Everything you need to know about GFRC facades

It is always the facades of buildings and houses, especially GFRC facades, that create the appearance of a city. Perhaps the first thing that initially draws your attention to a house or apartment is its facade. Therefore, paying attention to the type of materials used, its design and decoration is very essential for building a structure. The construction and implementation of the facade is one of the most important stages of building a structure. Along with the advancement of technology, progress in the field of facade construction is increasing day by day. The latest technology available in the field of facades and based on concrete is GFRC facades, which in addition to the beauty of the facade, have many advantages in slowing down the erosion process of the building’s exterior facade, preventing energy waste, reducing costs related to the facade, and properties such as resistance to water, fire, etc.

In the past, the facade of the buildings was made of concrete and it had few advantages due to its high weight and also not being resistant to weather conditions. Traditional facades lose their effect over time and suffer from erosion, cracking and even falling; But by using the serious generation of GFRC facade, these problems can be solved. In this article, we will first introduce the GFRC facade and its advantages, and then classify its types. In the next part, we will examine the difference between GFRC and GRS and explain the advantages and disadvantages of GFRC. Finally, we will guide you in the safe purchase of GFRC facade for the building.

GFRC Facade – What is GFRC?

GFRC or GFRC stands for glass fiber reinforced concrete, also known as drywall. It is similar to crushed fiberglass (the type used to form boat hulls and other complex three-dimensional shapes), but with much weaker strength. This technology has been used in the world for nearly half a century; but unfortunately, it has been abandoned in Iran and has not been used much. GFRC. It is a composite consisting of Portland cement, fine aggregate, water, acrylic polymer, alkali-resistant glass fiber reinforcement, and additives.

What are the features of GFRC facade?

GFRC uses concrete fibers and additives to improve the physical, chemical, and mechanical properties of concrete. The correct combination of these materials and the production of a composite with perfect proportion and integrity allows the use of concrete for uneven and curved surfaces. Therefore, facade designers are able to implement their designs without any restrictions. As an engineering material, the properties of GFRC can vary depending on the composition of its constituent materials. The glass fibers used in it have a higher tensile strength than steel. All types of elements made in this way require a mold and no part can be made without a mold. In a typical mix design, the compressive strength is about 8,000 to 6,000 psi.

In GFRC, glass fibers are used instead of steel to reinforce concrete. Since these fibers do not rust like steel, there is no need to protect the concrete coating from rust. With these unique features, these components can be used even in salty and marine environments. Therefore, they are compatible with any climate. Due to the high strength of GFRC, it is possible to produce parts with a thickness of 30.12 mm. Therefore, the weight of GFRC components is much less than traditional precast concrete components. The low weight of GFRC makes it easier, faster and more challenging to implement them on building surfaces. Lighter weight, resistance to tension and bending, water resistance and fireproof; it creates freedom for designers and architects to invent new designs in a variety of colors and textures for use on different surfaces.

Also, the low weight of this product due to its low thickness makes it possible to produce delicate and large parts with diverse and complex designs. Another advantage of prefabricated GFRC parts is the quick repair and replacement of new parts instead of damaged facade components. In many international markets, GFRC is referred to as GRC – Glassfibre Reinforced Concrete. This concrete is a unique and ideal combination for the construction industry.

What is the difference between this concrete and regular concrete?

Replacing steel with glass fibers

The difference between this concrete and conventional concrete is the replacement of steel with glass fibers to improve the tensile strength of the concrete. As a result of this replacement, the density is significantly reduced, and less volume is occupied. Due to the homogeneity of the material texture, the parts have high integrity and durability. The fibers in the composition allow GFRC to be installed in a smaller thickness. So that the thickness of a GFRC concrete piece can be reduced to about 8 mm. Therefore, the facade cladding panel made in this way can weigh up to 7 times less than a prefabricated concrete panel, which is typically about 30 kg per square kilometer.

Much higher flexural and tensile strength than conventional concrete

Glass fiber reinforcement results in a product with much higher flexural and tensile strength than conventional concrete, allowing it to be used in thin-walled applications. It also does not require reinforcement structures. GFRC is a lightweight and durable material that can be cast into almost unlimited shapes, colors, and textures, making it a great choice for high-rise building facades. It is also particularly useful in urban furniture and dome cladding due to its high strength, ductility, and light weight.

Greater adaptability to environmental conditions

According to numerous laboratory studies on the durability and longevity of GFRC, and in conditions that are fully compatible with environmental conditions, it is seen that GFRC performs well in many environments, such as exposure to salt spray or high humidity. Since the surface of GFRC is impregnated with a special polymer, cracking, abrasion and corrosion are not seen on the facade surfaces. In fact, the durability and resistance of GFRC to hurricanes, floods, fires and earthquakes have been proven in the laboratory as well as in many projects.

Thermal and acoustic insulation

If a building facade made of GFRC is exposed to fire, it does not burn, but acts as a fire regulator and protects the building surface behind it from flames. Compared to conventional concrete, it is less susceptible to weathering and erosion in various atmospheric conditions and has a higher resistance to freezing. It acts as a sound and thermal insulator and due to the high quality control of the components, the finished facade has minimal destruction and waste of building materials. The environmental impact of GFRC is much lower than that of concrete, stone or other traditional materials and is very environmentally friendly.

Ingredients of GFRC

Cement

The cement required is similar to other types of cement, and the volume of cement can be reduced by adding the maximum percentage of pozzolan.

Sand

The sand used in this concrete is natural, wind and silica sand or a combination thereof, which is determined according to the piece. Silica sand is used mainly in the construction of these pieces for better resistance and more beautiful appearance. The sand must be rounded and washed. Its dimensions vary from 0.1-0.05 mm depending on the piece. Depending on the design of the piece, up to 30% of the volume of silica sand can be washed sand of 5 mm.

Fibers

Glass fiber maintains its properties at high temperatures, has good strength and stiffness, good mechanical properties, good resistance to moisture and corrosion, and is relatively inexpensive. The six types of glass fibers are divided into the following:

• General E-glass uses
• Higher mechanical properties of R-glass
• Higher mechanical properties of S-glass
• C-glass chemical resistance
• Good acid and alkali resistance ECR-glass
• Good acid and alkali resistance AR-glass

The fibers required in GFRC are glass fibers. The latest generation of glass fibers are Ar-Glass. Glass fibers are used in a chopped (Chopped) surface. The length of the fibers varies according to the design and dimensions of the part.

The most important applications of GFRC

GFRC can be used to make columns and pillars, domes, decorative ceilings and walls, sculptures, railings, decorative pieces for interior and exterior decoration of buildings, as well as in the construction of marine structures such as docks and floating bridges, channels for cable laying, water channels, storage tanks and more.

Types of GFRC implementation methods

Two different methods are commonly used to apply GFRC to building facades: spraying and pre-grouting. Let’s take a quick look at both cost-effective composite methods.

Spraying

Spray-up for drywall is a process that is very similar to shotcrete, as liquid concrete slurry is sprayed into the formwork. In this process, a special spray nozzle is used to apply and spray the liquid concrete slurry and simultaneously cut and spray the glass fibers. Before application, the glass fibers are sprayed from one side and the slurry from the other. The fibers are cut as they enter the spraying machine. Spraying this way creates very strong GFRC, but the equipment can be a bit expensive to purchase.

Manual spraying is the most versatile and popular production technique and is the method usually chosen by start-up companies. A special spray nozzle is used to simultaneously spray crushed glass fibers and cement slurry onto the formwork. The mortar is then compacted by hand using a spring roller, followed by a second layer sprayed and compacted again. The resulting piece will be a composite with a good distribution of fibers and concrete. Using the spray method allows for the use of a high percentage of glass, which gives the facade the highest mechanical properties. This in turn also allows for the thickness of the facade surface to be reduced.

Benefits of implementing GFRC facades by spraying method

• The use of long fibers provides the maximum possible strength for parts made in this way.

Disadvantages of implementing GFRC facades by spraying method

• It requires expensive and specialized equipment, which means that despite the high quality of the parts, it does not have many fans.

Premix

The premix method means premix. As the name suggests, glass fibers are mixed into the cement slurry and then the resulting material is pumped into various molds. The mortar is then compacted after being placed in the molds. Unlike the spray method, premix does not require a fiber cutter, but it can still be a costly method due to the spraying of the glass fiber and concrete mixture.

In the premix method, spraying can also be used, but due to the short nature of the glass fibers, the fibers are no longer cut by the machine. Premix is ​​a special GFRC slurry that can be poured into a mold and compressed without the need for mechanical intervention. The premix process is often chosen for standard product production. The molds used in this method are more complex than spray molds and allow for a more optimized design. After the parts are manufactured in this way, they are placed in a temperature and humidity controlled environment until they are applied to the surfaces.

Advantages of implementing GFRC facades using the premix method

It is less expensive than the spraying method, although a special spray nozzle and pump are still required.

Disadvantages of implementing GFRC facades using the premix method

The orientation of the fibers is more random than using a spray, and the fibers are shorter and therefore less resistant.

Using a combined facade and grout method

One final option for creating GFRC is to use a hybrid method that uses a low-cost nozzle to apply the face coating and the molded grout. In the Sprayed Premix hybrid method, the grout is sprayed onto the mold. This combination combines the advantages of both the Hand Spray and Cast Premix methods and is becoming the primary choice for many small architectural projects. This is a cost-effective method to start with, but it is important to carefully create the face and back grout to ensure similar consistency and consistency.

Advantages of implementing GFRC facades using a combined method

It is a cost-effective way to get started. In this method, the cost of a hopper and air compressor will be much less than the spray nozzles used for spraying or premixing.

Since the facade surface grout and backer coating are applied at different times, careful attention must be paid to ensure that the grouts have a similar arrangement and order to avoid a disorganized appearance of the facade.

Benefits of drywall or GFRC facade for buildings

Glass fiber reinforced concrete has the characteristics mentioned earlier, including the following:

Optimal materials

The production of GFRC panels produces less waste and scrap than prefabricated panels. They also use fewer natural resources in their manufacture. Since the construction is completed in-house, there is little waste generated on the job site.

Possibility of implementation at any level

GFRC facade coverings can be applied in any position and can be easily applied to walls, ceilings, etc.

Weather and wind resistant

GFRC panels have a high degree of resistance to air and wind corrosion. Since the fibers are discontinuous, macroelectrolytic cells do not form. Therefore, the corrosion rate is remarkably reduced.

Fire resistant

GFRC is made from non-combustible materials, and its fireproofing is now a very important feature in the safety of a structure. Concrete acts as a thermal regulator in contact with fire. To resist thermal stress, a fireproof coating will be incorporated into the interior of the panel or as a layer between two GFRC layers. The joints between GFRC sheets are typically filled with silicone sealant.

Optimal environmental performance

In many environmental conditions when exposed to salt or moisture, GFRC usually performs optimally due to the lack of steel reinforcement.

Suitable weight

GFRC is 75% to 90% lighter than plain concrete, thinner and stronger. The weight reduction greatly contributes to easy and quick installation and on the other hand reduces the load on the structure. The light and stiff material also reduces transportation costs. It also allows for flexibility in design and reduces the impact on the environment. On the other hand, it increases the capacity to withstand seismic loads due to its better resistance.

Freeze resistant

GFRC is less vulnerable to weathering than other facades and more resistant to freeze-thaw than conventional concrete.

Suitable for both interior and exterior facades

GFRC/GRC is lightweight, dense, and durable, making it easily one of the best materials for building any type of interior architectural structure.

Nano insulation

Another advantage of dry facades is nano insulation. For information about what nano insulation is, you can visit the Klar website.

 

Disadvantages of using GFRC:

• In this facade coating, there is a possibility of corrosion of iron fibers.
• Their installation requires a separate anchor system.
• The larger the GFRC panels are made, the greater the reinforcement requirements for the facade installation.
• Its color additives may fade in sunlight.
• Some disadvantages, although few, of FRC are
• The fibers in concrete make it very rough, which may make it a little difficult to install.
• The fibers may not be evenly dispersed, which is not an ideal characteristic and results in a lower quality of concrete.
• Rough concrete may require a higher water/cement ratio due to the fibers, which is again not ideal.
• When using GFRC, a lot of planning is required for transportation as it is built on site prior to recovery.
• Although cheaper than many materials used in construction, GFRC is still more expensive than concrete.

What is the difference between GFRC and GRC?

When looking for the architectural components needed to build your desired drywall, you may come across two separate terms that seem to refer to similar products:

• GFRC
• GRC

When determining the type of coating to use, it is natural to get confused between the different terms. In this section, we will examine the two terms GFRC and GRC. What is the difference between GFRC and GRC? The difference between GFRC and GRC is actually nothing. They both refer to the same material. The reason for the two separate acronyms is because of variations of the term “fiberglass”:

• Reinforced Cement (Glassfibre GRC)
• Glass fiber reinforced cement or GFRC

In the construction industry, instead of using the full term, these abbreviations are used because the product is often known internationally only by its abbreviated name. Since both materials are the same, both are defined as safe and standardized cement, water, glass fibers and other chemicals. Fiberglass is also alkali resistant (AR) which increases its lifespan and is very suitable for use in concrete.

GFRC manufacturers

Preparing and installing GFRC facade covering for a building is a specialized skill. The amount of ingredients required to cover a durable and standard facade of a building, as well as the high efficiency of dry facade spraying devices on the building surface, is one of the most important concerns of fans of this facade. Also, these days, it is very difficult to buy from a reliable place that has standard and quality products and at the same time has a more reasonable price than other sellers. In this article, we will help you to experience a safe purchase. With the help of reputable sales sites, customers can become more and better acquainted with the quality specifications of GFRC facade implementation devices, review and compare prices, and finally choose the best product for purchase, considering all aspects.

Kalar Machinery

Kalar Machinery started its professional activity with its group of experts and engineers in 1995. This company is very specialized in manufacturing molds, parts and mortar spraying machines of various types. Among the mortar spraying machines are cement spraying machines, plaster spraying machines, GFRC spraying machines, fireproof plasters, grout injection, etc. . You can also contact the experts on the Klar website to receive guidance and advice on how to purchase and use or select machinery appropriate for the intended use. After purchasing each machine, Klar’s manufacturing engineers will fully train the buyer on how to use the machine and will also answer any possible questions.

GFRC facade price

The price of dry facade or GFRC (GFRC) depends on many factors, including the method of execution of the facade, the quality of the manufactured parts, the volume of the elements, etc., to get the prices of the elements you want, you can contact the consultants of the Klar machinsazi website.

In this article, we tried to provide you with comprehensive and complete information about GFRC. Introducing the newest building facade that has many fans in the world. This dry facade is the most advanced facade used in the present era, which is much lighter than concrete, and its countless advantages, including the beauty of the facade, high resistance to natural factors and fire, etc., make the use of this facade very economical for builders. On the other hand, due to the bending and lightness of this facade, architects and designers have no restrictions in designing this facade and can implement all their plans.