SUBJECT:

SKAB2112 – CIVIL ENGINEERING MATERIALS

TITLE:

ASSIGNMENT 2

ADVANCED TYPE OF MATERIAL IN CIVIL ENGINEERING

(GLASS FIBRE REINRORCED CONCRETE)

PREPARED FOR:

PROF. MADYA DR. ABDUL RAHMAN B. MOHD. SAM

PREPARED BY:

1. SITI NURAMIRAH BINTI AZMI (SX180667KAWS04)

2. AMIRAH HANUM BINTI MOHMAD YUSRI (SX180136KAWS04)

3. NORAIDA HANIM BINTI JAMAL (SX180653KAWS04)

TABLE OF CONTENT ii

1.0 INTRODUCTION 1-2

2.0 BENEFITS 3

3.0 FUNCTIONS 3

4.0 DISADVANTAGES 3

5.0 MANUFACTURING 4

5.1 SPRAYED GFRC 5

5.2 PREMIX GFRC 5

6.0 PROPERTIES 6

5.3 STRESS STRAIN RELATIONSHIP 7

5.4 STRENGTH CLASSIFICATION 8

7.0 THE REASONS GFRC IS BETTER THAN PRECAST 9-10

REFERENCES iii

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1.0 INTRODUCTION

GFRC is a construction material that is commonly used to form exterior cladding panels. It has grown
in popularity with architects and engineers because of its ability to be formed into virtually any size,
shape or profile such as the Heydar Aliyev Center in the Figure 1.

Figure 1: Heydar Aliyev Center

Figure 2: Close up of GFRC

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GFRC is composed from high-strength, alkali-resistant glass fibres embedded in a concrete matrix.
The fibres act as the principal load-carrying component, while the surrounding matrix keeps them in
position, and transfers load between the fibres. Both fibres and matrix are capable of retaining their
physical and chemical identities, while combining their properties to create a high-
performance composite.

GFRC is typically manufactured in thin sections, by machine-spraying an enriched ordinary Portland

GFRC panels are often used as a lightweight cladding system, and can be made to look almost
identical to natural stone. Installation is easier and more cost-effective due to the lower weight of the
panels, which is approximately 80% lighter than pre-cast steel reinforced concrete cladding. This
enhances the energy efficiency of GRC.

Panel molds can be created to replicate complex profiles. The panels are generally take a ribbed or
sandwich form, and offer good durability, fire resistance, weather resistance, and sound
insulation properties.

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2.0 FUNCTIONS

GFRC is primarily used as an exterior façade or cladding material for both new construction and for
recladding or restoration of existing building facades. For these applications, the Spray-Up process is
generally used and the GFRC “skin” is panelised on a steel stud frame and weighs 20-25 lbs per
square foot. Due to its extreme flexibility in design and function, it is also used extensively in
applications not requiring a steel stud frame and is generally produced using one of the Premix
processes. These applications include architectural ornamentation (column covers, cornices, window
and door surrounds, etc), terra cotta restoration and replacement, fireplace surrounds, concrete
countertops, faux rocks and planters. Without the frame, GFRC will weigh 7-10 lbs per square foot.

3.0 BENEFITS

One of the benefits of GFRC is its tensile and flexural strength. The tensile strength helps GFRC to
resist pulling apart forces while the flexural strength helps it to resist bending. The glass fibers and the
high polymer content of GFRC provide these unique properties that are essential to a long lasting
concrete countertop. Rather than using steel for reinforcement, GFRC relies on these glass fibers to
prevent cracking and breakage. Reinforcement is essential any time you create a concrete
countertop, and GFRC uses fibers to create this reinforcement. GFRC is able to be molded into
almost any shape and color which gives designer more freedom to design. The installation of GFRC is
quick and cost effectives. GFRC is weather and fire resistant and also economical.

4.0 DISADVANTAGES

There is no ductility. Ductility is a solid material’s ability to deform under stress.2. The cost of GFRC is
higher than traditional concrete. Due to the fiberglass being inside the concrete and the addition of
additives and acrylic co-polymer the price is steeper.3. GFRC is difficult to self-mix. Generally, a
contractor will mix and pour or spray this type of concrete.4. While the mix can be pretty versatile it
can fall apart if not properly applied or poured. The use of materials such as wire along the
foundations, walls and ceilings will help the concrete adhere and have a stronger finish.

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5.0 MANUFACTURING

GFRC is generally manufactured by either the sprayed process or the premix process. Premix GFRC
can either be vibration compacted, or manufactured using a self-compacting GFRC mix. The method
chosen is normally dictated by factors such as strength requirements, size of mold, architects
specification etc.

As a general rule, larger items, such as building cladding panels, are normally sprayed whereas small
items are manufactured using a premix GFRC method. Sprayed GFRC is generally stronger than
premix vibration cast GFRC. The reasons for this are firstly that with sprayed GFRC it is possible to
achieve a fibre content of 5% - 6% whereas premix GFRC is limited to around 3% - 3.5%. Secondly,
sprayed GRC usually has lower water content than premix GFRC.

Table 1 : Typical mix designs for Sprayed and Premix GFRC

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5.1 SPRAYED GFRC

 The water and admixture (and polymer if used) are placed in a "high shear mixer" and the
sand/cement are slowly added until a smooth creamy slurry is achieved. The consistency of the
slurry can be checked using a simple slump test kit. Mixing time is about 1 - 2 minutes.

 When ready the mix is transferred to a "pump/spray unit". The pump conveys the slurry at a
regulated rate of flow to the spray gun. At the spray gun fibre, in the form of a roving, is chopped
to a length of approximately 32mm and added to the slurry. The two materials are projected
onto the mold surface using an air supply from a compressor.

 The GRC material is sprayed and built up in thin layers until the required thickness is achieved -
normally 10 - 15mm. Simple hand rollers are used to compact the material between layers.

 The product is left in the mold and covered with polythene to prevent moisture loss until the next
day. The product is then demolded.

 After demolding the units are covered with polythene and allowed to cure for approximately 7
days. Alternatively, if a polymer curing compound is used in the mix the units can be exposed to
the atmosphere immediately although it is advisable to keep them protected from direct sunlight
or severe external conditions for a day or two. Reference should be made to the Polymer
Supplier's instructions.

5.2 PREMIX GFRC

5.1 x GRC

 The sand and cement are mixed dry and then the water/admixture and polymer (if used) are
added. Generally a two speed slurry/fibre blender mixer is used. With this type of mixer, the fast
speed is designed to create smooth creamy slurry. This takes about 1 - 2 minutes. The mixer is
then switched to slow speed and fibre in the form of chopped strand (length approximately
13mm) is added slowly. The fibre is blended into the mix for approximately 1 minute.

 Once the mix is ready, it is poured into molds which are vibrated using a vibrating table.

 The product is left in the mold and covered with polythene to prevent moisture loss until the next
day. The product is then demolded.

 After demolding the products are cured under polythene sheets to maintain moist conditions for
approximately 7days. Alternatively a polymer curing compound can be used as described for the
sprayed process.

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6.0 PROPERTIES

The final properties of GFRC depend greatly on the mix formulation, the processing method and the
overall quality of workmanship incorporated. Early 28 day properties are typically used to determine
appropriate design parameters and to monitor quality control throughout manufacturing. The values of
these properties for GFRC made with spray and premix processes are presented Table 2:

Table 2 : Typical values of GFRC properties at early 28 days

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6.1 STRESS STRAIN RELATIONSHIP

The stress strain relationship is important for the design and analysis of GFRC elements. The stress-
strain curve of GFRC tested in compression is similar to the curve which would be obtained from
testing the matrix alone. The compressive strength is several times the tensile strength, it is normally
the tensile characteristics that control the flexural behaviour of GFRC elements. General shape of the
stress-strain curves both in tension and bending for a typical spray-up GFRC material containing 5%
glass fibre is shown in the Graph 1.

Graph 1 : General shape of the stress-strain curves

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6.2 STRENGTH CLASSIFICATION

The International Glass Fibre Reinforced Concrete Association (IGFRCA) classifies GFRC into 3
grades of material based on the 28 day flexural strength. These are Grade 18, Grade 10 and Grade 5
and there are significant differences between them as illustrated by the nominal stress strain curve in
the Graph 2.

Graph 2 : Differences of flexural strength between GFRC grades

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7.0 THE REASONS GFRC IS BETTER THAN PRECAST

• GFRC is lighter and thinner:

Because GFRC can be made 1/2 the thickness of traditional precast, it is automatically 1/2
the weight. And, because GFRC does not use stone or as much sand, which are denser and
heavier than cement, the weight savings is even greater. The effective minimum thickness for
precast is 1.5” because of the strength and the steel reinforcing required. GFRC’s practical
limit is only about 1/4".

• You can make larger pieces with fewer seams:

Instead of breaking a kitchen up into 8 foot long slabs that each weigh about 300 lbs, with
GFRC you can make the slabs as long as possible. With precast, a much larger proportion of
projects reach the weight that requires very strong steel casting tables. Many established
GFRC pros have large steel casting tables, but those just starting out can complete most
projects without the need to invest in such a table.

• Fewer people are needed to handle slabs:

Two strong men can handle a 300 pound slab. Not so when you approach 500 or more
pounds. Imagine trying to install an 18-foot long precast panel. At 675 pounds, you would
need either special equipment or 5 or more people to handle the load, at risk to their backs
and their safety. GFRC reduces the number of employees and the labour costs.

• GFRC allows faster turnaround:

Because GFRC has high early strength, in part provided by the fibres, it can be demolded
quickly. Most GFRC projects can be demolded in 24 hours. In general, traditional precast
projects should stay in the molds at least a couple of days.

• Hard to crack:

Because of GFRC’s strength and toughness, it can take a lot more load before it cracks.
GFRC can even bend.

• No separate reinforcing is needed:

For most projects, the GFRC itself provides all the reinforcement needed, via the AR glass
fibres in the backer coat. Some applications require the addition of AR glass scrim, but this is
thin and easy to place between layers of backer.

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• No vibration is required:

Achieving a pinhole-free surface is easy with GFRC. By spraying the mist coat, you
automatically impart enough energy to drive out any air bubbles.

• Complex 3-dimensional shapes are easy:

If you can build the mold for it, you can make it out of GFRC. Even shapes that seem difficult
because of the spraying angle can be created by clever assembly of the mold.

• There’s less need for large steel casting tables:

Because GFRC is light and fast, most projects can be cast on more modest tables that simply
need to be flat and level and reasonably strong. With precast, a much larger proportion of
projects reach the weight that requires very strong steel casting tables. Many established
GFRC pros have large steel casting tables, but those just starting out can complete most
projects without the need to invest in such a table.

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REFERENCES

Mohamed Abdallah El-Reedy, Ph.D, Advanced Materials and Techniques for Reinforced Concrete
Structures, Edition 2 CRC Press, Published November 24, 2015

https://vdocuments.mx/gfrc-presentation.html

https://www.slideshare.net/seonotion/gfrc-presentation

https://www.slideshare.net/bhavinshah80/glass-fiber-reinforced-concrete-53784748

https://www.slideshare.net/abhiies1/glass-fibers-reinforced-concrete

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