internal cladding

Lightweight Strength: ShapeShell™ RT for Interior Projects

The Challenge of Building Better Interiors In today’s architectural landscape, interiors are no longer an afterthought. They are the spaces where people spend most of their time — studying, working, socialising, or simply living. Architects and consultants are under pressure to create environments that are not only visually engaging but also safe, durable, and efficient to build. Yet, many conventional interior materials come with trade-offs. Plasterboard may be light, but often lacks long-term durability. GFRC (glass fibre reinforced concrete) or precast solutions offer durability but are typically heavy, difficult to install, and limit design freedom. Even metal cladding, though strong, brings issues of corrosion, acoustics, and weight. What if there were a material that could combine the lightness of plasterboard, the durability of concrete, and the design versatility of polymers? A material that also simplifies installation while offering a high-end aesthetic finish? This is where ShapeShell™ RT — a fibre-reinforced thermoset system — is transforming how architects think about interior projects Why ShapeShell™ RT is Different ShapeShell™ RT is a next-generation fibre-reinforced thermoset material, engineered for architectural performance. Built from advanced fibres (glass, carbon, aramid, basalt, or steel) embedded in a polymer resin, RT delivers five times the strength of aluminium while remaining exceptionally lightweight. At its core, RT combines aerospace-inspired manufacturing with architectural intent: Lightweight panels with a thickness as slim as 3–8 mm for single skins, yet capable of spanning large internal surfaces. Strength and safety built into the fibre-resin matrix, including Class A fire rating under ASTM standards. Versatility in form: curved panels, freeform surfaces, and intricate detailing are achievable through advanced CNC tooling and vacuum infusion techniques. Unlike gypsum or concrete-based systems, ShapeShell™ RT does not absorb moisture, degrade over time, or require excessive maintenance. Its low water absorption (<0.1%) ensures that even in humid or high-traffic interiors, the panels retain their performance. Designed for Interiors While RT has proven itself in large-scale infrastructure — from bridge cladding on the West Gate Tunnel in Melbourne to façade systems in Houston — its benefits translate powerfully to interiors. For example, at Deakin University Law School, ShapeShell™ RT panels were used across 9,816 sqm of internal cladding. The result was a space that combined acoustic comfort, fire safety, and bold architectural form, all delivered within a fast installation timeframe. Inside, the material enables: Seamless finishes for lecture theatres, offices, and foyers. Durable surfaces that resist scratches, wear, and moisture. Custom geometries that reflect the architect’s design intent rather than the limitations of traditional boards or panels.   The Value of ShapeShell™ RT Indoors 1. Lightweight Advantage The most obvious benefit of RT in interiors is its lightweight profile. With a panel weight of only 5–32 kg/m² depending on thickness, it reduces structural demands on walls, ceilings, and secondary frameworks. For contractors, this translates to: Faster installation with less need for heavy lifting equipment. Lower labour costs due to simplified handling. Minimal disruption in retrofit projects, as panels can be fixed onto existing structures. In projects like the Queens Domain apartments in Melbourne, RT balustrade panels were installed using only a 500 kg winch system — a process that saved significant time and cost. For interiors, this efficiency can make the difference between a drawn-out fitout and a seamless delivery. 2. Durability and Safety Interior cladding must meet stringent fire safety, durability, and performance standards. ShapeShell™ RT achieves: Class A fire rating (ASTM E84) with low flame spread and smoke development. Resistance to corrosion, mould, and fungi, ensuring longevity in varied interior conditions. Impact resistance that far outperforms plasterboard or thin gypsum-based panels. This makes RT ideal for high-traffic spaces such as universities, airports, cultural venues, and commercial interiors where panels must remain intact and visually appealing for decades. 3. Design Freedom Architects increasingly seek materials that support freeform and expressive interiors. ShapeShell™ RT is designed for complex geometries. Using advanced 5-axis CNC tooling, it can be formed into sweeping curves, folded forms, or custom 3D panels without compromising structural integrity. Finishing options further expand the creative palette: Gloss or matte coatings in full RAL colour spectrum. Cementitious finishes that harmonise with concrete or off-form elements. Metallic finishes emulating bronze, titanium, corten, or stainless steel. Primed-only surfaces ready for project-specific coatings. This range ensures that RT is not only technically superior but also aesthetically adaptable to diverse interior schemes — from minimalist learning environments to premium cultural venues. 4. Sustainability Beyond performance, RT contributes to sustainability goals. Compared to traditional materials, ShapeShell™ products achieve up to 400% lower COâ‚‚ emissions by optimising raw materials and reducing weight across the project lifecycle. The material’s long life span (50-year structural warranty, 25-year surface finish warranty) further reduces replacement cycles, aligning with green building objectives such as LEED and Green Star. Criteria ShapeShell™ RT Plasterboard GFRC / Concrete Panels Metal Cladding Weight (kg/m²) 5–32 8–12 30–50 20–40 Fire Performance Class A (ASTM E84) Varies Non-combustible Good, but heat conductive Durability High (impact, moisture, wear resistant) Low High, but brittle High, but prone to corrosion Design Freedom Freeform geometries, slim profiles Limited to flat walls Moderate, heavy constraints Limited shapes Installation Fast, minimal equipment Easy Labour-intensive Moderate Maintenance Low Medium–high Medium Medium–high   Case Examples Deakin Law School, Melbourne ShapeShell™ RT was used to clad internal spaces across five levels, supporting biophilic and sustainable design principles. The lightweight panels allowed rapid installation while creating smooth, curved interior lines that elevated the academic environment. Sydney Opera House Concert Hall In 2022, 192 sqm of RT sound deflectors were installed as part of the Opera House renovation. The surfboard-shaped panels optimised acoustics while maintaining architectural harmony, showcasing RT’s functional and aesthetic versatility for interior applications. Wesley Place Lobby Pillar We deliver the lobby pillar and plinth wall panels for the main lobby, a high-traffic zone requiring both durability and refined detailing. Using ShapeShell™-RC, a lightweight fibre-reinforced concrete system, the panels were fabricated as thin-walled elements (15–25 mm) that balance strength with reduced weight. These examples illustrate how RT can shift from academic to cultural settings,

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Internal Systems That Last: How RC/GRC Supports Durable & Fire-Rated Internal Cladding

The Cladding Challenge in Interior Architecture Internal cladding systems play an essential role in shaping the performance, safety, and atmosphere of a building. While often perceived primarily as a visual finish, cladding must also deliver durability, contribute to fire safety, and integrate seamlessly into modern construction methods. In practice, many traditional materials used for interior cladding—such as plasterboard or standard cement-based boards—pose limitations. They can be heavy, prone to cracking, or difficult to form into complex geometries. In high-traffic environments, they may show wear earlier than expected, adding maintenance burdens. When fire safety standards are applied, some of these conventional solutions fail to deliver long-term confidence. This tension—between aesthetics, performance, and compliance—creates a consistent challenge for architects and building consultants. Reinforced material systems such as RC/GRC (Reinforced Concrete / Glass Fibre Reinforced Concrete) present a compelling alternative. Lightweight, strong, and fire-rated, RC/GRC is increasingly being applied not just to external façades but also to internal cladding systems where longevity, safety, and refined finishes matter most. This article explores how RC/GRC addresses the demand for durable, light, and fire-rated internal cladding within modern architecture. Why the Market Needs Better Internal Cladding In architectural design, internal cladding serves three interconnected purposes: Visual expression – shaping how occupants perceive and experience spaces. Functional performance – protecting structural elements and supporting acoustic, thermal, or fire requirements. Lifecycle value – maintaining integrity and aesthetics without premature repair or replacement. However, relying on traditional materials exposes several shortcomings: Weight and load implications: Standard cement-based panels or thick gypsum solutions often add considerable dead load, complicating structural and installation requirements. Fire performance gaps: Not all commonly used internal finishes are non-combustible or tested to international standards, leaving risks in high-safety environments. Durability issues: Plasterboards and non-reinforced gypsum systems are prone to cracking, moisture absorption, or impact damage. Design restrictions: Complex curvatures or seamless large spans are often unachievable without introducing multiple joints or heavy reinforcement. As a result, architects and consultants are frequently forced into trade-offs—sacrificing either design intent, performance, or cost efficiency. The question is: Can an internal cladding system provide strength, fire resistance, lightness, and aesthetic flexibility—without compromise? Introducing RC/GRC for Internal Cladding RC/GRC represents a class of engineered materials where cementitious matrices are reinforced with glass fibres or other fibres to significantly improve tensile strength, impact resistance, and performance compared to traditional gypsum or cement boards. RC (Reinforced Concrete) in thin-walled form provides exceptional durability and fire resistance while reducing embodied energy. GRC (Glass Fibre Reinforced Concrete, often termed GFRC) enhances tensile and flexural strength, allowing thin sections (as little as 15–25mm) while maintaining structural stability. By introducing fibre reinforcement, RC/GRC achieves: Up to 30% lighter weight than traditional GFRC alternatives. Higher flexural strength (typically around 25 MPa) and compressive strength exceeding 45 MPa. Non-combustibility, meeting AS 1530.1 and ASTM fire classifications. Versatility of form, enabling flat panels, double-curved geometries, domes, and intricate internal finishes. This makes RC/GRC a natural fit for interior applications such as: Wall cladding panels in high-traffic public buildings. Column wraps and ceiling features. Custom feature walls and vaulted ceiling elements. Acoustic panelling with integrated fire safety. Durable surfaces in transit hubs, universities, and civic spaces.   Why RC/GRC is Ideal for Internal Systems 1. Lightweight but Strong Despite being cement-based, RC/GRC achieves high strength-to-weight efficiency. With panel thicknesses as low as 12–25mm, internal systems avoid unnecessary structural loads while still delivering resilience. Compared to plasterboard, RC/GRC is significantly stronger, and compared to traditional precast panels, it is substantially lighter. For example, ShapeShell™ RG (Reinforced Gypsum) offers 30% less weight than GFRC while maintaining strength for internal applications. 2. Fire Safety and Compliance Fire resistance is critical in interior applications, particularly in public buildings, transport hubs, and commercial complexes. RC/GRC is inherently non-combustible, with fire testing certifications including: Class A / Group 1 fire rating (ASTM and AS standards). No flame spread, smoke development, or fuel contribution under ASTM E84 testing. This ensures compliance with stringent building codes while providing peace of mind in high-occupancy environments. 3. Durability and Longevity Unlike plasterboard or standard cement sheet, RC/GRC resists: Impact damage in corridors, classrooms, and public spaces. Moisture absorption, reduces the risks of warping, swelling, or mould growth. Cracking, thanks to distributed fibre reinforcement that mitigates brittle failure modes. The result is reduced maintenance and a significantly longer service life, lowering lifecycle costs. 4. Aesthetic and Design Flexibility RC/GRC excels in supporting architectural intent: Smooth off-form finishes directly from moulds. Textured acid-wash or aggregate finishes for tactile variation. Polished or coated surfaces compatible with RAL colour systems, PVDF coatings, or metallic effects. This allows architects to use RC/GRC as both a functional cladding system and a design language, ensuring consistency across project interiors. 5. Ease of Installation RC/GRC panels are designed with engineered mounting systems that allow ±20mm on-site adjustability. Panels can be mechanically fastened to secondary frames using standard drywall techniques. The lightweight nature simplifies handling, reduces crane or hoist requirements, and speeds installation. For high-rise interiors, this provides direct cost and time savings. 6. Sustainability Credentials Sustainability is no longer optional. RC/GRC supports environmental objectives through: Reduced embodied energy compared to traditional concrete. Options for silica-free formulations using recycled glass. Longevity that reduces replacement cycles and waste. By combining green materials with high durability, RC/GRC aligns with modern environmental benchmarks such as Green Star or LEED. Applications in Practice Transport Infrastructure High-traffic transport hubs require materials that resist impact, remain non-combustible, and maintain their finish under constant use. RC/GRC internal cladding panels deliver these qualities while supporting acoustic treatment for public spaces. Educational Buildings Universities and schools benefit from RC/GRC’s impact resistance and fire rating. Internal panels or feature walls retain integrity in demanding environments, reducing long-term maintenance costs. Civic and Cultural Buildings Museums, galleries, and civic centres often demand large spans of visually seamless cladding. RC/GRC enables complex geometries such as domes, vaulted ceilings, and curved walls—without introducing weight penalties. Commercial Interiors Office lobbies and retail environments demand finishes that project durability and refinement. With textured or

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