Ball Consulting Ltd.-- Forton MG, Polymer Modified Gypsum, gfrc, grc and mold materials

Glass Fiber Reinforced Concrete

Ambridge, PA | Dallas, TX

Orlando, FL | Linden, NJ

Los Angeles, CA

Tempe, AZ | Portland, OR

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Architectural facades, decorative architectural ornamentation, restoration and replication of natural facade materials, standard products, fountains, flower pots, rocks and lower cost housing systems.

Versatility

GFRC is a versatile product and can be combined with various pigments, aggregates and other post-finishing techniques to provide a wide range of custom looks. GFRC can also replicate mold detail and surface textures exactly to accomplish many different architectural styles.

With GFRC's unique casting ability, combined with an integral structural steel stud framing system, Architects and Designers can achieve ornate design detail without a weight penalty to the structural steel framing of new construction or an existing building.

GFRC's lightweight material feature is particularly important in the restoration process where new architectural pieces have to be attached to existing building structures.

Forton VF-774
Forton VF-774 is an all acrylic, co-polymer dispersion (51% solids) specifically formulated for the GFRC production process. It is UV stable in the high pH matrix associated with Portland cements.

The primary benefits of VF-774 are:

The elimination of the seven (7) day wet cure required to achieve the maximum strengths of concrete
Significant improvements in the long-term durability of the GFRC composite, especially the maintenance of the long-term flexural strain to failure property.

Get pdf of 20-year paper

Cem-FIL A-R fibers
Rovings, chopped strands, chopped strand mats and woven meshes, manufactured from Cem-FIL A-R fibers, reinforce the GFRC composites for long-term flexural strength in alkali matrixes and provide impact resistance. The wide-range of products facilitates various manufacturing processes.

Meta Max
Meta Max metakaolin is also available as an additive to the GFRC mix to improve long-term durability of the composite, eliminate efflorescence and improve the surface density when used in the face mix of form finish castings.

Qwix™
Cementitous additive to increase the strength development of GFRC mixes thereby reducing demolding times to increase productivity.

Colors and Textures
GFRC producers have a variety of pigments, aggregates and post-finishing and sealing techniques available to them. The numerous combinations of these variables provide the customer with a wide range of looks and textures from which to choose.

GFRC is a UV stable product with many of the positive features associated with a pre-cast concrete cladding system, but without the weight associated with pre-cast concrete.

It is important to understand the thermal movements and differential stresses built up between the face mix and the back-up mix when choosing the type and size of the aggregate to use in the face mix. Otherwise, warping, bowing, or in the worst case, de-lamination may occur.

Cast product photos by: 1. & 2. Moonlight Molds 3. Clark Pacific

Qwix™ is patented and trademarked by the Ultimax Corp. It is produced under license by the Heartland Cement Co. a wholly owned division of the Buzzi Unicem Corp.