3

Glass-fibre
reinforced cement

The material and its advantages

Glass-fibre-reinforced cement is a composite material

consisting of ordinary Portland cement, silica sand and
water, mixed with alkali-resistant glass fibres. It has
been described by Young (1980) as an ‘ideal marriage
between brittle materials, cement, sand and glass, to
produce a tough composite’. At that time, the most
common percentage constitution of the material by
weight was as follows:

Portland cement 40%

Water 20%
Sand 40%
Glass fibre 5% (for spray techniques)
3–4% (for premix)
Later formulations included 0–5 % acrylic polymer.

The ultimate strength of glass-fibre-reinforced cement

(GRC) is essentially determined by the presence of
the fibres, and is therefore dependent upon the glass
content, the orientation of the fibres, the degree of cure,
and the bonding of the fibres to the cement/sand matrix.
The glass fibre is introduced into the cement mix
to carry the tensile forces, thus overcoming the main
disadvantage of cement, which is unreliable and has a
relatively low tensile strength. The glass content
controls the maximum loading that the material can
withstand, the impact performance and the durability
of the composite. The incorporation of sand into the
 The material and its advantages 65

Fig. 3.1 UOP Fragrances, Tadworth, Surrey (architects: Richard Rogers and Renzo Piano).

GRC mix helps to reduce shrinkage during drying out projects experienced problems with microcracking,
and reduces in-service moisture movement. surface shadowing and panel tolerances. The industry
When GRC was first developed in the late 1960s, did not respond positively to these problems, and GRC
after pioneering studies by Dr A.J.Mujumdar at the fell out of favour with British architects, as they became
Building Research Establishment, it was claimed that more interested in the development of metal-faced
it would become a widely used form of building cladding. composite cladding.
Metallic claddings were not yet fully developed, and Thus in the years since the Architects’ Journal’s
GRC promised to combine the best features of precast detailed coverage of the performance of GRC
with less bulk, lighter weight and tighter tolerances. (Brookes, 1986), UK architects have not used GRC
These benefits led to early uses on prestigious cladding to the extent that was originally predicted.
projects such as UOP Fragrances (architects: Richard However, GRC continued to be extensively used in
Rogers and Renzo Piano) at Tadworth in Surrey (Fig. continental Europe and in the Middle East, where
3.1). As the use of GRC began to increase, some manufacturers were actively developing their basic
66 Glass-fibre-reinforced cement

formulations, manufacturing methods and cladding GRC wall panels. Stein (1995) shows several
systems. European manufacturers include: projects in the Middle East
Dyckerhoff and Widmann in Germany; Besinor, Design guidance is available describing the
CMEG Creabat, Fiberton in France; Dragados y properties of glass reinforcement cement Young (1978)
Construcciones in Spain; and Hibex in The describes the properties of GRC and its methods of
Netherlands. UK manufacturers with an active GRC manufacture, and gives guidance on the specification
programme include BCM Contracts, Mouldform, and design of such factors as finishes, fixings and joints
Techcrete (Eire) and Graham Precast. with reference to a number of case studies. Brookes
By reducing the cement: sand ratio (from 1:3 to and Ward (1981) cover developments and feedback
1:1) and by refining the fibre/polymer mix, the amount from practice. Pilkington (1979) produced design
of daily moisture movement was reduced, resulting in guidance on the use of GRC, which included a detailed
improved surface quality, elimination of microcracking description of such properties as its creep and stress
and tighter tolerances. One of the new formulations rupture, fatigue, density, thermal expansion, thermal
using Metakaolin pozzolanic aggregate, CemFil ‘Star’ conductivity and air and water permeance, with
was marketed by CemFil International Ltd, who methods of design for determining working stresses,
claimed that it did not go brittle with age and that it loading, thermal, acoustic and fire performance of a
kept its early strength and ductility. Early use of this particular design. Information was also given on
new formulation includes the Espace Forbin building component testing, quality control and typical
at Aix en Provence. specifications.
As for many new materials, the use of GRC was Designers intending to use the material in
at first inhibited by lack of experience in use and general complicated shapes or in conjunction with composite
rules governing design and adequate codes of practice. insulation core materials should seek further advice
At the international congress on glass-fibre-reinforced from the manufacturers involved. They also may wish
cement in London, October 1979 (GRCA, 1980), to review the recent guidance notes on GRC published
although some speakers complained of the lack of by Fachvereingung Faserbeton (FVF), the German
adequate standards, at the same conference GRC trade association. A similar guide is published in
M.W.Fordyce and D.Ward described moves towards the UK by the GRCA entitled GRC Architectural
standard specifications. Components, and a Guide to Fixings for Glass
A number of major projects have been built Reinforced Cement Claddings is also available from
using GRC. In the UK, the Credit Lyonnais building in GRCA.
London is still seen as a classic use of GRC
moulding, as is the use of composite GRC panels by Production methods
Richard Rogers at UOP Fragrances Ltd at Tadworth
in Surrey. More recent examples include the Process methods that have so far been developed for
Grosvenor Hotel and Classic Cinema in Glasgow. A the fabrication of GRC components are spray and
large number of projects have also been built in the premix. Premix processes are those where the
Middle East, Spain and Japan, and J.B.Ford (GRCA, constituents are mixed together into a paste and
1980) has described 12 projects in the USA using subsequently formed by casting, press moulding or slip
 The material and its advantages 67

Manual spray

Manual spraying is labour intensive, but offers the

designer more flexibility in shape and profile than other
methods of fabrication. Using the manual spray the
operator moves the spray backwards and forwards
across the mould surface until the required thickness of
GRC, typically 10–12 mm, as opposed to an average
3–6 mm for GRP, is built up. Greater thickness tends to
increase GRC production costs. As with GRP, the
material can be built up locally around fixings and inserts,
while roller compaction ensures total contact with the
mould and removal of entrapped air. Roller compaction
should be used after the first 3 mm layer has been
sprayed to ensure a good surface finish. For an operator
to spray effectively from either side of the mould a
dimension of not more than 2 m width is recommended.
For greater widths it is possible to erect some sort of
working platform above the mould, but this makes
spraying difficult, and could affect the quality and cost of
Fig. 3.2 Typical hand lay-up operation. production. Figure 3.2 shows manual spraying of GRC
wall panels. Robotic spray techniques have also been
developed for three-dimensional products.
forming. Spray processes, in which wet mortar paste
and chopped glass fibre are simultaneously deposited Mechanized spray
from a dual spray-head into a suitable mould, currently
account for a large percentage of GRC production. The hand spray can be easily mechanized for the
The properties of GRC premix are inherently production of simple flat components; the moulds are
different from, and usually inferior to, those of sprayed- moved along a conveyor and pass below a boom on
up GRC, because more air is introduced into the which the dual spray-head is mounted, moving to and
mixture, and there is less control over the fibre fro to give uniform thickness and correct fibre
orientation. Thus for cladding panels spray processes distribution through the composite. The mechanical
are normally used. Three ways of spraying GRC are spray thus ensures greater consistency and more
available: uniform thickness than hand spraying. The restriction
on width of the mould, as mentioned above, also does
– manual spray; not apply. It has been shown possible to automate the
– mechanized spray; manual spray method completely using computer-
– spray-dewater process. controlled robot units. However, the cost of mechanized
68 Glass-fibre-reinforced cement

spraying of complicated shapes and window openings of GRC used between the sheets of insulation to
becomes prohibitive unless continuous mass stiffen the panel.
productions runs are used, and so far these production – Suitable foam may be injected between the two
methods have not been used for one-off cladding preformed skins of GRC. Foams include
designs in the UK. Post-forming of flat sheets can also polyisocyanurate, polyurethane and phenolic. In the
be used to produce two-dimensional products. last case internal webs of GRC are also used,
because the shear performance of the foam is
Spray-dewater process
inadequate.
A variant of the mechanized spray process is the
spraydewater process, in which the mould surface Moulds
consists of a filter membrane through which excess
water can be drawn off by vacuum immediately after Although GRC, being a moulded material, offers the
spraying. The mechanical properties of the laminate architect great flexibility in shapes and contours to be
are improved by the dewatering process, which designed, in practice the types of mould and methods of
produces a denser composite. spraying may restrict the size and shape of the unit. This
A typical automatic spray-dewater plant for the is particularly true for sandwich panels. As with GRP, the
continuous production of flat sheets consists of a mixer effect of the mould costs on the finished panel is
and pump conveying the GRC slurry to a slurry spray dependent upon complexity, the numbers taken off the
and glass chopper mounted on a traversing head. A mould, and the number of specials required. It is therefore
conveyor belt passes the sprayed sheet through a necessary to keep the number of specials to a minimum.
finisher and vacuum box to draw off the excess water. Where possible, the basic mould should be adaptable to
After cutting and trimming, the ‘green’ sheet so produce panel variants. For example, at the UOP
produced can be removed, using a vacuum lift, in its Fragrances factory, Tadworth, Surrey (architects: Piano
limp state for post-forming into simple shapes. Although and Rogers), various adaptor pieces were inserted in the
such production processes are used in the UK, timber and marine ply moulds to provide the seven panel
manufacturers tend to use dewatering processes only variants, and detachable pieces were needed to allow
for the production of small flat units, such as wall or moulding of the complex edge shapes.
ceiling tiles, and find the manual spray methods more Most GRC production using the spray method
suitable for complex shapes. However, the increasing requires anything up to 24 hours before demoulding.
use of superplasticizers has reduced the benefits of Thus the speed of production will be determined by the
this process, which has limited application. number of moulds available. Requirements for higher
mould utilization have led to developments in rapid-
Insulated panels setting types of Portland cement and accelerated
The inclusion of insulation between two skins of GRC dewatering processes.
is carried out in two main ways, as follows. The number of units to be cast will determine the
material from which the mould is made. In general,
– Panels of polystyrene may be placed in position timber moulds are used for ‘short’ runs, where a small
and then covered with a slurry, or preformed webs number of units are required (approximately 30 castings
 Finishes 69

can be obtained from a single mould). For most

purposes, moulds in GRP are the most appropriate
material, because they are more durable than timber
and offer a better standard of surface finish. Steel
moulds can be used for long continuous runs.
Using spray production, it is possible to obtain a
smooth finish only on the mould side. The non-moulded
face will have the textured surface of the compaction
roller or a trowelled finish.
Cast or moulded GRC allows for the formation of
very intricate surface detailing in cladding panels, as
demonstrated on the renovation of existing buildings
such as St George’s Hospital at Hyde Park Corner and
the Grosvenor Hotel in Glasgow. The Woolworth
building in New York also makes extensive use of GRC.
While it does not offer the aesthetic flexibility of
reconstituted stone, it does have an advantage in terms
of lower weight and thinner sections.
Typical dimensions of GRC panels are shown in Fig. 3.3 Typical panel dimensions.
Fig. 3.3.

Finishes curing patchiness of the material and slight surface

crazing produce an effect not unlike marble.
Normally, GRC components would cure to the greyish There are four basic ways in which the colour
colour of ordinary Portland cement. White Portland and texture of GRC can be modified:
cement has often been used for cladding panels to
improve their appearance, but complete uniformity of – surface treatments and textured moulds;
colour from one panel to another may not be achievable – pigmented colouring;
because of variations during manufacture. Panels – applied paint coatings;
produced in smooth-surfaced moulds will have a glossy – PVC film.
finish on one side only, which tends to accentuate small
surface defects and show up the inherent post-curing Surface treatments and textured moulds
patchiness of the material. The cement-rich layer at
the surface may also show a slight surface crazing. As with concrete, some surface treatments can be
For example, according to Young (1978), panels at the applied either during moulding using textured moulds
Melrose Centre, Milton Keynes (architects: Colquhoun or after casting using acid-etching, grit blasting or
and Miller) showed that a combination of white cement, smooth grinding techniques. These techniques can be
a smooth glassy mould surface and the inherent post- particularly valuable in removing any excess cement/
70 Glass-fibre-reinforced cement

sand laitance, and hence can reduce the tendency to generally be avoided, as they can lead to an increased
crazing. Considerable skill is needed in retaining risk of interstitial condensation, particularly with
minimum component thickness after the treatment has sandwich panels. If the panels are not allowed to
been applied. Any textured layers must be considered ‘breathe’, then moisture migrating to the surface will
as surface treatment only, and must not be taken into cause any impermeable paint to blister or flake.
account in determining the structural performance of Proprietary textured permeable finishes, such as
the cladding. those used for coating external masonry, e.g. Muroplast,
Large-aggregate finishes, as used with precast Sandtex and Glamrock, are often used. Such finishes
concrete, are not normally recommended, because were used at Heathrow Eurolounge and at Newton
they have to be embedded in 10–15 mm of cement, Heath Library.
making the panels heavier and less manoeuvrable. Clear surface coatings of the silicon type, which
Normally only aggregate less than 12 mm is used are particularly useful in protecting the surface of white
because of the excessive amount of GRC required GRC panels against dirt and fingermarks, can be used
behind larger aggregate. without fear of blistering, as they allow the GRC to
Surface finishes of GRC can also be modified breathe.
using applied acrylics, formed textures, or exposed Care must be taken when applying paint
aggregates. Typically, very fine aggregates may be coatings, whether in the factory or on site, to ensure
used, opening up a wide range of aesthetic possibilities, that the surface is free from grease or any trace of
including reclaimed ground glass as the aggregate. mould release agent, so that an adequate bond is
High-gloss finishes are possible but expensive; also, maintained between the GRC and the paint system
these have the disadvantage that any surface base coat.
irregularity will be emphasized in bright light. Some GRC panels have been produced to
emulate the aesthetic features of flat metal systems by
Pigmented colouring incorporating a PVC finish. The PVC sheets are either
cast in line integrally with the PVC facing or adhesive
Like precast concrete, coloured panels have been bonded to the GRC subsequent to moulding. Such
manufactured using pigments and coloured sands, or panels were used at the Oxford Ice Rink (architects:
by adding coloured Metakaolin pozzolanic aggregates. Nicholas Grimshaw & Partners) (Fig. 3.14) and at the
Naturally, the colours tend to be muted and limited in Sheffield Arena (architect: HOK).
range to softer colours. Thus coloured panels can be obtained by the use
of pigments and coloured sands or by adding coloured
Applied paint coatings Metakaolin. However, these colours are muted and
limited in their colour range, and architects may prefer
As with all cement-based systems, GRC is also subject to specify acrylic-based emulsion applied on site or in
to moisture movement in that it expands during water the factory. High-gloss finishes are possible but
uptake and contracts when drying. Great care should expensive. Also, these high-gloss surfaces have the
therefore be taken in the consideration of any applied disadvantage that any surface irregularities will be
coating. Impermeable coatings for external use should emphasized in bright light.
 Performance characteristics 71

Performance characteristics

Wind loading

Simplified tables are now available for determining the

spanning characteristics of varying thicknesses of GRC
in relation to wind loading (Table 3.1). For example,
10–12 mm flat sheets will span 1.0 m under a wind
pressure of 1.0 N/m2, but sheet of the same thickness
can be profiled or ribbed to span up to 4.0 m under the
same wind pressure. For greater spans or wind
pressure, it may be necessary to design using sandwich
construction, ribs or, more commonly today, a stud
frame construction.

Thermal characteristics

A 20 mm single-skin GRC construction of approximate

density 1800–2100 kg/m3 gives a negligible insulation value,
in the region of 5.0 W/m2 °C. For improved thermal insulation
(up to a U value of 0.7 W/m2 °C), it is necessary to
incorporate an insulation core into the construction or to
incorporate some form of insulation behind a single-skin
facade, a method that is finding increasing use in continental
Europe.Table 3.2 shows the thermal performance of varying
thicknesses of GRC sandwich panels.

Fire performance

In terms of fire performance, GRC is non-combustible

when tested to BS 476. Even with an organic paint
finish, GRC performs to Class 0 standard when tested
in accordance with Part 6. This is generally comparable
to metal and precast performance. However, it is
important to check the use of polymer additives,
because they affect the fire performance of the panel.
In terms of fire rating, 1.5 hours fire resistance is
claimed by some sandwich panel manufacturers, such
Fig. 3.4 Curved G.R.C. panels.. as Veldhoen.
72 Glass-fibre-reinforced cement

Table 3.1 Panel thickness and span

*Can also use profiled or ribbed single skin GRC

 Types of cladding 73

Table 3.2 Thermal performance of varying thicknesses construction; however, if it is necessary to connect the
of GRC sandwich panels. Material from BS 5427:1976 is
outer and inner skins for structural reasons, this will
reproduced by permission of the British Standards Institution,
reduce the sound insulation for the whole panel.
2 Park Street, London WIA 2BS
Density
A piece of flat GRC 10 mm thick weighs approximately
20 kg/m2.

Shrinkage and moisture movement

Like other cement-based materials, GRC exhibits

nonreversible shrinkage during the curing process, and
long-term moisture movement caused by changes in
humidity. The incorporation of 40% silica sand into the
matrix reduces both types of shrinkage but, even so,
actual movements in use could in theory be 1.5 mm/
m. In practice, movement of 1.0 mm/m may be
experienced, which is approximately double that of
ordinary reinforced concrete. Care has to be taken in
the design of fixings to allow for this movement.
Impact loading

GRC is also good at withstanding impact loading.

CemFil International quote an impact strength of 10–
25 kJ/m2 for hand or machine spray products and 10–
15 kJ/m2 for vibrated cast products.

Note: PBAC-polystyrene bead aggregate concrete. Types of cladding

Acoustic performance Several systems of GRC cladding and roofing have

been developed over the past decade, including:
A 10 mm single skin of GRC at 20 kg/m2 density gives
sound reduction indices from 22 dB at 350 Hz to 39 dB – single-skin cladding or roofing;
at 4000 Hz, or an average of 30 dB over the normal – profiled sheeting;
range of frequencies. Even if the single skin is increased – composite panels with foamed polyurethane;
to 20 mm, which is beyond the thickness normally – cast or moulded products.
recommended, the average reduction indices will
increase to only 35 dB. For greater acoustic In single-skin form, GRC can be mounted onto a
performance it is possible to specify sandwich metal stud framing (Fig. 3.5). This framing provides
74 Glass-fibre-reinforced cement

Fig. 3.5 Fixing method for a stud frame system.

support and stiffness against out-of-plane forces, and The total effective depth of large panels can
permits expansion and contraction of the GRC skins. usually be reduced using sandwich construction, as
This approach has been extensively used in Germany large single-skin panels would require deep stiffening
and the USA and increasingly in the UK and continental ribs to prevent deflection under load.
Europe. In sandwich construction a larger overall
The choice of the type of construction (single skin, thickness than indicated by strength calculations would
profiled or sandwich) will be governed by a combination usually be used to satisfy fire and thermal
of requirements that need to be satisfied: fire, thermal, characteristics and also minimize bowing. This may also
acoustic, weight etc. Table 3.3 shows the relationship be minimized by limiting panel length or width, because
between various types of wall construction and the the effect is proportional to the square of either
performance requirements for spans, fire resistance dimension; increased panel thickness has a directly
and weight, which are usually the most critical. beneficial effect in minimizing bowing. Bowing has not