GFRC panel also known as Glass fiber reinforced panel concrete is fast becoming one of the most commonly used construction materials and the material of choice for architects who are looking to add high quality, durable architectural features to buildings and structures. This is because GFRC is known to be tough, strong, lightweight and versatile for hundreds of uses. Even better is the fact that GFRC does not need further reinforcement.
Products can be used in the design and implementation of building elements not only in the exterior but also in the interior design. Thanks to the wide use of imprinted matrices, it is easy to achieve the full spectrum of different surface areas not only for cladding plates and GFRC panel. But also for more complex architectural elements, shaped and space elements and design solitaires.
What is GFRC panel?
GFRC (Glass Fiber Reinforced Concrete) is a new construction material in Vietnam today. GFRC is also known as glass fiber concrete – a type of coarse fiber reinforced concrete mixed in a mixture of fine aggregates: cement, clean water, clean sand, polymer, colorants and plasticizers.
Product is made by molding and injection method, which ensures to maintain the physical and chemical uniformity of the fiberglass and mortar content. GFRC fiberglass concrete has a wide range of products for the modern construction industry.
GFRC easily creates large facade panels, giving unique architectural features to building facades. And it is lighter than reinforced concrete. In addition, GFRC panel is also applied in decorating architectural details such as moldings. Column tops, interior decoration, garden landscaping and shaping in fine art decoration. So what is GFRC panel?
GFRC panels are elements of GFRC in a designed shape that can be fix onto the substructure. For example these can be square, rectangular, trapezoidal or round. The size and shape is defined by the design of each particular project. GFRC panels can create standalone cladding or can be a part of united facade or a combined system.
Why use GFRC panel for projects?
So many of the benefits of using GFRC panel in place of traditional concrete add up to one very big advantage – cost effectiveness. Here is a rundown on what makes this building material cost effective.
What Does Cost Effective Mean?
Cost effective does not mean cheap or low cost. What it does mean is that the product or service does offer value in terms of the money spent and the return it will offer. Usually this relates to the return that the person receives after spending the money and how that return will either save money or create an intangible benefit.
While there may be cheaper building materials out there, these may not be cost effective like GFRC panel. Which offers significant benefits that the other materials cannot deliver.
Any product that is produced and used on the market, in addition to the advantages it brings to the user, still has certain disadvantages and limitations. The same goes for GFRC panel. It has the advantage of being thin and light, diverse in design, giving constructions a modern and luxurious beauty, but it still has some disadvantages of its own. So what are the advantages and disadvantages of product ? We also learn about the advantages and disadvantages of GFRC panel, so that we can make the best choice when building buildings.
Advantages and disadvantages of GFRC panel
There are a number of ways that value is created with GFRC as compared to other building materials commonly used:
Advantages
Product has high aesthetic value
GFRC panel are formed by injection molding or by machine injection from a pre-mixed mortar mixture. So it is easy to create products with diverse designs. Depending on the architecture of each building, it will create different types of facades with different beautiful designs, diverse natural colors, and can create complex shapes such as: curved, folded, wavy… The products be application brings unique and impressive features to the facade of each building.
Easy to compress, shape
As an innovative product, GFRC panel can also be shaped into virtually anything as well as made to look like any other type of building material and in any color. This means it can be formed into a wide range of architectural products that other materials simply cannot.
GFRC panel is durable
With a lower weight and significant higher strength, its performance is second to none. Which means it is made to last through all types of contact, including water, fire, seismic activity, wind and extreme temperature changes. Lab tests have confirmed its high resistance and durability over time as well as its ability to perform better than other materials like concrete. Although it is lightweight, one of its biggest benefits is its incredible strength and durability, offering more than traditional concrete. Here’s why and how.
Low Maintenance
Not only is GFRC panel made to last, it also requires very little maintenance. This saves on other types of costs that are often part of the equation if other building materials were uses.
GFRC panel is easy to install
Because of the lighter weight, GFRC is easier to transport, handle, and install. This can cut project time and labor costs, making it very cost effective over other materials that are heavy, cumbersome. And require larger equipment to install. Because of this lightweight feature and strength combined. GFRC can often be uses in new ways for construction projects, including pre-cast concrete panels for a building.
Environmentally Friendly
There are a number of reasons to use GFRC as an environmentally friendly building material:
It is made up of stable and inert natural minerals that are not considered pollutants or toxic in nature, which means that it is not polluting the air or water.
GFRC often uses recycled aggregates, glass fiber, sand and cement in its production.
Its durability means that there are fewer building projects to restore a structure, which reduces emissions, saves fuel and energy, and minimizes waste.
Since it can be finish and painted prior to installation, this further reduces air pollution.
Its lightweight design means easier to transport and fewer trips to the construction site are require.
Overall, less material by volume is require for construction projects. Which means that this is more efficient and not wasteful like traditional building projects.
In the construction industry, the regulatory environment is changing and requiring more ‘green’ materials. Switching now to an environmentally friendly building material like GFRC can create a competitive advantage. And remove any future costs or potential penalties for emissions or pollution.
Additionally, the GFRC panel helps the inside of the building in many ways as well to also use less energy over time and provide a comfortable environment for its inhabitants. The material is good for insulation purposes, keeping the temperature of the structure regulated so that it is cool in summer and holds the heat in winter. This means less use of artificial heating and cooling. This is also an important aspect of creating a green building.
Disadvantages
The mechanical properties of GFRC make it ideal for various requirements. However, one potential disadvantage for some users is the cost of GFRC panel.
GFRC panels can be expensive to use when compared to ordinary concrete. Of course, the added cost comes with additional strength and several other benefit.
Depending on the structure and architectural design of each specific project to manufacture and install appropriate GFRC panels.
The implementation of GFRC panel construction is done mostly from the outside of the building. Therefore, it is necessary to prepare lifting equipment, vertical transportation system for employees to work.
Application of GFRC panel in modern building architecture
After learning the introductory information about decorative GFRC panel and the outstanding advantages of this material. We see that this is a material that is well applies to the construction industry today. So how is GFRC material applies in the construction industry in the world and in Vietnam?
In today’s countries, this material plays an important role in decoration and interior materials. Especially in areas with harsh climates. The weather often changes. Decorative GFRC cladding can survive and avoid any external influences. Materials always maintain sustainable aesthetics and features. The following are design ideas that have been create by construction units and architects from GFRC:
Works with high decorative application of GFRC panel:
Concrete countertops, white fiber-reinforced kitchen island: Investors and customers always prefer pure white on the countertop. After using GFRC sheet, it helps to reduce the weight of the tabletop, while creating durability. Especially the pure white color that the aesthetic requirements put forth.
Garden interior and exterior decoration: Because it can be molde into any shape. So GFRC panels are suitable for decorating every corner of the garden, aquarium, house wall, … anywhere there is light. Especially it can with stand harsh weather and is a material with high fire resistance.
GFRC is applies at construction sites in details such as: GFRC facades, GFRC moldings. GFRC column head and garden decoration products, fine art.
Decorative GFRC panel offer freedom. Creativity and natural harmony for architecture. The diversity of this material creates space for personal realization. And unique of each project without any boundaries and limitations. GFRC facade panels can be in flat panel form. Or shaped details – linings, shutters, squares, corners, shutters, etc. The fiberglass reinforced concrete details are manufacture according to the customer’s size requirements.
Is the price of GFRC panel expensive?
GFRC panel provide solutions for flexibility and high durability, replacing natural stone products with large facade panels. The price of GRC panel depends on the design, production and finishing construction and erection at the site. High-quality GFRC manufacturers face few risks, as they consistently provide truly innovative construction solutions for large-scale projects. Depending on the area, there will be different prices, although it is slightly more expensive than regular concrete, but ensures durability and quality for your projects later.
MILLI TILES – SPECIALIZED IN CONSTRUCTION OF GFRC PANEL FOR PROJECTS
MILLI TILES is a leading unit in the field of new construction materials – GFRC fiberglass concrete. We, with the motto of creative, dynamic and effective work of a team of professional, experienced staff, will bring customers and partners satisfaction and trust through each service and product. After referring to the information about GFRC panel with common types of concrete used in construction, we see that: This product has more advantages and in terms of overall cost, using GFRC panel for construction projects. program is very suitable. Contact us today for more information about these durable fiberglass reinforced concrete products!
MILLI CONSTRUCTION MATERIAL COMPANY LIMITED
📱 Hotline: 0939 102 568 📞
We will quote a specific % discount for you depending on the quantity or total value of the order
Contact us to order today, to get the best price support.
Instructions for construction of wind cement bricks, you can read and download below:
FILE INSTRUCTIONS FOR Brick Construction, DOWNLOAD HERE
Facade GFRC – glass fiber concrete is a modern new construction material. This is a product manufacture by injection molding and injection technique from a mixture of fine aggregates: cement, clean sand, clean water, alkali resistant fiberglass and plasticizers. Because it is molded, the GFRC facade is a finished product. Diverse in designs and colors, uniform to every little detail. The advantage of GFRC glass fiber concrete facade is thin and light. It is possible to create large facade panels, helping to reduce the load on buildings. GFRC facade has been treated with waterproofing and surface acid washing during production, so it doesn’t need too much maintenance and is absolutely waterproof. It is often applies to decorate the facades of modern and different beautiful buildings.
What is facade GFRC?
Facade is the front part of a building. Facades are always carefully design and built, because they represent the unique architectural style of each project.
Today, architects and investors have more diverse options in the design and construction of facades for buildings. There are some types of traditional facades such as reinforced concrete or aluminum glass or Alu… or more modern facades GFRC.
Facade GFRC is a new construction material appearing and popularly used in recent years. These are products manufacture by injection molding or by injection from a fine aggregate mixture of clean sand, clean water, alkali resistant glass fibers and plasticizers. Facade GFRC is evaluate to have high strength, great bearing capacity, along with very good bending and tensile strength, compact weight and can be molded into large slabs. They are commonly use in modern high-rise buildings, commercial centers, Spas and residential buildings today.
Any product when produced and used on the market. In addition to the advantages that it brings to the user, there are still certain disadvantages and limitations. So is the facade GFRC. It has the advantage of being thin and light, with a variety of designs. Bringing to the construction works modern and luxurious beauty, there are still some disadvantages of its own. What are the pros and cons of this product? We also learn about the advantages and disadvantages of GFRC facades, so that we can make the best choice when building buildings.
Advantages and disadvantages of facade GFRC
Advantage
GFRC facade has high durability
These are finished molded products, which have been treated with waterproofing, acid washing, and surface treatment before installation, so they have very high durability. During use, they have good fire resistance, absolute waterproof. In addition, GFRC facade is less affected by weather, retains its original color and minimizes maintenance costs. Their application helps the building to keep its beauty over time.
Has great bearing strength
Manufactured from a mixture of fine aggregate concrete, clean sand, clean water, alkali resistant fiberglass and plasticizers. This mixture helps the product to have higher flexural and tensile strength than normal concrete. The facade GFRC has an average compressive strength of about 70 MPa. The bending strength is about 20-30 MPa, so it is able to with stand large forces with very thin thickness. Therefore, it is widely use for facades of buildings, replacing traditional facades such as aluminum and glass, alu, brick wall…
Highly artistic
GFRC facades are shaped by injection molding or by machine injection from a pre-mixed mortar mixture, so it is easy to create products with diverse designs. Depending on the architecture of each building, it will create different types of facades with different beautiful designs, diverse natural colors, and can create complex shapes such as: curved, folded, wavy… The facade GFRC application brings unique and impressive features to the facade of each building.
Thinner, lighter than concrete
With the advantage of being thin, light, capable of laminating (from 10-25mm) without causing cracks, cracks, peeling on the surface. When applied at the facades of buildings, GFRC helps to reduce the volume of impact on the work load, creating a gentle elegance for the facades of buildings.
GFRC facade is environmentally friendly
GFRC is an sunburnt material with most of its ingredients originating in Vietnam (except glass fiber and some other additives). Meet the requirements of green standards for the project. GFRC facades can replace products made from asbestos fibers and are completely non-toxic to the environment.
Respond to fast construction requirements
GFRC is cast with an existing mold, creating finished products so the erection process is quick, ensuring the construction schedule for each project. The application of GFRC facade helps reduce costs for investors and construction contractors when implementing projects.
Disadvantages
Facade GFRC price is higher than other types of facade. Depending on the structure and architectural design of each specific project to manufacture and install suitable facade GFRC.
The construction of this facade is done mostly from the outside of the building. Therefore, it is necessary to prepare lifting equipment, vertical transportation system for employees to work.
Thus, through this article, you have clearly understood the advantages and disadvantages of the product. Therefore, when conducting construction works, you will have the choice of the most suitable building materials.
As we all know GFRC is a new building material commonly used in architectural facades of buildings. GFRC facade has the advantages of light and thin, diverse in designs and surface finishes with beautiful and luxurious colors. They are appreciated by architects and engineers all over the world for the use they bring to buildings. So what is the use of facade GFRC? Let’s learn about the use of facade GFRC.
Uses of facade GFRC
The use of GFRC facade is to create a luxurious highlight for modern constructions, meeting the creative design needs of architects.
This product is manufactured by injection molding or injection molding, so it is easy to create a variety of beautiful designs. Even curved, wavy, and folded surfaces… GFRC facades are diverse in color and have different architectural details to help create beautiful accents for the works. High-strength products allow the design of thin and light facade panels, helping to reduce building loads.
It can replace precast concrete – a type of concrete that often has problems with weight and shape. Or substitute for aluminum, glass, alu… which is easily affect by weather and strong impacts.
As a new construction material commonly used in the decorative cladding of the exterior of large, modern and luxurious architectures. Besides, its use also helps to decorate houses and other constructions today.
Thus, they have had great use in the construction of the exterior of the works, meeting the increasing requirements of the construction industry in the world in general and in Vietnam in particular.
When learning about any product, the important thing that we focus on is the price and quality of the product. With GFRC products in general and facade GFRC products in particular, you are completely assured of quality and price. Because GFRC is manufacturing using modern techniques, creating the best products for the construction industry today. So how much is the facade GFRC price?
Facade GFRC price
Facade GFRC offers solutions for flexibility and durability. Replace natural stone products with large facade panels. Their prices depend on the design, production and complete erection at the site. Manufacturers of high-quality GFRC face little risk. Because they always provide truly innovative construction solutions for big projects. Thus, the facade GFRC price will be suitable for projects like this.
Compare GFRC facade prices and other types of facades
Traditional facades such as aluminum, glass, alu… are usually valid for a certain period of time, maybe 10 years, 15 years. They can be easily faded, old, broken or rusted due to the effects of the weather, costing to maintain, maintain or replace… The GFRC facade price with the initial cost will be higher. But their durability is superior to other traditional facades. GFRC is not affect by weather, does not stick to dirt, keeps its luxurious beauty forever. Using GFRC facades will not cost you for maintenance or replacement. The investor only needs to spend 1 time initially for the erection of GFRC facades, and then the building will be durable over time.
Facade GFRC manufacturing techniques
Mold making method
After having design drawings of GFRC facades for specific works. Depending on the shape, surface, and technical requirements of each product, we will make molds. And usually there are specific mold forms as follows:
Positive mold: Positive molds are made in a variety of ways and with a variety of material compositions. It is possible to use a real product, create positives by the method of wood jigsaw, or cast clay, plaster, CNC cut on wood, foam, plastic materials …
Negative mold: Negative mold usually has 3 types as follows:
Wood molds are suitable for simple shapes such as flat, solid, can also be use for curved blocks. Wood molds use a low mold rotation coefficient of about 7 times, and they need to be replace with a new mold. Therefore, in order to save economic costs, it is more reasonable to use wooden molds for a small number of panels, with a small surface.
GRP molds (plastic molds) are suitable for complex flat, block, curved, and curved shapes. Plastic mold has a rotation coefficient 500 times higher than that of wood mold, so it is more economical to use and is suitable for products with a large number of panels, helping to bring higher economic efficiency.
Silicone molds (rubber molds) are suitable for products with complex shapes, curved, folded, wavy surfaces, elaborate pattern details, to easily separate the mold after GFRC injection. Silicone molds are very durable.
MILLI TILES – SPECIALIZED IN CONSULTATION AND CONSTRUCTION FACADE GFRC FOR PROJECTS
MILLI TILES is a leading unit in the field of new construction materials – GFRC fiberglass concrete. We with the motto of creative, dynamic and effective working of a team of professional, experienced staff. Will bring customers and partners satisfaction and trust through each service and product. Contact us today if you have any questions or need advice on facades GFRC for your project. MILLI TILES will work with you to create a beautiful and impressive architectural space.
MILLI CONSTRUCTION MATERIAL COMPANY LIMITED
📱 Hotline: 0939 102 568 📞
We will quote a specific % discount for you depending on the quantity or total value of the order
Contact us to order today, to get the best price support.
Instructions for construction of wind cement bricks, you can read and download below:
FILE INSTRUCTIONS FOR Brick Construction, DOWNLOAD HERE
GFRC Cladding has become more and more popular choice as an architectural finish material. People consider Glass reinforced concrete cladding as a relatively new type of construction material. Although, the construction industry has been using it for over 50 years it’s only getting more attention in the 21st century. GFRC cladding is very versatile and that is why it’s gaining popularity among architects and specifiers. Due to its high elastic properties designers use GFRC cladding in solutions where resistance to live loads is necessary.
GFRC cladding systems require high quality standards in manufacture and meticulous record keeping. If you use glass fibre reinforced concrete cladding or panels in your projects. It is important to employ subcontractor or installation crew with GFRC cladding experience. Follow the article below of MILLI TILES for more detailed information about this material!
What is GFRC?
GFRC materials are known in the modern construction industry by many different names: Glass Fiber Reinforced Concrete (GFRC), Verre Cement Mixture (CCV), Fiber Reinforced Concrete. This is a new construction material, produced by injection molding and machine injection from a mixture of fine aggregates: cement, clean sand, clean water, alkali resistant fiberglass and plasticizers. GFRC materials have high durability, diverse shapes, beautiful designs, natural colors… have become materials that play an important role in the economy. Technology and aesthetics of the construction industry worldwide. GFRC is applied in construction works in details such as: GFRC facades, GFRC moldings, GFRC column tops and garden and art decoration products. The fibers serve a purpose similar to the reinforcing steel in reinforced concrete, which is placed primarily in tensile stress areas. Because the glass fibers add flexural, tensile and impact strength, Architectural panels made from GFRC are strong, durable, and lightweight. GFRC cladding are finding wide spread use in the restoration and renovation of historic buildings. And are considered by many to be the best solution available for the repair and replacement of terra cotta tiles that are deteriorating under the influence of time and weather.
Where are GFRC Cladding used?
GFRC cladding are widely use as the exterior facade material in the construction or renovation of many types of commercial and institutional buildings. They are available as wall units, window wall units, spandrel, mullion, and column covers. As well as for fascia panels, soffit, para pets, sunscreens, mansard roofs, and interior feature panels.
Each cladding is custom design for the specific application, and their largest dimension can be either vertical or horizontal. Panels 400 square feet and larger are possible, reducing production, shipping, and installation cost.
GFRC cladding is widely used today for both new building construction and for renovations of existing building facades. In renovations applications. GFRC cladding can often be installed directly over the old cladding with minimal superimposed load on the existing structure, and minimal upset to existing tenants and operations.
GFRC cladding is a new building material, which has more advantages than previous traditional building materials. Using GFRC materials brings practical benefits to investors and construction contractors when building works. So what are the advantages of GFRC material? Let’s learn the advantages of GFRC materials through the following article:
Advantages and Disadvantages of GFRC cladding
Light load
GFRC material is 75% lighter than traditional concrete, which reduces the load on the building, reduces transportation costs and is easy to install.
GFRC cladding have high bearing strength
Compressive strength: 50-80 MPa, Bending strength 20-30MPa as well as having a high strength-to-weight ratio. The GFRC components used to construct lightweight panels are non-flammable minerals. In addition, the face coat of concrete protects against fire and acts as a temperature regulator.
Create a variety of shapes
GFRC molded or injection molded easily creates products with diverse shapes, including complex designs such as: folded, bent, wavy. GRC is suitable for complex architectural styles that require high sharpness and meticulous decoration.
GFRC cladding good durability
GFRC does not have surface cracks, even large products, is waterproof, and is not affected by the impact of the environment. This strength is increasingly being applied effectively thanks to the use of low alkaline cement and puzolan admixture.
Beautiful natural colors
GFRC cladding has a beautiful natural color due to the use of natural sand and the spraying process makes the surface layer without air holes or any voids.
High adaptability
GFRC is highly adaptable, suitable for all architectural styles. GFRC products are widely used in facade decoration, architectural details, interior decoration to garden landscape decoration.
Sustainable, eco-friendly
GFRC uses less cement than conventional concrete and significantly recycled materials are use, so GFRC is very sustainable and environmentally friendly. Due to the fiber coating of GFRC, the alkali-resistant fibers act as extra protection. The resulting panels resist rain, moisture, alkali attack, corrosion, or other environmental issues.
The mechanical properties of GFRC cladding make it ideal for various requirements. However, one potential disadvantage for some users is the cost of GFRC. GFRC cladding can be expensive to use when compared to ordinary concrete. Of course, the added cost comes with additional strength and several other benefits, already mentioned in previous sections.
The Basic Uses of GFRC cladding
There are many applications and projects where glass fiber-reinforced concrete is the ideal choice. Some of these applications are:
Facade GFRC: Facade decorative GFRC cladding have good fire resistance and absolute waterproofing. In addition, GRC façade is less affected by weather, retains its original color and minimizes maintenance costs. Application of GRC facade helps the building keep its beauty over time.
Concrete Countertops: GFRC countertops are becoming more and more common today due to their high aesthetic appeal and crack resistance. Color pigments can make countertops match the required color.
Wall cladding: GFRC wall cladding provides a beautiful look while reducing the overall weight. These panels are long-lasting as well as decorative for home and office interiors.
Concrete Dining Tables: Nowadays, it is common to see concrete dining tables in restaurants and houses. The concrete for these dining tables is GFRC due to its lightweight nature and high sheen. In many cases, integrated countertops and dining tables create a beautiful kitchen island design.
Outdoor Furniture: GFRC is resistant to adverse environmental conditions. Therefore, GFRC furniture, such as tables, benches, and chairs, is an excellent choice for outdoor places like parks.
How are GFRC cladding manufactured?
Glass Fiber Reinforced Concrete (GFRC) is made by using the following materials:
Fine Sand: The fine sand should be 0.4 mm to 0.5 mm, and the accepted range is 0.3 mm to 0.6 mm. Finer particles decrease the flowability of concrete, and coarser particles can be deflect after striking the surface during spraying.
Cement: Ordinary Portland cement is acceptable for making glass fiber-reinforced concrete. The weight of cement is usually equal to the weight of the sand used.
Polymer: There are many types of polymer and concrete matrix mixtures, such as Ethylene Vinyl Acetate (EVA), Styrene Butadiene Rubber (SBR), and Acrylic polymer. Acrylic polymer is the preferred choice for glass fiber-reinforced concrete. The weight ratio of polymer to concrete is usually 6 grams of solid polymer per 100 grams of the cementitious mixture.
Water: The water content in the concrete mix is critical, as too much water can ruin the mixture. It is essential to consider the water content of the polymer mixture to determine the overall water content. The ratio of total water to concrete should fall between 0.30 to 0.35.
Admixtures: Manufacturers produce various admixtures to use in GFRC. Common admixtures are silica fumes and superplasticizer.
Glass Fibers: The addition of chopped-up alkali-resistant (AR) glass fibers is the defining factor of glass fiber-reinforced concrete. The amount of glass fiber will vary based on the type of manufacturing method used, as discussed below.
Sand, cement, polymers, water, and admixtures are also common in other types of reinforced concrete. GFRC is unique in terms of materials because of the addition of glass fibers.
There are three manufacturing methods for Glass Fiber Reinforced Concrete Cladding:
Spray – up GFRC
Spray-up GFRC is the conventional way to create precast concrete panels. In this method, the Glass Fiber Reinforced Concrete is spray into a mold by hand.
A concentric chopper spray gun is use to spray long glass fibers into the concrete mix. The mixing occurs in the gun’s nozzle.
On average, this method contains a glass fiber content of about 5%, a higher fiber content than the usual concrete premix. This method requires skilled labor to be successful, and good quality equipment and quality checks of the work in progress.
Vibration Casting
The defining factor of vibration casting is the use of premix concrete. The premix concrete mixture is poured into a mold. Then the mold is vibrated so that the concrete achieves consolidation.
This method is simpler and cheaper than sprayed GFRC. However, the molds in this method should be water tight. Vibration casting should not be use with rock molds.
Hybrid Casting
Hybrid casting is the combination of spray-up and the use of a premix. A specialized spray head using a peristaltic pump is used to spray the concrete.
Hybrid casting introduces the benefits of spray-up GFRC and vibration casting. While sprayed GFRC requires highly skilled labor, hybrid casting is possible with moderate skill.
Due to using a spray instead of vibrations for the premix, the strength of the resultant concrete panel is higher than the vibration casting methods.
Why should use GFRC cladding instead of precast concrete panels?
Weighing up to 80% less than architectural precast. GFRC cladding materially reduces the weight and cost of the foundation, footings, and structural framing needed to support multi-story buildings. This enables the owner to reduce overall construction costs and accelerate schedules without sacrificing the durability or the architectural aesthetic of precast concrete fabrication.
GFRC cladding does not crack due to the process used for making GFRC. Instead of directly pouring a fluid concrete mixture into a mold. GFRC is spray into the mold by special sprayers. Spraying makes the GFRC more adhesive and resistant to cracking in the short or long term.
How much does GFRC cladding cost?
The cost of GFRC depends on many factors, such as:
Whether you want GFRC precast or GFRC premix. Precast GFRC comes in a ready-to-install form matched to your required shape. In the case of GFRC premix, you will need to hire an expert who can use it correctly. Correct proportions and casting methods are crucial, and the tiniest oversight may ruin the final result.
The GFRC manufacturing method. Hybrid, sprayed, or vibration casting? Hybrid is the go-to choice for most people since it offers a good balance between price and strength.
The thickness and area of the GFRC panels.
The cost of GFRC cladding generally comes as a price per square foot for a given thickness of GFRC. For an accurate idea about how much GFRC will cost youper square foot. The Installation cost of GFRC panels will vary based on the average panel size, accessibility to building connection points, building site location and availability and type of cranes required.
MILLI TILES – Don’t let obstacles stop you from creating creative masterpieces
Milli Tiles – The unit that supplies and constructs GFRC cladding for projects. . If you need strong and lightweight concrete, precast GFRC cladding could be the ideal material for your project. You can contact MILLI TILES to learn about different GFRC products and at the same time we also accept GFRC construction for projects. Please contact us today for advice on GFRC cladding products!
MILLI CONSTRUCTION MATERIAL COMPANY LIMITED
📱 Hotline: 0939 102 568 📞
We will quote a specific % discount for you depending on the quantity or total value of the order
Contact us to order today, to get the best price support.
Instructions for construction of wind cement bricks, you can read and download below:
FILE INSTRUCTIONS FOR Brick Construction, DOWNLOAD HERE
GFRC moulds is key to advancing towards a fully automated and digital process for complex geometry GFRC. Existing mould systems are not sufficiently flexible to meet the demands of today’s requirements. Therefore a new method to produce the mould must be developed
Concrete is used in a wide range of applications. Most construction projects utilize concrete, from the walls and roofs of buildings to thick dams to mind-blowing skyscrapers.
Due to the variety of applications, many different forms of concrete have developed. These concrete forms differ vastly in terms of their physical properties, appearance, usability, benefits, and many other factors.
One of the most popular forms of concrete is Glass Fiber Reinforced Concrete (GFRC). It is a significant improvement over traditional concrete and has been steadily replacing it in countless cases. In order to make products easier and faster to produce, the GFRC moulds with different sizes and designs were born. Aim to best meet the production process.
What is Glass Fiber Reinforced Concrete?
GFRC stands for Glass Fiber Reinforced Concrete. This type of fiber-reinforced concrete contains glass fibers. The concrete matrix binds to these glass fibers, and the addition of glass fibers leads to improved reinforcing and mechanical properties of the concrete and higher tensile strength.
GFRC weigh less than traditional concrete panels but are stronger; hence, their popularity when additional reinforcement is necessary. Therefore, using a thinner GFRC panel instead of a bulkier panel with steel reinforcing bars leads to a saving in space.
Development of a new GFRC moulds system
Generating the GFRC mould is key to advancing towards a fully automated and digital process for complex geometry GFRC. Existing mould systems are not sufficiently flexible to meet the demands of today’s requirements. Therefore a new method to produce the mould must be developed. The method described in Henriksen, Lo, & Knack, (Citation press) only addresses the mould systems using premixed thin-walled GFRC. Therefore a variation has been developement that allows the production of complex geometry thin-walled GFRC using the sprayed method while simultaneously allowing an edge-return.
Advantages of manufacturing GFRC materials by moulds
The production of the new GFRC mould is the first stage of the production process for complex geometry GFRC. This method will enable unique complex geometry-shaped foam to be cast with the possibility of an edge-return that can be used as moulds for GFRC panels. The method enables a faster mould production method for GFRC than the current CNC milling solution and enables the re-use of the flexible table to produce many foam moulds.
While the foam mould replicates the surface generated on the flexible table, it does not allow for an edge-return if a GFRC panel was cast directly onto it. In principle it would be possible to use a silicone band to mark the boundary of the panel but when the fibre concrete mix is spray this would only allow for a panel with a constant thickness and not permit an edge-return that protrudes from the back surface of the GFRC panel.
The new GFRC moulds system allows the concrete to cure for 28 days on a more cost-effective foam mould, rather than leaving it on the flexible table to cure. This leaves the flexible table free to be used to produce further moulds rather than remaining unused during the 28-day curing process.
The process for producing the new GFRC moulds has been patent and contributes significantly to the development of a novel fully automated and digital design and manufacturing process for complex geometry thin-walled GFRC. This would allow the production of panels at a lower cost combined with increased production speed and higher finished surface quality.
Disadvantage of GFRC moulds
The limitation of the GFRC moulds is that it is restricted to the size of the flexible table and that the edge-return must be project from the surface. The next steps will be to test the mould with the GFRC cast on the mould. Additional research must to be done to development the mold system to allow for edge-returns that are normal to the surface. And potentially edge-returns with variable angles to the surface.
Classification of GFRC moulds
Typical formwork in GRC production is usually made from plaster, clay, silicon, plastic, foam or wood. These are the components used to create molds when producing GRC materials. Depending on each products requirements, we have different GRC production molds. The following are commonly used GRC production molds:
Wood moulds pattern: usually used for products with few details or that do not require sharp details such as flat wall panels or panels with few decorative details.
Silicone moulds: often used for products with many intricate and sharp decorative details. To create a silicone mold, we first put the ingredients into the mold, then use a spacer to fix the mixture, and then add silicone or rubber. Often silicone formwork is used to produce reliefs or statues.
Moulds manufactured by CNC cutting technology: made from foam or wood or cut from silicone or rubber. Using CNC cutters, this formwork can produce extremely precise flat panels.
GFRC production moulds help save costs because they produce finished architectural products right from the first time. The products GRC creates are very diverse but uniform to every little detail. In addition, for works that need repair, we can rely on damaged parts to produce suitable formwork. Moreover, the formwork can be reused for subsequent projects, or to be reassembled for a larger architectural product.
How do GFRC manufacturers make GFRC materials?
There are three manufacturing methods for Glass Fiber Reinforced Concrete:
Spray-up GFRC
Spray-up GFRC is the conventional way to create precast concrete panels. In this method, the Glass Fiber Reinforced Concrete is spray into a mold by hand.
A concentric chopper spray gun is uses to spray long glass fibers into the concrete mix. The mixing occurs in the gun’s nozzle.
On average, this method contains a glass fiber content of about 5%. A higher fiber content than the usual concrete premix. This method requires skilled labor to be successful, and good quality equipment and quality checks of the work in progress.
Pros: Allows for very high fiber loads using long fibers resulting in greatest possible strength. Cons: Requires expensive, specialized equipment (generally $20,000 or more).
Vibration Casting
The defining factor of vibration casting is the use of premix concrete. The premix concrete mixture is pours into a mold. Then the mold is vibrate so that the concrete achieves consolidation.
This method is simpler and cheaper than sprayed GFRC. However, the molds in this method should be watertight. Vibration casting should not be uses with rock molds.
Pros: Less expensive than spray-up, although a special spray gun and pump is require. Cons: Fiber orientation is more random than when using spray-up and fibers are shorter resulting in less strength.
Hybrid Casting
Hybrid casting is the combination of spray-up and the use of a premix. A specialized spray head using a peristaltic pump is use to spray the concrete.
Hybrid casting introduces the benefits of spray-up GFRC and vibration casting. While sprayed GFRC requires highly skilled labor, hybrid casting is possible with moderate skill.
Due to using a spray instead of vibrations for the premix. The strength of the resultant concrete panel is higher than the vibration casting methods.
Pros: Affordable way to get start. A hopper and air compressor run about 400$ – 500$. Much less than the spray guns used for spray-up or premix. Cons: Since the face coat and backer mix are applies at different times careful attention is need to ensure the mixes have a similar makeup to prevent curling.
Why should GFRC materials be manufacture using GFRC moulds?
GFRC moulds can be use which reduces cost and fabrication time compared to previous production
A face coat without fibers can be spray to avoid visible fibres in the surface of the panels.
Secondary support structure can be integrated in panel to reduce the GFRC material.
The fiber orientation of the GFRC can be control using the sprayed method.
The thickness of the panel can easily be varied dependent on requirements and local reinforcements.
Support anchors can be sprayed into the panel and reinforced locally.
The GFRC panel can be reinforce locally, adding sprayed fibers perpendicular to the tension stress in the material.
MILLI TILES – RECOGNITION OF GFRC MATERIALS FOR BIG, PRESTIGE, QUALITY PROJECTS
The birth of GFRC moulds manufacturers is extremely reasonable. There are now many builders and architects who are aware of the properties of GFRC and use this concrete mix in their structures. If you need strong and lightweight concrete. Precast GFRC could be the ideal material for your project. You can contact MILLI TILES to learn about different GFRC products and at the same time we also accept GFRC construction for projects. Please contact us today for advice on GFRC products!
MILLI CONSTRUCTION MATERIAL COMPANY LIMITED
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