NEWS RELEASE_4 March 2010

Injection-Moulded Full-Height Wall and Fence Panels
A development of Ace-Wall™ International Pty Ltd
Adelaide, South Australia

Ace-Wall™ is a fibre-reinforced, water-resistant, gypsum-based, non-load-bearing wall panel, designed for external and internal applications within modern residential, commercial and industrial low-rise and high-rise developments. The product is set to revolutionize the construction industry due to its low product and installation cost, rapid installation, high strength-to-weight ratio, advanced sound/thermal/fire performance and strong eco-friendly characteristics.

In Adelaide Ace-Wall™ panels are manufactured from a length of 2100mm - 3600mm and a width of 600mm and thickness of 100mm.


100mm detail
100mm Panel Detail



  • Products:
    • Light Weight.
    • Low Cost.
    • Rapid Installation.
    • High Quality Finish (smoth, flat, crack-free).
    • High Resistance (thermal, sound, fire, earthquake, termite, water).
    • Low Carbon Footprint (low embodied energy, abundant natural materials).
    • Recycable (re-calcination).
  • Factory:
    • High Capacity (one panel per minute).
    • High Energy and material efficiency.
    • Advanced computerized, automated operation.
    • Modular (expandable, re-locatable close to major development sites).
    • Eco-Friendly.

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  • Gypsum (Beta quality)*
  • Water
  • Fiber-Glass (short fiber)
  • Waterproofing Agent
  • Retarder
  • Activator
  • Optional Infill (e.g. concrete, perlite)

* Can be obtained by calcination of industrial waste material such as "flue gas" or "phospho" gypsum.

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Ace-Wall™ Panels
  • Pre-fabricated non load bearing
  • Hollow section (filled or unfilled options)
  • Precision moulded construction
  • Fiber-reinforced water-resistant gypsum
  • Advanced perlite infill option
  • Dimensions
    • Height - 2.1 m to 3.6 m
    • Width - 60 cm
    • Thickness - 12 cm
  • Nominal Weight
    • 38 Kg per sq.m. (unfilled)
    • 45 Kg per sq.m. (e.g. perlite infill)
  • Precision Cut to tight tolerance
  • Rapid Installation
    • 250 sq.m. per 8 hour shift
    • 7 installers
  • Tongue and groove joints
    • Integral spacing control
    • Plaster adhesive in joints
    • Flush finish
    • High quality finish
  • No rendering required
    • External: Ready for texture coating
    • Internal: Ready for painting or tiling

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Ace-Wall™ Panel Section Detail 120mm





Ace-Wall™ Panel Performance


Ace-Wall™ Panel Physical


Strength Test

  • Practical test to demonstrate the strength of the panel:
    • Steel bar fixed to an installed demonstration wall.
    • Fixings – 4 x 6mm fixing screws (HILTI screw locking devices).
    • Man weighing 85 Kg successfully supported.


The panel is capable of supporting the weight of a standard TV, central heating or air conditioning units, but will not support heavy wall-mounted bathroom fixtures (e.g. toilet, bidet, washbasin) unless these are also supported by the floor. If a wall suspension is required the solution is to make a local break in the wall and backfill locally with a concrete mix.

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Ace-Wall™ Factory Layout
(Currently installed in the Dubai Investment Park)

  • Precision moulding process
  • Computerized operation
  • Advanced automation
    • Process control
    • Palletization
    • Process Alerts
  • Capacity
    • 1 panel per minute
    • 750,000 sq.m. per year
  •  Environmentally friendly
    • No emissions


DIP Factory Layout 1
 DIP Factory Layout 2

Ace-Wall™ Factory

  • Advanced PLC-based automation.
  • Full built-in fault monitoring and diagnostic management.
  • Control, monitoring and diagnostics possible via internet-link.
  • Full chemical and mechanical process control.
  • Full safety interlocks and sensors.
  • Designed for 24/7 operations.
  • Rapid automated production of high quality panels (one per minute).
  • Free or forced air convection drying of panels prior to shipment.

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Ace-Wall™ Panels (9) Palletized



Carbon Emissions

  • Kyoto Protocol – Carbon Credit mechanism adopted by 170 countries.
  • Low carbon footprint (embodied energy) of Ace-Wall™ product due to:
    • Extraction of raw gypsum materiel (can use industrial waste gypsum products)
    • Production process, local transportation to site, installation process
    • Full recyclable disposal at the end of useful life (re-calcination)
  • Avoidance of brick, cement and concrete produced by burning of fossil fuels
  • Brickworks give rise to soil erosion caused by mining of clay
  • Gypsum based building materiels now preferred in countries such as China
  • Ace-Wall™ Factory:
    • Environmentally friendly
    • Gypsum may be extracted from industrial waste (flue gas or phospho gypsum)
    • No pollution, no water or materiel waste (mould cleaning water recycled)
    • No gas or chemical emissions
    • Low noise level (no ear protection required)
    • No sewerage disposal necessary (other than for workforce and office)

Australia - Energy Consumption

  • Upto 10% of Australia’s annual energy consumption has been attributed to energy embodied in the construction of residential buildings (includes materials and construction process)
  • Estimates suggest that the embodied energy in a current standard residential building construction is equivalent to 15-20 years of occupational energy
  • The Australian materials industry accounts for 20% of the national energy budget each year
  • Since Australia mostly uses fossil or solid fuel as its energy source there is a direct correlation between Embodied Energy and CO2 emission
  • Embodied Energy is therefore an important component of the life-cycle energy use attributable to residential buildings in Australia
  • Ace-Wall™ has significantly lower Embodied Energy than its counterparts such as concrete, cement and brick.

CO₂ Emissions - A Comparison¹

Ace-Wall™ technology compared to brick veneer as external wall cladding of residential buildings in Australia.

It is estimated that Australia-wide use of Ace-Wall™ type product instead of brick veneer for external cladding of residential dwellings would result in a saving of 63% of applicable CO2 emissions.

It is further estimated that this saving equates to the total amount of emissions liberated in a year from domestic consumption (heating, cooling and cooking) of all households in South Australia.

1 – Data source: Ecologically Sustainable Development: Approaches in the Construction Industry

Robert  Omahen, Regensburg University, 2002 

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Market Segments

  • Internal partition walls.
    • Internal partition walls for high rise developments, new housing and industrial projects as well as upgrades to existing premises, including offices, factory premises, railway stations, hospitals, schools, airport terminals, etc.
  • External walls for housing and low rise buildings.
    • Housing and building development projects which traditionally use textured concrete panels or brick veneer for external wall solutions.
  • Feature walls.
    • The panel has a number of diverse applications such as external border or feature walls for residential and non-residential projects.

Product Cost Advantages

  • Light Weight (reduced cranage, foundation costs).
  • Precise Dimensions (certainty in design and construction tolerances). 
  • Reduced Construction Time (30% of conventional blockwork).
  • Reduced Site Labour (50% of conventional blockwork).
  • Elimination of Rendering (no rendering costs).
  • High Strength-to-weight ratio (construction materiel efficiency).
  • Reliable Supply (abundant raw materiel). 
  • Minimal Training (avoids blockwork and rendering skills).
  • Reduced Materiel Holding (rapid “delivery to installation” time).
  • Reduced Project Management (simplified logistics and skill interaction).
  • Carbon Credits (avoidance of penalties for excess carbon emissions). 

= Reduced Cost!!

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