Ball Consulting ltd

GFRC

How is it used?

GFRC 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 per square 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), terra cotta restoration and replacement, fireplace surrounds, concrete countertops, faux rocks and planters. Without the frame, GFRC will weigh 7-10 lbs per square foot.

For further discussion on GFRC uses and production, click below for the PCI videos.

PCI Video 1
PART 1

PCI Video 2
PART 2

  • Project – Sutardja Dai Hall
  • Project – Stanford GSB
  • Project – San Jose State Univ. Student Housing
  • Project – Fresno Convention Center
  • Project – Joey Restaurant

Glass fiber reinforced concrete (GFRC) was first introduced to the building industry in the early 1970’s in the United Kingdom. Today, it is one of the most popular and innovative building materials used throughout the United States, Europe, Middle East and Asia.

What is GFRC?

It is a composite of Portland cement, fine aggregate, water, acrylic co-polymer, glass fiber reinforcement and additives. 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 the Premix process. The Premix process is further broken down into various production techniques such as spray premix, cast premix, pultrusion and hand lay-up.

For a brief “how to” video on spray premix, click below.


GFRC Spray Premix Video

What are the benefits of GFRC?

  • Highly durable and safe
  • Design freedom since GFRC is able to be molded into almost any shape and color
  • Requires very low maintenance
  • Installation is quick and cost effective
  • Weather and fire resistant
  • Economical
  • Energy efficient


What products are available through Ball Consulting?



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.

For the VF-774 TDS, click here.

The primary benefits of VF-774 are:

  • The elimination of the seven 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

To get the 20 year Durability Paper, click here.

Additional Benefits of VF-774 include:

  • Reduces crazing and drying shrinkage cracks
  • Improved workability of the mix at low water/cement ratios
  • Reduces moisture absorption
  • UV stable
  • Uniform distribution of pigments for batch to batch color consistency

Why should you use Forton VF-774 in GFRC? Click here to learn more


NEG ARG fibers

NEG ARG fibers: alkali resistant rovings, chopped strands and scrims, manufactured by NEG, reinforce the GFRC composites for long-term flexural strength in alkali matrixes and provide impact resistance. The wide range of product configurations facilitates various manufacturing processes.

To learn more about NEG ARG fibers, click here.

VCAS™ 160

VCAS™ 160 is a pozzalon material 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. VCAS™ Pozzolans are “green” construction materials made from industrial by-products that help contribute to the sustainability of cement and concrete, bringing environmental benefits to the concrete operation. The use of VCAS in GFRC also increases the potential contribution towards LEED credits.

To learn more about the use of pozzolans in concrete mixes, click here.

To learn more about VCAS environmental benefits, click here.

For the VCAS 160 Data Sheet, click here.

Qwix™

Qwix™ is a mineral additive used to increase the strength development of GFRC mixes thereby reducing demolding times and increasing productivity. Its use will also improve the physical and chemical properties related to durability.

For Qwix FAQ’s, click here.

Equipment

Ball Consulting, Ltd provides sales support and training for Rimcraft Equipment by FRP Equipment.com. We have a full line of GFRC mixers and sprayers, as well as a Continuous Mixer. For additional information on equipment, click on the link to FRP Equipment.com below or review the Data Sheet for all GFRC Equipment:

FRP Equipment.com

For Data Sheet for GFRC Equipment, click here.

For a complete listing of our GRFC products, call 1-800-225-2673 or email us at info@ball-consulting-ltd.com.