Glass Fibre Reinforced Cement Cladding Panels

GLASS FIBRE REINFORCED CEMENT
CLADDING PANELS (GFRC)

INDEX
INTRODUCTION
CONSTITUENTS AND MATERIALS
MANUFACTURING
PROPERTIES
APPLICATIONS
ADVANTAGES AND DISADVANTAGES
FIXING DETAILS
COSTING
INTRODUCTION
DEFINITION:
GRC (GLASS REINFORCED CONCRETE) IS A
COMPOSITE MATERIAL COMPRISING OF CEMENT, FINE
AGGREGATE ALKALI RESISTANT GLASS FIBRE AND
ADMIXTURES.
IT IS MAINLY USED IN EXTERIOR BUILDING FAÇADE
PANELS AND AS ARCHITECTURAL PRECAST CONCRETE.
CONSTITUENTS AND MATERIAL
PROPORTIONS
GLASS REINFORCED CONCRETE IS A COMPOSITE OF CEMENT ,SAND AND ALKALI
RESISTANT (AR) GLASS FIBRE IN PROPORTION OF 40%-60% CEMENT, 20% WATER, UPTO
25% SAND AND 3.5-5% GLASS FIBRE BY WEIGHT.
GRC SPRAY MIX IS A FIBRE REINFORCED PRE-CAST CONCRETE WITH A CEMENT SAND
MATRIX IN A TYPICAL WALL THICKNESS OF 12- 15MM THICK.
MANUFACTURING
PROPERTIES
GRC PRODUCTS ARE LIGHTWEIGHT, EASY TO HANDLE AND FAST TO ERECT.
GRC PRODUCTS REDUCE LOADINGS ON BUILDING LEADING TO SIGNIFICANT SAVING IN
SUPERSTRUCTURE AND FOUNDATIONS.
GRC DOES NOT SUFFER FROM CORROSION OF THE REINFORCEMENT UNLIKE TRADITIONAL
CONCRETE.
GRC PANELS ARE LIGHT AND EASY TO TRANSPORT, SMALL UNITS.
THE STRENGTH OF GRC IS SUFFICIENT SO THAT, EVEN THIN SKIN CONSTRUCTION, SMALL
MODULAR BUILDINGS CAN DE DESIGNED WITHOUT HEAVY STRUCTURAL FRAMES.
GRC IS AN IDEAL MATERIAL FOR USE IN RENOVATION. THIN LIGHT WEIGHT PANELS ARE
EASY TO FIX AND MINIMIZE THE WEIGHT IMPOSED ON THE EXISTING STRUCTURES.
IT OFFERS GREATER VERSATILITY DUE TO ITS SUPERIOR COMPRESSIVE STRENGTH AND
MOST IMPORTANTLY FLEXURAL PROPERTIES.
APPLICATIONS
GLASS FIBRE REINFORCED CEMENT 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
PANELIZED ON A STEEL STUD FRAME AND WEIGHS 20-25 LBS/SQ.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. ) , TERRACOTTA RESTORATION AND REPLACEMENT , FIREPLACE
SURROUNDS , CONCRETE COUNTERTOPS , FAUX ROCKS AND PLANTERS .
WITHOUT THE FRAME , GFRC WILL WEIGH 7-10 LBS/SQ.FOOT .
CASTING GFRC
COMMERCIAL GFRC COMMONLY USES 2 DIFFERENT METHODS FOR CASTING GFRC
SPRAY UP
THE APPLICATION PROCESS FOR SPRAY UP GFRC IS VERY SIMILAR TO SHORTCRETE IN THAT THE FLUID CONCRETE
MIXTURE IS SPRAYED INTO THE FORMS . THE PROCESS USES A SPECIALIZED SPRAY GUN TO APPLY TO FLUID
CONCRETE MIXTURE AND TO CUT AND SPRAY LONG GLASS FIBRES FROM A CONTINUES SPOOL AT THE SAME
TIME .
SPRAY UP CREATES VERY STRONG GFRC DUE TO THE HIGH FIBRE LOAD AND LONG FIBRE LENGTH , BUT
PURCHASING THE EQUIPMENT CAN BE VERY EXPENSIVE .
PREMIX
PREMIX MIXES SHORTER FIBRE INTO THE FLUID CONCRETE MIXTURE WHICH IS THEN POURED INTO MOULDS OR
SPRAYED SPRAY GUNS FOR PREMIX DO NOT NEED A FIBRE CHOPPER , BUT THEY CAN STILL BE VERY COSTLY .
PREMIX ALSO TENDS TO POSSESS LESS STRENGTH THEN SPRAY UP SINCE THE FIBRES AND SHORTER AND PLACED
MORE RANDOMLY THROUGHOUT THE MIX .
HYBRID
ONE FINAL OPTION FOR CREATING GFRC IS USING A HYBRID METHOD THAT USES AN INEXPENSIVE
AN HOPPER GUN TO APPLY THE FACE COAT AND A HAND PACKED OR POURED BACKER MIX .
A THIN FACE ( WITHOUT FIBRES) IS SPRAYED INTO THE MOULDS AND THE BACKER MIX IS THEN
PACKED IN BY HAND AND POURED IN MUCH LIKE ORDINARY CONCRETE .
THIS IS AN AFFORDABLE WAY TO GET STARTED , BUT IT IS CRITICAL TO CAREFULLY CREATE BOTH THE
FACE IX AND BACKER MIX TO ENSURE SIMILAR CONSISTENCY AND MAKEUP.
ADVANTAGES OF G.R.C
GRC CAN BE MOULDED INTO A WIDE VARIETY OF COMPLEX SHAPES,
PROFILES AND ARCHITECTURAL COMPONENTS.
GRC IS IDEALLY SUITED TO THE POPULAR FAST-TRACK APPROACH OF
USING LIGHTWEIGHT, PREFABRICATED CLADDING PANELS FOR THE
EXTERIOR OF MODERN BUILDINGS.
THE MAIN ADVANTAGE OF GRC PANELS OVER THE CORRESPONDING
PRECAST CONCRETE ALTERNATIVES IS THE CONSIDERABLE SAVING IN
WEIGHT.
THIS RESULTS IN SAVINGS IN THE COSTS OF TRANSPORTATION,
HANDLING AND ERECTION OF PANELS.
OTHER NOTABLE ADVANTAGES OF GRC CLADDING ARE ITS DURABILITY,
SEISMIC CAPABILITIES, CHEMICAL RESISTANCE, NON-COMBUSTIBILITY AND
GOOD SOUND/HEAT INSULATION PROPERTIES.
DISADVANTAGES OF G.R.C
THE COST OF GFRC IS HIGHER THAN CUSTOMARY CEMENT.

BECAUSE OF THE FIBREGLASS BEING INSIDE THE CONCRETE AND THE EXPANSION OF ADDED
SUBSTANCES AND ACRYLIC COPOLYMER THE COST IS MORE EXTREME.
GFRC IS HARD TO SELF-BLEND. FOR THE MOST PART, A TEMPORARY WORKER WILL BLEND AND POUR
OR SHOWER THIS SORT OF CEMENT.
WHILE THE BLEND CAN BE REALLY ADAPTABLE IT CAN BREAK APART IF NOT APPROPRIATELY
CONNECTED OR POURED.
TYPES OF
GRC PANELS
SINGLE SKIN GRC PANEL SHAPED GRC PANEL

USUALLY HAS A THICKNESS OF 10mm- SHAPING OF PANELS ADDS A DEGREE
15mm OF STIFFNESS IN ADDITION TO
REQUIRES SOME FORM OF STIFFNING FLANGES
PROVIDED BY FLANGES
FIXING DETAILS
RESTRAINT FIXING
USUALLY PROVIDED BYA SATILESS STEEL SOCKET THAT IS
CUT INTO THE BACK OF THE SOLID FLANGE OF A GRC
PANEL AS IT IS BEING MANUFACTURED.
THE SOCKET IS THREADED READY FOR A STAINLESS STEEL
BOLTS.
THE BOLT IS FITTED TO AN OVERSIZE HOLE IN AN ANGLE,
WHICH IS BOLTED TO THE UNDERSIDE OF A CONCRETE OR
STEEL BEAM.
THE BOLT IS HELD IN PLACE IN THE ANGLE BY STEEL
WASHERS, AND SOME MOVMENT IS PROVIDED FOR BY
WASHERS AROUND THE ANGLE.
STUD FRAMES
TO PRIOVIDE SUPPORT FOR LARGE SINGLE SKIN PANELS AND AT THE SAME TIME MAKE ALLOWANCE FOR
MOISTURE MOVMENT, A SYSTEM OF STUD FRAMES WAS DEVELOPED AND HAS BEEN EXTENSIVELY USED.
A FRAME OF HOLLOW AND CHANNELS STEEL SECTION IS PREFABRICATED WITH WELDED JOINTS TO THE TOP,
BOTTOM AND SIDE MEMBERS, AN INTERMEDIATE VERTICAL SECTION SPACED ABOUT 600mm.
9.5MM ROUND STEEL SECTION ANCHORS ARE WELDED TO THE HOLLOW SECTION STUDS AT ABOUT 600MM
C/C TO SERVE AS FLEX ANCHORS TO THE GRC PANELS.
NEAR THE BASE OF THE FRAME, T-SECTIONS ARE WELDED TO THE SIDES OF THE EDGE STUDS TO SERVE AS
GRAVITY ANCHORS.
ANGLES ARE ALSO WELDED TO THE BACK FACE OF THE STUDS AS SEATING ANGLES TO SUPPORT THE STUD
FRAME
AS THE GRC PANEL IS BEING MANUFACTURED, AND THE SKIN AND FLANGES AND RIBS ARE FORMED THE STUD
FRAME IS PLACED ON THE BACK OF THE COMPACTED AND STILL MOIST GRC, WITH THE FLEX ANCHORS AND T-
BEARING AT THE BACK OF THE PANEL
JOINTS BETWEEN GRC PANELS
THE JOINT WHICH IS TO BE USED DEPENDS UPON THE OVERALL SIZE OF PANEL
AND THERFORE THE MOISTURE MOVEMENT THAT THE JOINT WILL HAVE TO
ACCOMMODATE, THE EXPOSURE OF THE PANEL TO DRIVING WIND AND RAIN AND
THE CONVENIENCE IN MAKING THE JOINT.
APPEARANCE AS A PART OF OVERALL DESIGN MAY ALSO BE A CONSIDERATION
MASTIC JOINT
USED FOR SMALL GRC PANELS WHERE THE MOISTURE
MOVEMENT OF THE CEMENT RICH MIX IS LIMITED.
IT IS A SEALENT JOINT COMMONLY USED FOR
ADVANTAGE OF SIMPLICITY OF APPLICATION AND
RENEWAL AS NECESSARY.
MADE BETWEEN THE SQAURE EDGES OF UNIFOR WIDTH
JOINTS BY RAMMING A BACKING STRIP OF CLOSED
CELLS POLYETHYLENE IN TO THE JOINT AS SUPPORT AND
BACKING FOR THE MASTIC SEALANT
A MASTIC SEALANT JOINT SHOULD BE NO WIDER THAN
15MM
GASKET JOINT
A GASKET JOINT IS USED FOR LARGER GRC PANEL.
THE EALSTICITY OF GASKET IS CAPABLE OF
ACCOMMODATING THE MOISTURE MOVEMENTS OF
THE PANEL WHILE MAINTAINING A WEATHER SEAL.
A GASKET JOINT MAY BE USED FOR VERTICAL AND
HORIZONTAL JOINTS OR FOR VERTICAL JOINTS
ALONE WITH OVERLAPPING REBATED HORIZONTAL
JOINTS.
FOR GASKET JOINTING, THE EDGES OF THE PANEL
ARE REBATED TO PROVIDE SPACE FOR THE
INSERTION OF THE GASKETS.
A BACKING STRIPS AND MASTIC SEAL IS FORMED
ON THE BACK FACE OF THE JOINT TO EXCLUDE
WIND.
THE STRIP OF NEOPRENE GASKET IS RAMMED INTO
THE JOINT TO MAKE A WEATHER TIGHT SEAL
OPEN DRAINED JOINT
OPEN DRAINED,VERTICAL JOINTS ARE USED FOR THE
LARGER GRC PANELS WHERE IT IS NOT PRACTICAL TO
FORM THE NARROW, ACCURATELY FITTED JOINTS
NECESSARY FOR BOTH MASTIC AND GASKET JOINING.
PLASTIC CHANNELS ARE CAST IN A CHASE IN THE
VERTICAL EDGES OF PANELS INSIDE WHICH A PLASTIC
BAFFLE IS HUNG AS A LOOSE FIT.
THE INSIDE JOINT BETWEEN PANELS IS SEALED WITH A
BACKING STRIP AND A MASTIC SEALANT JOINT.
THE ADVANTAGE OF THIS JOINT IS THAT IT ALLOWS
FOR MOVEMENT OF THE PANEL, INACCURACIES IN
MANUFACTURE AND ASSEMBLY AND ACTS AS A
REASONABLE BARRIER TO WIND DRIVEN RAIN.
COSTING
GRC RATES PER SQ FT IN 2010-2015=180-230RS
GRC RATES PER SQ FT IN 2016-2017=200-270RS
SOURSE-INDIAN MART

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What are the constituents and material proportions of GRC?

What are some applications of GRC?

GLASS FIBRE REINFORCED CEMENT

CLADDING PANELS (GFRC)

THE COST OF GFRC IS HIGHER THAN CUSTOMARY CEMENT.

SINGLE SKIN GRC PANEL SHAPED GRC PANEL

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