermal and acoustic insulation.
The controlled environment in which these panels are manufactured ensures that each component is of consistent quality, reducing the risk of structural weakness. Additionally, the interlocking design of these panels contributes to their stability, creating a seamless, monolithic and resilient structure.

The use of advanced sustainable construction technology, including computer-aided design and manufacturing (CAD/CAM), further guarantees the accuracy and reliability of wall blocks. This commitment to precision translates into buildings that not only meet but often exceed structural standards, offering a durable and secure solution for various construction projects.

Types of sustainable construction​
Residential

Residential Homes

Passive houses are These wall panels have found extensive use in residential construction, offering homeowners a faster and more efficient building process. These panels are customisable, allowing for diverse architectural designs while maintaining energy efficiency. The speed of construction is particularly advantageous for meeting tight deadlines or accommodating homeowners who seek quicker occupancy.
Commercial

Commercial Applications

In the commercial sector, where time is often of the essence, wall blocks shine as a time-efficient and cost- effective solution. From office buildings to retail spaces, the versatility of these panels caters to various design requirements. Their ability to support the installation of utilities, such as electrical wiring and plumbing, further streamlines the construction of commercial structures.
Industrial

Industrial Applications

In industrial settings, where durability and functionality are paramount, readymade wall panels offer a robust solution. These panels can withstand heavy loads, extreme temperatures, and harsh industrial environments. The speed of construction is also a significant advantage in industrial projects, minimizing downtime and maximizing operational efficiency.
Summing up everything we can surely say that the adoption of readymade wall panels marks a significant leap forward in construction technology. From their humble beginnings to the hallowed present, these panels have evolved into being a cornerstone for the modern construction, offering efficiency, sustainability, and versatility. As the construction industry continues to embrace innovative solutions, readymade wall panels stand as a testament to the ongoing pursuit of building better, faster, and smarter.
FAQ

Readymade walls are exceptionally durable, often surpassing the durability of traditional on-site constructed walls. The controlled manufacturing process ensures high-quality materials and construction.

Absolutely! Readymade walls can be customized to meet specific design requirements, offering flexibility in both residential and commercial construction projects.

Yes, many readymade wall systems are designed to meet stringent safety standards, making them suitable for construction in earthquake-prone regions.

While initial costs may vary, the overall cost of construction using readymade walls is often lower due to reduced labor expenses and minimized material waste.

Certainly! Readymade walls are versatile and can be used for both interior and exterior walls, providing a comprehensive solution for various construction needs.

The installation time for readymade walls is significantly shorter than traditional construction methods, with many projects seeing completion in a fraction of the time.