Facade GFRC - The beauty of the soul of modern projects

What is GFRC concrete? Why you should be using GFRC for your concrete projects?

by Kate Eve | Aug 22, 2023 | Facade GFRC, Uncategorized, What is GFRC concrete?

What is GFRC concrete? If you aren’t yet familiar with glass fiber reinforced concrete (GFRC), you should be. GFRC is a specialized form of concrete. It’s a cement-based composite material reinforced with alkali-resistant glass fibers.

The fibers serve a purpose similar to the reinforcing steel in reinforced concrete, and they also add flexural, tensile and impact strength. As a result, GFRC can be used to produce strong, lightweight architectural concrete products such as building panels.

It can also be used to create decorative concrete products such as facade wall panels, fireplace surrounds, vanity tops and concrete countertops due to its unique properties and tensile strength. Most concrete countertop professionals use GFRC as their technique of choice due to its versatility, strength and lighter weight.

One of the best ways to truly understand the benefits of GFRC is to take a deeper look into this unique compound.

What is GFRC concrete?

GFRC stands for Glass Fiber Reinforced Concrete. It is a composite comprised of Portland cement, fine aggregate, water, acrylic co-polymer, alkali resistant glass fiber reinforcement and additives. In many international markets, it is referred to as GRC – Glass fibre Reinforced Concrete. The glass fibers reinforce the concrete, much as steel reinforcing does in conventional concrete. The glass fiber reinforcement results in a product with much higher flexural and tensile strengths than normal concrete, allowing its use in thin-wall casting applications. GFRC is a lightweight, durable material that can be cast into nearly unlimited shapes, colors and textures. There are two basic processes used to fabricate GFRC – The Spray-Up process and Premix process.

It was first created in the 1940s in Russia, but it wasn’t until the 1970s that it became popular in the mainstream.

There are many benefits to using GFRC, including:

It can be used to construct lightweight panels as it can be made thinner and lighter than traditional concrete
It has a high tensile strength
It is more flexible than traditional concrete
It is resistant to cracking
It is extremely durable and can outlive steel-reinforced concrete
It requires very little maintenance
It is resistant to climate changes and fires
It is cost-effective

Let’s find out specifically with MILLI TILES about the benefits of GFRC concrete

Some Reasons to Love GFRC

It’s lighter than precast concrete.

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 sustained than cement, the weight savings is even greater. Although the relative density is similar to concrete, GFRC panels can be much thinner than traditional concrete panels, making them lighter.

Precast is typically made 1.5″ thick and weighs 18 pounds. 3/4″ thick GFRC weighs 8 pounds per square foot.

What is GFRC concrete? Is it really thin?

The effective minimum thickness for precast is 1.5″ because of the strength and the steel reinforcing required. GFRC is practical limit is only about 1/4″.

You can work fast with it.

Because GFRC has high early strength, in part provided by the fibers, it can be demo quickly. Most GFRC projects can be demo in 24 hours. In general, traditional precast projects should stay in the molds at least a couple of days. Faster turn around means you can do more projects and bring in more revenue.

There’s less likelihood of cracking compared to precast.

Because of GFRC’s strength and toughness, it can take a lot more abuse before it cracks. GFRC can even bend. The high dose of glass fibers leads to high tensile strength while the high polymer content makes the concrete flexible and resistant to cracking. Proper reinforcing using scrim will further increase the strength of objects and is critical in projects where visible cracks are not tolerable.

What is GFRC concrete? 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.

What are the components of GFRC concrete?

To better understand what GFRC concrete is and what it can be used for, it can be helpful to find out what this type of concrete is made up of.

Cement

Portland cement is the most commonly used cement for making GFRC concrete. It is available in white and grey. Grey Portland cement should be avoided if you want to add colour as the dark grey pigment is hard to overcome. Overall, white cement is the better option, but it is more expensive than grey.

Silica sand

Silica sand, often referred to as industrial sand, is the perfect type of sand for GFRC concrete as it helps to prevent blockages and delivers less abrasion to the equipment. It is worth noting that this type of sand can be difficult to find, although your local masonry should have some in stock.

Do not use basic playground sand, as this will clog up your equipment.

AR glass fiber

AR (alkaline resistant) glass fiber has been used in GFRC concrete for decades due to its durability and alkaline-resistant which is a result of adding zirconia to the glass. These fibers are often used for countertops, fireplace surrounds, and other decorative applications.

AR glass fiber is available in chopped strands, in a ball of twine known as roving, and as scrim, which is a grid-like pattern that is sold on a roll.

Water

When it comes to how much water to add to GFRC concrete, the less water you use, the stronger the concrete. Typically, spray-up GFRC has a low water-cement ratio. The water you use should be free from contaminants and as clean as possible.

Forton VF – 774

Forton VF-774 is an acrylic, co-polymer dispersion that has been specially formulated for GFRC concrete. It is also designed to be able to remain stable and durable when combined with the high PH levels of Portland cement.

Other benefits of this key component of GFRC concrete include easy spraying on vertical surfaces, UV stability, and the elimination of spider cracking and crazing.

Plasticizer

A plasticiser is a chemical compound that enables the production of concrete with roughly 15% less water content. You can also find super-plasticisers that reduce the amount of water needed by up to 30%.

Plasticisers are also used to retard the curing of concrete.

Pigment

Concrete pigment is a dry powder that is used to add colour to GFRC concrete. The more pigment you use, the more intense the colour. Typically, a 5% dosage is added. Pigments are available in a wide range of colours.

What is GFRC concrete? Why should GFRC mix designs?

The GFRC mix design basically refers to the ratio that the components are mixed at. There are two different GFRC mix designs that you can choose from:

What is GFRC premix concrete?

This is by far the most common GFRC mix design and is suitable for both small and medium-sized users. The premix process involves spraying through a hopper gun, with the back mix added by hand.

Premix is a much cheaper option than spray-up, although a special spray gun and pump are needed. However, fiber orientation is more random, and the fibers are shorter, which results in less strength.

What is GFRC spray – up concrete?

This GFRC mix design process is far less common and is mostly used by high-end producers who use large volume spray equipment. The spray-up process is typically used for very large architectural panels and provides a higher glass percentage.

On the plus side, spray-up allows for very high fiber loads using long fibers, which results in the greatest possible strength and durability. However, the specialised equipment needed is expensive, typically over $20,000.

How to make GFRC concrete

The process of making GFRC concrete is simple but must be follow in the correct order to avoid a lumpy end product. You can make GFRC concrete in a standard concrete mixer but for optimum results, opt for a high shear mixer that has been specifically design to make GFRC concrete.

If you want to know how to make GFRC concrete or how to make GFRC panels, follow the below steps:

Weigh or batch all materials
Add all the liquids, including the Forton VF-774 and 2oz of plasticiser, to the mixer
Start the mixer on slow – 300-500 rpm
Add pigment if colour is desired
Add the silica sand
Add the Portland cement and increase the mixer speed to high – 1,000-1,800 rpm
Mix on high for 1-2 minutes
Add the remaining plasticizer to achieve the desired consistency
Reduce the mixer speed to slow and gradually add the Premix fiber until fully dispersed

Once you have added the fiber, you must not mix for too long or tattoo high a speed as this can damage the fiber, resulting in placement issues and/or reduced strength.

Casting, spraying & curing GFRC concrete

Casting

For casting GFRC concrete, pour the mixture into a single spot at the lowest point of the mould and allow the mixture to seek its level. After casting, consolidate the slurry and remove any entrapped air using either a hand vibrator or vibrating table.

Spraying

Spraying can be use for both higher volume smaller parts and lower volume applications.

For higher volume – GFRC slurry can be sprayed into molds using rotor/stator or peristaltic pumps that are specifically designed for GFRC. Whichever spray pump you use, a face coat without fiber is typically applies first. Once this has stiffened, a fiber backup mix is applies in multiple passes, with compaction between each pass.

For lower volume – A hopper gun can be used to apply face mix, and then the GFRC backup mix is applied by hand.

Curing

After placement, you should cover GFRC concrete with a plastic tarp or sheet in to prevent moisture loss and to maintain the heat of hydration. Allow the concrete to cure in the mold for between 12-16 hours. Curing temperatures should be maintained above 50°F/10°C in order to ensure proper film-forming of the Forton VF-774.

What is GFRC concrete use for?

GFRC concrete is used in the below construction works:

Building renovations
Water and drainage works
Bridge and tunnel lining panels
Permanent formwork method of construction
Architectural cladding
Acoustic barriers and screens

It is most commonly used in exterior cladding. However, due to its strength, flexibility, and chemical properties, GFRC can be used for a wide range of applications.

As it can take the form of pretty much any shape or size, GFRC concrete can be found in architectural features such as moldings and landscapes. It can also be used for modular buildings, as well as walls, roofs, floors, and foundations.

In the engineering sector, GFRC is used to construct bridges, tunnels, and drainage.

It is also used as ornamental concrete to create items such as fountains, statues, domes, and planters.

Most recently, decorative concrete artisans have started to use GFRC concrete to create decorative panels such as fireplaces, countertops, and artificial rock work.

MILLI TILES – ENHANCED VALUE OF MODERN CONSTRUCTION ARCHITECTURE

Glass fiber reinforced concrete is lighter, faster, and stronger than traditional precast concrete.

It can be use to create almost anything that traditional concrete can, and it has the added benefit of more aesthetic options for users.

Whether you opt for the spray-up option, which uses a liquid concrete mix that sprays glass fibers, or you go for a premix in which the liquid concrete is poured into molds, glass fiber reinforced concrete is suitable for a variety of different projects and guarantees a superior finish.

Please contact us to answer any questions about Glass Fiber Reinforced Concrete GFRC need advice.

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Facade GFRC – Application of GFRC concrete facades in modern construction architecture

by Kate Eve | Aug 22, 2023 | Facade GFRC, GFRC panel, Uncategorized

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.