OUTLINE GFRC SECTION, APA HANDBOOK

PART 1 - GENERAL

1.01. Definition

Glass fiber reinforced concrete ( GFRC ) is a composite material consisting of

Portland cement, fine aggregate, water, alkali-resistant glass fibers and additives
which, when mixed in certain proportions and manufactured under controlled
conditions with appropriate equipment, achieves physical properties that allow it
to be used for numerous cladding applications, especially those where weight is a
significant factor in the design.

Although mix proportions can vary widely, extensive research and industry
practical experience has shown that the most typical GFRC mix, consisting of 1
part cement, 1 part sand, a 5% by weight of total mix glass fiber content, a
water/cement ratio of 0.33 and a 5% by volume acrylic copolymer additive, can
produce a composite with significant flexural, tensile and impact strength,
provided it is mixed, sprayed, compacted and cured properly.

1.02. History

The composites were developed in the late 1960=s after pioneering studies at the
Building Research Establishment in England, by Dr A.J.Majumdar, who
successfully produced a glass fiber containing zirconium oxide which was capable
of resisting the alkali attack when mixed with normal hydrating Portland cement.
( Figures 1 and 2 ).

The BRE work was patented by the British National Research Development
Council which approached Pilkington Brothers, a major glass producer, to assist
in the development, production and commercialization of alkali resistant glass
fibers.

By 1971 the fibers were being produced in commercially viable quantities and a
licensing system was in place, ensuring development of the technology with
controlled quality and design standards.

It wasn=t until the late 1970=s that standard specifications were developed and
implemented and by 1980, twelve projects in the USA had been built using GFRC
wall panels.

1.03. References

Attach Aconsolidated@ PCI list.

1.04. Uses
GFRC composites can be designed and fabricated as wall panels, spandrels,
column covers, soffits, architectural ornaments such as cornices, brackets, quoins,
railings, pilasters, copings and trim in general, as well as site furnishings such as
planters, bollards, urns, tables and fountains.

GFRC has also made a significant contribution to historical restorations due to

it=s fine texture, allowing almost perfect replication of building ornaments and
terra-cotta.

In Europe, other uses have been widely developed such as sandwich panels, bus
shelters, noise barriers, permanent and temporary formwork, fire doors and
partitions, cable ducts, floating pontoons and storage tanks.

Other less common uses are sewer pipes, gutters, window and door frames, sun
screens and utility boxes.

The lightweight nature and relative ease of manufacture of GFRC lends it to a

very creative use, allowing the designer the freedom to innovate without
imposing undue burden on the supporting structure and on cost.

Products will normally weigh from 9 to 25 pounds per square foot. Small
ornamental pieces can be installed without the use of lifting equipment and with
very simple attachments, while large cladding panels can be installed with much
lighter equipment and smaller attachments when compared to hard rock precast
concrete units.

1.05. Design

1.05.A. Engineering

The design philosophy of GFRC is similar to that of reinforced concrete with one
major exception. While in conventional reinforced concrete, the amount and
positioning of rebars is determined by design forces and assumed material
properties, in GFRC, since material properties vary depending on each
manufacturers mix composition and processing, the design must be based on
production testing of each manufacturer.

The ultimate strength of a GFRC composite is determined by the presence of the

glass fibers and consequently, it is dependent upon glass content, size,
distribution and orientation of the fibers, degree of cure and compaction of the
fibers within the cement/sand slurry.

Careful consideration must be given to the long term properties of GFRC.

Extensive research has shown that a GFRC composite will lose strength and
ductility over time. Under normal environmental conditions, testing shows that
the aged flexural ultimate strength ( AFU ) is at least equal to the early flexural
yield strength ( EFY ). ( Figure 3 ).

Test data to determine the average 28-day flexural yield strength and the average
28-day flexural ultimate strength of at least 20 sets of coupons ( refer to 1.06
Quality control ), provides the designer with the basic information required to
establish design parameters and load factors.

By limiting design stresses due to factored loads, to an assumed and reduced

aged flexural ultimate strength, sufficient safety factors can be built into the
design. The basic formula is:

fu = Os f=u where

O = 0.75 is a strength reduction factor to allow for variations in material

properties.
s = shape factor assumed equal to 1 for solid rectangular sections and equal to 0.5
for flanged, boxed or I sections.
f=u = assumed aged ultimate flexural strength, determined by statistical analysis
of test results.

Other stresses to be considered by the designer are: tensile, in-plane shear,

interlaminar shear, thermal and moisture induced stresses.

Tensile stresses should be limited to 40 percent of the flexural strength. Shear

stresses rarely control the design but should be checked in highly unusual shapes.

See Table 1 for typical properties of GFRC composites. ( ATTACH COPY OF PCI
TABLE 4, PAGE 18 )

Thermal and moisture induced stresses can be minimized by careful analysis of

Aneutral zones@ and allowing the composite to shrink or expand relative to these
zones without restraint.

Deflection due to handling and in service loads can sometimes impose a minimum
stiffness in the backing frame or ribbing.

1.05.B. Responsibility

As with ordinary architectural precast concrete, design calculations should be

prepared by a registered professional engineer.
It is extremely important that the designer work closely together with the
manufacturer and understand it=s production methods, mix designs and physical
properties. The manufacturer must provide testing data
of it=s particular mix designs to the designer.

Connection design, joint configurations and locations and preparation of erection

and shop drawings is essentially the same as for architectural precast concrete.
Recognition of GFRC limitations is clearly the manufacturers responsibility and
preliminary assistance to the architect / engineer of record is highly
recommended.

1.05.C. Tolerances

Joint tolerances must take in consideration the volumetric changes a GFRC

component will experience during it=s life cycle.

Changes due to initial drying shrinkage, cyclical moisture and temperature

differentials, effects of temperature differences at adjacent surfaces ( shaded and
unshaded portions ) must be accounted for when designing joints, to allow
movement without detrimental stresses.

Normal manufacturing operations and variables require that reasonable

tolerances be established. The appearance of the final installation as well as
economics must be understood by the designer.

Ease of manufacturing and speed of installation are critical factors to be

accounted for when determining product tolerances.

Tolerances should be established by the specifier, within industry accepted

guidelines and the designers are encouraged to consult with local producers on
the practical aspects of specified tolerances.

Unit length, width, depth, thickness, squareness, bowing, warpage and locations
of openings or blockouts, as well as positioning of attachments or back up framing
must be carefully evaluated for each project.

1.05.D. Joints

Joints between GFRC components are typically sealed with elastomeric sealants
such as silicones, urethanes or polysulfides. Sealants must be able to withstand
anticipated joint movement due to volumetric changes within the product and
due to building movement.

Joint design should encourage water to flow away from the joints, protect the
sealant from direct exposure to sunlight and, if economically feasible, provide a
secondary line of defense.
Proper preparation of joints with primers, installation of backer rods and
application of sealant must follow manufacturers recommendations.

For small ornamental components, a 3/8@ to 1/2@ joint width is usually adequate.
Larger units such as cladding panels should be designed to have minimum 3/4@
wide joints.

Certain corner conditions may require larger joints if determined by the designer
that they will be subject to significant building movement. This is especially
critical in seismic zones.

Aesthetics and functionality are the dictates for joint design. Joints within larger
components ( skin breakup ) are required to eliminate or minimize induced
internal stresses. The rule of thumb is that GFRC should not be allowed to extend
more than 20 feet without skin joints.

1.05.E Weathering

GFRC samples have been tested for freeze-thaw resistance under ASTM C666,
Procedure A and have shown good results.

Samples were subjected first to accelerated aging, then to as many as 300

freezing-thawing cycles and finally to flexural testing. Testing was done with
unreinforced mortar samples as well as with glass fiber reinforcement.

Results show that the unreinforced mortar samples severely deteriorated after
200 cycles, while the glass reinforced samples showed minor flaking of the form
side ( normally the exterior side of a product ) after 300 cycles.

Since most cementitious materials would show some degree of deterioration after
such severe testing, the results have led to the conclusion that GFRC performs
quite well under freeze-thaw cycles.

Good design, with proper drainage of horizontal surfaces preventing water from
ponding will make GFRC as good as any other cementitious cladding material, on
freezing environments.

Thermal conductivity of GFRC depends on composite density and moisture

content. Conductivity ranges in the 3.5 to 7.0 BTU/in./hr./ft.2/deg.F.

Permeability of GFRC depends on the matrix characteristics, consolidation and

compaction. It compares favorably to other cementitious materials in laboratory
tests, where GFRC panels have been subjected to water blown under a 75 miles
per hour wind.
Moisture absorption tests indicate an absorption rate in the 8 to 16 percent by
weight range.

1.06. Quality Control

Because the physical properties of GFRC composites are so dependent on each

manufacturer=s raw materials, processes, type of equipment and curing methods,
the establishment of certain minimum standards is essential for proper design.

Fiberglass content, distribution and consolidation within the composite, slurry

mix proportions and degree of curing are the most significant factors affecting
early and ultimate flexural strength properties for design purposes.

There are two different categories of most common tests, which are performed on
a standard quality control program:

1.06.A. Wet composite testing:

Slurry slump test is done at beginning of each shift to assure consistency,

sprayability and workability of each batch. The test is somewhat similar to a
concrete sample slump test in which the mix or slurry is placed inside a standard
size plastic tube, located at the center of a plastic plate engraved with a series of
concentric circles, numbered from 0 to 8, with corresponding diameters varying
from 2.5 in. to 8.875 in.

The tube is then slowly raised, allowing the slurry to flow out over the plate.
Slump value is given by noting to which circle the slurry flows. Three tests are
done with each slurry sample.

Slurry flow rate or bucket test is done at beginning of each shift and measures
the pump flow rate.
Once the pump delivers a steady flow of slurry, the sample material is collected
in a 2 gallon bucket for 15 seconds and weights are recorded.

Glass chopper rate or bag test is done at the beginning of each shift and
measures the output of the fiberglass chopper gun. Material is collected in a
plastic bag for 15 seconds.

Glass content or wash out test is done by cutting out two 4 in.x 4 in. specimens
from a freshly sprayed test board, placing each specimen in a wire mesh basket
for weighing, carefully washing out the slurry until only fiberglass is left, and
then drying fiberglass in an oven for further weighing. Appropriate calculations
are made with the relative weights for determination of glass fiber content.
Unit weight test is done in accordance with ASTM C138 ATest Method for Unit
Weight, Yield and Air Content of Concrete@ by removing slurry sample directly
from the mixer and not consolidating the slurry.

1.06.B. Dry composite testing:

Flexural strength tests are performed in accordance with ASTM C947 AStandard
Test Method for Flexural Properties of Thin Section Glass Fiber Reinforced
Concrete@. Two inches wide coupons cut out from a cured test board, conditioned
in water for 24 hours immediately prior to testing, are subjected to a simple beam
with third point loading method, with appropriate equipment. Calculations are
made of the flexural modulus of elasticity and loads are recorded at point where
the stress-strain graph deviates from linearity ( flexural yield ), and at point
where coupons have no more load carrying capacity ( flexural ultimate ).

Bulk density and absorption tests are performed in accordance with ASTM
C948 AStandard Test Method for Dry and Wet Bulk Density, Water Absorption
and Apparent Porosity of Thin Sections of Glass Fiber Reinforced Concrete@.

Anchor pull off tests are performed at the designer criteria for each type of
anchor, in tension and shear.
Special testing equipment and fixtures are required, capable of applying uniform
loads without eccentricities. Results are recorded and compared to design forces
and assumptions, for determination of adequate safety factors.

PART 2 - PRODUCTS
2.01. Materials

2.01.A. Cement

The most common type of cement used in GFRC composites is a Type I Portland
Cement, conforming to ASTM C150. Type III or other specialized types of cement
can be used provided adjustments in mix composition and proper admixtures are
utilized, to accommodate for different chemistry and fineness.

The manufacturer must select the best type of cement to be used based on color
requirements, it=s equipment capabilities, manufacturing methods and laboratory
test results, to confirm compliance with assumed design parameters.

2.01.B. Aggregates
Fine sand used in a GFRC backing composite should be washed and dried and
free of contaminants or organic matter. It shall conform to ASTM C144 and it
shall be properly graded so as to be sprayable, without constant clogging of the
spray nozzle.

The primary function of fine sand is to reduce shrinkage without significant loss
of strength. Reduced shrinkage minimizes cracking and bowing of the composite.
A 1 to 1 ratio of cement to sand has proved to be the most economical, while
providing ample strength and excellent long term performance.

2.01.C. Water

Water shall be free of deleterious matter, potable or non-potable. Generally,

water from a municipal source is adequate. Water from questionable sources shall
be tested for chemical composition.

2.01.D. Admixtures

Commercially available water reducing agents, superplasticizers, accelerators,

retarders and air entraining agents can be used in GFRC. They shall conform to
ASTM C494 or C260.
Pigments shall conform to ASTM C979 and shall be stable, color fast and
compatible with the cement.
Color admixtures should be ordered in a single lot for the entire job.
Curing admixtures proved to eliminate the need for moist curing, generally
acrylic thermoplastic copolymers shall be used per manufacturers
recommendations.

2.01.E. Facing materials

Course aggregate for facing mixes shall conform to ASTM C33 but generally
should not exceed 3/8@ in particle size. Face mixes must have drying shrinkage
ratios consistent with those of the backing mix, to prevent undue internal
stresses and cracking.

Course face mixes can be sprayed or hand troweled depending on unit shape and
equipment availability.

Thickness control is very critical when using face mixes and thickness tests must
be made after applying each mix layer, to assure minimum thickness of the
structural backing mix. No flexural strength is attributed to the facing mix, for
design purposes.
Stone veneer, thin brick and ceramic tile have been used as facing material. Stone
must be mechanically anchored and a bond breaker used, to minimize bowing and
internal stresses due to differential shrinkage and thermal / moisture movement.

Experience with brick and tile is rather limited and further testing is
recommended.

2.01.F. Reinforcing

Alkali resistant glass fibers containing a minimum 16% of zirconia, designed for
use in cementitious composites, are added to the slurry through the spray gun,
chopping a continuous roving into approximately 1 1/2@ long filaments. These
chopped fibers impart tensile properties to the slurry and control the maximum
loading the composite can withstand, as well as impact resistance and durability.
The fibers add substantial ductility to the composite and to some extent help
control drying shrinkage and thermal movement.
Fibers must be stiffer than the cement matrix, added in sufficient quantity (
generally 5% of mix weight ), be of adequate length uniformly distributed
throughout the composite and well encapsulated by the matrix so as to develop
sufficient bond between the fibers and the cement matrix.
Fibers are randomly distributed in a two directional manner and generally in two
to three layers.

2.01.G. Connection materials

Large units such as wall panels, spandrels and column covers are generally
connected to the structure through a metal frame consisting of light gage metal
studs, structural or ornamental tubes, channels and basically any metal item
required to achieve the necessary stiffness of the overall unit, in order to allow
for stripping, handling, loading, erection and in-service loads, without any undue
stresses to the GFRC skin.

Light gage metal studs must conform to ASTM A446 and galvanized in accordance
with ASTM A525 with a minimum G-60 coating. Other steel parts must conform
with ASTM A36 for open shapes or ASTM A500 Grade B for tubes.

Small ornamental units can be connected with cast in anchors, inserts, straps,
wires or any mechanical fastener designed to withstand anticipated forces.

Occasionally and depending on application, small units can be adhered with

mortar, provided sizes are such that anticipated thermal / moisture movement
will not break mortar bond between GFRC and the substrate.

Final connections to the building are basically the same as for ordinary precast
concrete units and must conform to the same ASTM standards.

2.02. Fabrication
2.02.A. Plant and Facilities

A GFRC fabrication facility must have covered areas for the storage of dry raw
materials and the actual manufacture of GFRC units.

Areas for preparation of molds, back up frames, jigs, hardware, storage and
finishing are basically the same as for ordinary precast concrete products.

Stripping and handling equipment are required for larger units, of such capacity
to safely move product without damage.

An area near production is required for the preparation of test samples and
quality control.

The two most common methods of GFRC manufacturing are spray up and
premix.

The spray up method, which accounts for the largest percentage of GFRC
production, consists of simultaneously depositing a wet cement/sand/admixtures
slurry and the chopped glass fibers, with a concentric spray head or gun, into an
open mold with the desired shape.

Two speed high shear mixers are utilized for the preparation of the wet slurry.
Batches are sized on the basis of a half sack or a full sack of cement, an equal
weight of dry fine sand, water and admixtures in the appropriate proportions.

These wet batches are transferred to a hopper mounted over a screw type
mechanical pump, similar to those used to spray plaster or fireproofing, The
slurry is pumped through hoses into the spray head, where it is atomized
pneumatically. The glass fiber which is normally supplied as a roving, is also
pulled into the spray head pneumatically, running through a chopper and cutting
the roving into predetermined lengths.

By adjusting pump speed and air pressure, a trained operator is able to obtain the
proper proportions of slurry and fiber, in accordance with design parameters and
quality control restraints.

The operator then moves the spray head in back and forth movements into an
open mold, building up the desired thickness with several layers, typically 1/4@
thick. Each layer is then roller compacted by hand, with extreme care so as not to
push fibers through the layer but rather, with the aim of fully encapsulating the
fibers with the slurry and removing entrapped air.
Thickness gauging is performed in several locations, after each layer is sprayed.
The most typical total thickness used is 3/4@. A substantial amount of overspray
occurs around the edges of the form so good housekeeping is a must, in order to
keep work areas safe and relatively clean. A 10% waste factor is common.

Built up edges, blockouts, anchors, stiffening ribs or frame flex anchor pads are
done by hand, generally with the same mix coming out of the chopper gun.

Products are allowed to cure for at least 12 hours but only the experience of each
manufacturer, with it=s unique combination of raw materials, curing methods, air
temperature and humidity as well as wind conditions, can determine the ideal
production cycle. Tests must be performed under varying conditions in order to
determine stripping strength.

The premix method consists of mixing all components, including the pre-chopped
glass fibers into a special mixer and then pouring and vibrating, pressing or slip
forming on the molds. Physical properties of a premix GFRC are generally lower
than those of a sprayed-up GFRC, due to more air being trapped into the mix and
less control over fiber orientation.

2.02.B. Shapes and sizes

One of the biggest advantages of GFRC is it=s relative strength to weight ratio,
which is far greater than that of ordinary hard rock precast concrete.

Weighing between one third and one sixth of typical precast concrete, allows for
larger units to be manufactured without imposing great restraints in handling
equipment. More ornate shapes, with deep reveals, returns and setbacks provides
the designer with much greater flexibility and creativity, and, at the same time
maintaining economic parameters.

The lack of backforming on most GFRC shapes greatly simplifies and reduces the
cost of formwork, as well as time required to reset forms on a daily basis.

Although the spraying of GFRC is more labor intensive and time consuming than
an equivalent precast concrete component, the weight advantages of GFRC bring
economy of scale all the way to the final installation.

There are few restrictions on unit sizes and, as long as the designer has a good
understanding of the material properties, namely shrinking characteristics and
flexural strength, panels up to 40= long can be constructed, provided enough skin
joints are incorporated into the architectural design, and the back up frame is
stiff enough to allow product handling without undue skin stresses.

Limitations imposed by trucking, routing and jobsite access must be evaluated.

The reduced weight of GFRC will allow far more product to be loaded onto the
same truck, as compared with precast concrete. Smaller lifting equipment
generally makes installation easier.

2.02.C. Finishes

As with precast concrete, the most typical finishing techniques utilized in GFRC
components are sandblasting, acid etching, retarding, polishing or smooth
sacking.

The greatest limitation with GFRC is the absence of large aggregates in the face
mix and, although 3/4@ coarse aggregates have been successfully utilized, the
general consensus is that the maximum size aggregate on a face mix should not
exceed 3/8@.

Natural stone veneers can be anchored to the GFRC back up mix with stainless
steel mechanical anchors and bondbreakers. Extreme care must be exercised in
analyzing differential thermal and moisture movement of the GFRC composite
and the natural stone. Stone anchoring shall not allowed to restrain the GFRC
composite.

Brick and tile veneer have been utilized to a limited extent, due to the anchoring
limitations. As long as units are very small, with limited shrinkage and
appropriate thin set mortars are used, then these veneer materials should
present no problem.

2.02.D. Storage and shipping

The reduced thickness of a GFRC composite imposes certain restrictions and

demands extreme care when handling product.

Small units can be placed directly on pallets and moved to a finishing and storing
area. Larger units require far more careful handling, due to the risk of breaking
edges. These larger units should never be allowed to rest directly on the GFRC
skin but rather, should be supported of it=s back up frame.

The engineer must consult with the manufacturer as to it=s storing and loading
process, so as to make sure that the back up frame is stiff enough to carry all
loads imposed by the handling process, without damage to the skin.

The same applies to shipping where special dunnage must be built to prevent
damage to edges of larger units. When resting on the GFRC is the only practical
solution, then proper blocking of the skin to the back up frame is necessary.
Tie downs must also be carefully evaluated to avoid damage to the skin. Packing
materials must be of non staining nature and plastic film wrapping should be
avoided in wet weather to prevent excessive efflorescence.

3. EXECUTION

3.01. Erection

3.01.A. Equipment

Generally, equipment required to erect larger GFRC units is the same as for
conventional precast concrete elements.

Small, ornamental pieces may not even need special equipment and many times
can be installed by hand.

The reduced weight of GFRC units allows the use of relatively light hoisting
equipment such as straps or slings but also imposes careful attention to wind
conditions. As with all other handling operations, care must be exercised in not
stressing unit edges or returns and placing rigging equipment in such positions so
as not to cause units to crack or distort under self weight.

In most cases, units can be picked directly from the steel back up frame, without
the need for special lifting inserts. When this is not possible, picking jigs can be
built to safely lift the units into position or additional framing members can be
added to the back up frame, for the sole purpose of erecting units and may need
to be cut off after installation is completed.

Sometimes it is required to allow holes in the skin for attachment of rigging.

These holes can be patched after installation is complete and should be placed in
inconspicuous locations whenever possible.

3.01.B. Techniques

In general, the techniques involved in the installation of GFRC components are

the same as for ordinary precast concrete units.

Good coordination between the manufacturer, installer, trucker and general

contractor or builder is essential for a smooth and efficient operation.

The basic functions of layout, checking of poured in place embeds or verification

of structure blockouts to receive the product are all necessary. Locating
prewelded or premounted hardware and miscellaneous steel supports, and
making sure these conform with the erection drawings and plan layouts is also
part of a well planned installation.
Units must be temporarily secured into position until final welding, bolting or
grouting is performed.

Alignment of pieces should immediately follow the installation, to ascertain that

the entire installation will conform to the plans and tolerances are not being
accumulated.

Units must be handled in a manner that will prevent soiling or damage.

3.01.C. Safety

GFRC components must be installed in a way that is consistent with their shape,
size, location on the structure, in a safe and workmanlike manner. Only personnel
who are familiar with the unique characteristics of GFRC should be involved in
it=s installation.

Units must be lifted into position with equipment in good working condition.
Rigging must be properly sized to safely secure and move product without undue
stresses on components and without failure at picking points.

3.02. Cleaning and repairs

Stains due to packing materials or handling can generally be removed with

common household cleaning products.

More stubborn stains such as efflorescence or grease can be removed by abrasive

sandblasting or by acid washing with a light solution of muriatic acid, followed by
thorough washing. In either case, a test area should be cleaned prior to
proceeding with general cleaning in order to assure that the intended approved
finish is not compromised.

There can be a vast number of stain or dirt causes and each condition shall be
carefully evaluated by following the cleaning product manufacturers
instructions.

Repairs of damaged edges or minor manufacturing errors must be allowed,

provided they do not compromise the aestethics of the final installation and that
the repair will last the life of the product.

3.03. Warranties
GFRC products shall have a one year warranty against proven defects in material
or workmanship, from the date the product has been accepted by the end user, or
from a formal notice of completion.