The original philosophy
OysterShell Systems® buildings were originally intended to be simple, prefabricated panels which have all the electrical, windows and doors already built into them at the factory. Made of strong materials and well insulated they could travel tightly packed and at destination be assembled quickly by simply bolting together.
A typical three bedroom single story house could be erected in a day and the roof in the following day and a half. Thus allowing the build to be completed within one week.
The OysterShell Systems® solution is a new system that was initiated only ten years ago and has undergone continuous improvements in the quest for perfection. The reasoning was that quality control is easier to implement in a factory than in a construction site. Therefore, the final product would be better and less expensive as well as being fast to assemble.
OysterShell Systems® panel houses have been very successful and are in high demand. However there is in the marketplace a lot of prejudice against panel joints. Common wisdom has it that a joint will sooner or later either leak or mould or both.
As we continue to fabricate panels we are also developing new building techniques to meet popular demand and offering in parallel, a system which eliminates the panels while still utilizing them.
Alternatives
In the past decade a system known as “Steel Frame” houses has taken hold and is universally accepted and regulated by the world’s building codes.
“Steel Frame” houses have become mainstream and not only engineers and Governments accept them, but the banking industry also uses them as security for financing. The only problem with “Steel Frame” houses is that it takes forever to assemble them. Thousands of screws have to be drilled and skilled labour (which is hard to find in many countries), needs to be present. And in the end “Steel Frame” houses have a sound which is hollow, and people in many countries have a strong prejudice against walls that resonate, even though they may be strong, (and they are; but this does not remove the prejudice).
The solution
At OysterShell Systems®, we now have added a new system which is in essence a “Steel Frame” structure but without the problems. We assemble whole sections of steel frame walls about 4 meters long in the factory where the environment and the availability of powerful tools enables quick and accurate assembly under sigma six quality control.
All the parts that comprise the sections are cut to a tolerance of 0.3mm. These sections are fitted with electrical conduits, windows and doors right in the factory. They are light enough to be man handled and can travel packed in a container just like the old panels.
At destination they are assembled more quickly than panels and infinitely more quickly than traditional steel frame structures. But when they are assembled there is no difference with them because the amount of steel is the same and so the building codes of the world accept them to be labelled steel frame, as do the bankers and the engineers.
The cladding is made from Fibre Cement board which has been pre-cut to a precision of 0.3mm at the factory and numbered so that every part has a position. These boards are placed in position and quickly screwed in. If in any given position there is an opening like an electrical switch or a window, the board is pre-cut. No cutting at the site is needed.
Finally when the whole “Steel Frame” is covered by board a mixture of sand, cement and polystyrene pellets in liquid form is poured from the top and flows through the whole wall system through the many holes provided. This gives the system added strength and so it becomes even stronger than a steel frame. When the cement sets the walls don’t have the hollow sound because they have acquired mass, and to the human touch and feel even when hitting it the feeling is that of a concrete wall. The polystyrene insulates much better than concrete.
Advantages
- Universal recognition for building approvals and financing
- Strength of the “Steel Frame”
- Speed of assembly
- Low volume for transportation
- No panels when the structure is filled with cement it becomes monolithic eliminating the fear of joints
- Good insulating walls
- Low cost
- High quality
OysterShell Systems® solutions are all manufactured in China by an Italian designer and German technicians.
