1 :

.1.I,It: :
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IlL 1 1.11.1 •
Recommended Practice
for
Glass Fiber Reinforced
Concrete Panels
Fourth Edition
prepared by

PCI COMMITTEE ON GLASS FIBER

REINFORCED CONCRETE PANELS
F William Horsley Chairman
-

TASK GROUP ON RECOMMENDED PRACTICE

Edward S. Knowles Chairman
-

Hiram P. BalI, Jr. Dushyant Manmohan

Sidney Freedman Ray A. McCann
Kim R. Hammon Edwin A. McDougle
Thomas J. Hill Henry J. Molloy
F William Horsley Ivars Renemans
John Jones James E. Tolson, Jr.
Edward S. Knowles Robert E. Tysinger

This Recommended Practice provides information on the planning,

preparation of specifications, design, execution and supervision of
the manufacture and installation of glass fiber reinforced concrete
panels. Primary emphasis is on thin-walled architectural panels
made of glass fiber reinforced concrete by the spray-up process
under controlled factory conditions.
 MNL-1 28-01
Copyright © 2001
Precast/Prestressed Concrete Institute
All rights reserved. This book or any part thereof may not be
reproduced in any form without the written permission of the
Precast/Prestressed Concrete Institute.

Substantial effort has been made to ensure that all data and
information in this Recommended Practice are accurate. However,
PCI cannot accept responsibility for any errors or oversights in the
use of material or in the preparation of engineering plans. This
publication is intended for use by professional personnel competent
to evaluate the significance and limitations of its contents and
able to accept responsibility for the application of the material it
contains. Special conditions on a project may require more specific
evaluation and practical engineering judgment.

ISBN 0-937040-67-3
Printed in U.S.A.
 CONTENTS

GLOSSARY V 4.12 Acoustical Properties

4.13 Density
CHAPTER 1 INTRODUCTION
— 1 4.14 Thermal Properties
1.1 Scope 4.15 Permeability
1.2 General Description 4.16 Moisture Absorption
1.3 Historic Development 4.17 Property Summary
1.4 Plant Certification
1.5 Applications and Advantages CHAPTER 5— DESIGN 17
1.6 Building Codes 5.1 Scope
1.7 Types of GFRC Panels 5.2 Background
5.2.1 Design Philosophy
CHAPTER 2— PROJECT RESPONSIBILITIES 4 5.2.2 Panel Stiffeners and Methods of Support
2.1 Responsibilities Design Loads
5.3
2.2 Contractual Responsibilities 5.3.1 Panel Service Loads
2.3 Design Responsibility 5.3.2 Load Factors and Combinations
2.4 Resposibilities of General Contractor/Construction
5.4 Limiting Stresses (Strength)
Manager
5.4.1 Flexure
CHAPTER 3— MATERIALS 6 5.4.2 Shear and Tension
3.1 Face Mix and GFRC Backing Materials 5.5 Deflection
3.1.1 General 5.6 Panel Types
3.1.2 Cement 5.6.1 Panel Layouts
3.1.3 Facing Materials 5.7 Panel Frame System
3.1.4 Sand for GFRC Backing 5.7.1 Skin Design
3.1.5 Mixing Water 5.7.2 Anchorage of Skin to Panel Frame
3.1.6 Admixtures and Curing Agents 5.7.2.1 Flex Anchors
3.2 Reinforcement 5.7.2.2 Gravity and Seismic Anchors
3.2.1 Alkali Resistant Glass Fiber 5.7.2.3 Anchor Evaluation
3.3 Panel Frame and Hardware 5.7.2.4 In-Plane Anchor Restraint Stresses
3.3.1 Panel Frame 5.7.2.5 Out-Of-Plane Restraint Stresses
3.3.2 Anchors and Inserts 5.7.3 Panel Frame Design
3.3.3 Handling and Lifting Devices 5.7.4 Connection of Panel Frame to the
3.3.4 Connection Hardware Building Structure
3.4 Integral Rib Formers 5.8 Inserts and Embedments
3.5 Welding 5.9 Finishes One and Two Material Skins
--

3.6 Joint Sealants and Backer Rods 5.10 Facing / Backing Interaction
3.7 Coatings 5.11 Joints
5.12 Condensation Control
CHAPTER 4— PHYSICAL PROPERTIES 9
5.13 Architectural Details
4.1 Factors Affecting Physical Properties
4.2 Tensile and Flexural Strengths CHAPTER 6—TOLERANCES 35
4.3 Modulus of Elasticity 6.1 General
4.4 Compressive Strength 6.2 Product Tolerances
4.5 Impact Resistance 6.3 Erection Tolerances
4.6 Shear Strength 6.4 Interfacing Tolerances
4.7 Shrinkage and Other Moisture-Induced
Movement CHAPTER 7— MANUFACTURING 41
4.8 Thermal Movement 7.1 Panel Manufacture
4.9 Creep 7.2 Plant Facilities
4.10 Freeze-Thaw Resistance 7.3 Molds
4.11 Fire Endurance 7.4 Proportioning and Mixing
4.11 .1 Joint Treatments: One-Stage Butt Joints 7.4.1 Face Mix
4.11.2 Fire Safing 7.4.2 GFRC Backing Mix
I. 7.5 Spray Application of Mist Coat Appendix G — Facing I Backing Interaction
7.6 Placing and Consolidating of Face Mix Stress Analysis Ratio
- -

7.7 Spray Application of GFRC Backing Coefficients 76

7.8 Surface Finishes
I .
7.8.1 Mist Coats Appendix H — Combining Load Factors and
7.8.2 Face Mixes Limiting Stresses 77
7.8.3 Veneers
7.8.4 Coatings Appendix I — Alternate Cementitious Systems
7.9 Panel Frame For GFRC Panels 78
7.10 Curing
7.11 Stripping Appendix J — Premix GFRC 79
7.12 Cutting and Grinding
7.13 Handling Appendix K — Specification for AR Glass
7.14 Yard Storage Fiber 82

CHAPTER 8—QUALITY CONTROL 48 Appendix L — Specification for Polymer

8.1 General Curing Admixture 83
8.2 Acceptance Testing of Materials
8.3 Preproduction Testing GUIDE SPECIFICATIONS 84
8.4 Production Testing of Aggregates Part 1 GENERAL
8.5 Production Testing Wet — 1.1 Related Documents
8.6 Production Testing After Curing 1.2 Summary
8.7 Inspection 1.3 Definitions
1.4 Performance Requirements
CHAPTER 9— LOADING AND DELIVERY 51 1.5 Submittals
1.6 Quality Assurance
CHAPTER 10— INSTALLATION 53 1.7 Delivery, Storage, and Handling
10.1 Coordination Part 2 PRODUCTS
10.2 Erection 2.1 Manufacturers
10.3 Connections 2.2 Mold Materials
10.4 Protection of Work 2.3 GFRC Materials
10.5 Acceptance 2.4 Anchors, Connectors, and Miscellaneous
10.6 Patching and Repair Materials
10.7 Cleaning 2.5 Panel Frame Materials
10.8 Joint Sealing 2.6 GFRC Mixes
10.8.1 Width of Joints 2.7 Panel Frame Fabrication
10.8.2 Sealant Installation 2.8 Mold Fabrication
10.9 Sealers Clear Surface Coatings
- 2.9 GFRC Fabrication
2.10 Fabrication Tolerances
REFERENCES 59 2.11 Finishes
2.12 Source Quality Control
Appendix A — Students t 63 Part 3 EXECUTION
3.1 Examination
Appendix B — Limiting Stress Determination . . .64 3.2 Erection
3.3 Erection Tolerances
Appendix C — Integral Rib Wall Panel - 3.4 Repairs
Wind Stress Analysis 65 3.5 Cleaning and Protection

Appendix D —Panel Frame I Skin -

Wind Stress Analysis 68

Appendix E — In-Plane Anchor Restraint -

Skin Stress Analysis 69

Appendix F — Facing I Backing Interaction

Stress Analysis
- 71
 Glossary

A (Aged)* One of two general ages in the life of GFRC

- Chopped glass Non-continuous multi-filament glass
-

composites. No specific time interval is intended (unless fiber strands; it is chopped from roving in the spray-up
otherwise indicated). It is a general term associated with process.
GFRC composite properties after the time-dependent Cladding panel A light weight non-structural GFRC pre
-

changes discussed in Sections 4.2 and 5.2 (usually, but not
always, modified by F or T and Y or U).
Admixture A material added to modify the properties of
-
fabricated building component produced by the spray-up
process for use as an exterior wall panel.
Clearance Interface space (distance) between two items.
-

mortar or cement slurry.

Compaction The process whereby the volume of the face
-

Air Permeability The rate of air flow through a material;

mix or GFRC backing is reduced to the minimum practical
-

commonly expressed in perm-inches.

volume by the reduction of voids usually by vibrating,
Alkali Resistant (AR) Glass Fiber Fiber made from -
tamping, rolling or some combination of these.
glass having a high zirconia (minimum 16%) content for
Composite A material obtained by combining two or
mulated to improve resistance to attack by aqueous alka
-

more materials; but so interconnected that the combined

line solutions.
components act together as a single member and respond
Ambient temperature The temperature of the air sur
-
to load as a unit, e.g., GFRC.
rounding an object.
Connector (Connection) Device for the attachment of
-

Anchor- Devices for the attachment of the skin to the

GFRC units to each other or to the building structure.
panel framing system; includes the flex, gravity and seis
mic anchors. Coupon Specimen for testing.
-

Artificial Aging A condition to which test specimens are

-
Crazing A network of fine cracks in random directions
-

subjected in order to simulate their exposure to natural breaking the surface of a panel into areas of 1/4 to 6 in. (6
weathering; the intent is to accelerate any aging effects. to 152mm) across.
(See Ref. 1, Appendix F, Test 10). Creep The time dependent change in dimension or shape
-

Attachinents Term which includes both anchors and con

- caused by a sustained load.
nections. Curing The maintenance of appropriate moisture and
-

Backing The GFRC mix deposited into the mold after the
- temperature of freshly placed face mix and backing during
face mix or veneer has been placed and consolidated. some definite period following placing, spray-up, or finish
Blocking Materials used for keeping GFRC elements
-
ing to assure satisfactory hydration of the cementitious ma
from touching each other or other materials during storage terials and proper hardening of the skin. When the curing
and transportation. temperature remains in the normal environmental range
Bondbreaker A substance placed on a material to pre
-
[generally between 60 and 90 deg. F (16 and 41 deg. C)] it
vent it from bonding to the GFRC, or between a face mate is considered normal curing; when the curing temperature
rial such as natural stone and the GFRC backing. is increased to a higher range [generally between 90 and
120 deg. F (41 and 50 deg. C)] it is considered accelerated
Bonding agent A substance used to increase the bond be
-

curing.
tween an existing piece of GFRC and a subsequent appli
cation of GFRC such as a patch. Draft The slope of the mold surface is relation to the di
-

Bonding pad A supplemental section of GFRC material

-
rection in which the GFRC element is withdrawn from the
that covers the foot of the flex, gravity or seismic anchor. mold to facilitate stripping.
Boss A thickened section of a backing mix into which an
- Dry density The weight per unit volume of an oven dry
-

insert can be embedded. specimen; commonly expressed in pounds per cubic foot
BOP Bend over point (tensile) in some literature; re
-
(pcf) (kg per m_).
placed herein by TY, tensile yield. Ductile Appearing or Pseudo-Ductile Large permanent
-

deformation without apparent rupture but in fact having

Carbonation Reaction between carbon dioxide and a hy
-

multiple microcracks; unaged GFRC has this characteris

droxide or oxide to form a carbonate, especially in cement
paste or mortar; the reaction with calcium hydroxide to tic.
produce calcium carbonate. Dunnage See Blocking.
-

*The abbreviations A or E, F or T, and Y or U are used in this Recommended Practice in appropriate combinations to de
scribe particular conditions. For example, AFY indicates that state of material in the Aged Flexural Yield condition.

V
E (Early)* One of two general ages in the life of GFRC
- GRC Glass Reinforced Concrete or Glass Fiber Rein
composites. Often but not always associated with 28 days.
Specifically an age prior to the time-dependent property
changes (usually, but not always, modified by F or T and Y
or U).
E-Glass Fiber Borosilicate fibers widely used for the re
-
inforcement of plastics, but not recommended for use with
portland cement.
Efflorescence A deposit of salts, usually white, formed
-
on the surface of the skin. It is a substance that has
emerged in solution from within the GFRC backing or face
mix and deposited by evaporation.
Erection drawings A set of instructions in the form of
-
diagrams and text. The instructions typically describe the
location and assembly details of each GRFC element at the
construction site.
F (Flexural)* Flexural strength at either yield (Y) or ul
-
timate (U). The apparent maximum stress when GFRC is
subjected to flexural loading (Mdl). This is the most com
monly determined measure of strength (herein usually, but
not always, modified by A or E and Y or U).
Face mix A proportined mix of unreinforced mortar, con
-
crete and admixtures at the exposed face of GFRC unit
used for specific appearance reasons..
Facing aggregate An aggregrate complying with ASTM
- Matrix The cement paste into which various amounts of
C33 except for gradation, predominately retained on the
No. 20 (850 zm) sieve with a 1/4 inch (6mm) maximum
size.
Fiber An individual glass filament with an average diam
- GFRC backing mix but without glass fiber, applied to the
eter of 13 to 20 microns and not less that 9 microns in di
ameter.
Fiber content The ratio, usually expressed as a percent
-
age, of the glass fiber to the total composite; can be by
weight or by volume.
Flex anchor Rod or bar which connects the GFRC skin
-
to the panel frame. See illustration for parts of anchor.
FRC Fiber Reinforced Concrete or Fiber Reinforced Ce
-
ment; concrete containing dispersed, randomly oriented
steel, plastic, natural or other fiber; not intended to by syn
onymous with GFRC.
Form See Mold.
-
Gap-graded (aggregate) concrete A face mix with one
-
or a range of normal aggregate sizes eliminated, and/or
with a heavier concentration of certain aggregate sizes over
and above standard gradation limits; it is used to obtain a
specific exposed aggregate finish.
GFRC Glass Fiber Reinforced Concrete. In this Recom
-
mended Practice, GFRC is a sprayed composite with an
absolute minimum of 4 percent by weight of total mix with
a minimum design thickness of 1/2 in. (13 mm) as pro
duced by a PCI Certified Plant Group G. -
vi
-
forced Cement; intended to be synonymous with Glass
Fiber Reinforced Concrete.
Gravity anchor Rods, bars or plates which transfer the
-
weight (gravity load) of the skin to the panel frame.
Hardware A collective term applied to items used in
-
connecting GFRC units or attaching or accommodating ad
jacent materials or equipment. Hardware is normally di
vided into three categories:
Contractor’s hardware Items to be placed on or in the
-
structure in order to receive the GFRC units, e.g.,
anchor bolts, angles or plates with suitable anchors.
Plant hardware Items to be part of the GFRC units
-
themselves, either for connections and GFRC erector’s
work, or for other trades, such as mechanical, plumbing,
glazing, miscellaneous iron, masonry, or roofing trades.
Erection hardware All loose hardware necessary for
-
the installation of the GFRC units.
Insert A threaded connecting or handling device cast into
-
a GFRC panel or the structure. Inserts are machine or coil-
threaded to receive a bolt or slotted to receive a bolt head,
nut, strap anchor or threaded rod.
LOP Limit of proportionality (flexural) in some litera
-
ture; replaced herein by FY, flexural yield.
-
aggregate particles and/or glass fibers are incorporated.
Mist coat A thin [1/8 in. (3mm) nominal] coat of port
-
land cement/sand slurry of a composition similar to the
surface of the mold to give a smooth even surface and hide
the glass fibers. It may be the exposed face of a GFRC
unit used for specific appearance reasons.
Modulus of Elasticity Ratio of normal stress to corre
-
sponding strain for tensile, flexural, or compressive
stresses within the elastic limit of material.
Moisture migration The movement of moisture through
-
the skin.
Moisture-induced movement Volume change of the skin -
due to change in moisture content. Volume change may be
contraction or expansion.
Mold The container or surface against which fresh GFRC
-
is deposited to give it a desired shape; sometimes used in
terchangeably with form.
MOR Modulus of rupture (flexural) in some literature;
-
replaced herein by FU, flexural ultimate.
Panel The entire prefabricated GFRC assembly.
-
Panel Frame Plant attached steel frame of cold formed
-
studs and track and/or structural shapes used to support and
stiffen the skin and provide a means for connecting the
skin to the building frame.
PEL Proportional elastic limit in some literature and used
-
to apply to either flexural or tensile values; replaced herein members and such units and adjacent materials.
by FY, flexural yield and TY, tensile yield. Sealers Clear chemical compounds applied to the surface
-

P-GFRC Polymer (Modified)-Glass Fiber Reinforced

- of GFRC units for the purpose of reducing water absorp
Concrete with a polymer solids content 10 percent or tion or improving weathering qualities.
greater by volume (not covered in this Recommended
Seismic anchor Rods, bars or plates which transfer the
-

Practice).
seismic load of the skin to the panel frame.
Plastic cracking Short cracks often varying in width
-

Shop drawings (1) Collective term used for erection

-

along their length, that may occur in the surface of the

fresh skin soon after it is placed and while it is still plastic.
Polymer As used in this Recommended Practice, an
-
emulsion of an alkali resistant synthetic thermoplastic in
water obtained by polymerization and used as a curing ad
mixture and to improve long term durability.
Premix A process of mixing cement, sand, chopped AR
-
drawings, production drawings and hardware details; (2)
Diagrams of GFRC members and their connecting hard
ware, developed from information in the contract docu
ments. They show information needed for both field as
sembly (erection) and manufacture (production) of the
GFRC units.
Sizing Coating materials applied to the glass fibers dur
-

glass fiber and water together into a mortar and subse
quently spraying or casting with vibration, press-molding,
extruding or slipforming the mortar into a product.
ing manufacture to facilitate and/or improve the processing
and performance of the fiber.
Skin The thin exterior section of a panel, including the
-

Production drawings A set of instructions in the form of

-

face mix/veneer finish and GFRC backing mix but exclu

diagrams and text. The instructions contain all the informa
sive of ribs, bosses, panel frame, etc.
tion necessary for the manufacturer to produce the unit.
Skin segment The discrete sections of skin within a
-
Retarder An admixture which delays the setting of ce
-

ment paste. —
panel separated by control joints.

Retarder, surface A material used to retard or prevent

-
Slump test A plant test for determining the apparent vis
-

the hardening of the cement paste on a GFRC surface cosity of a cement slurry.
within a time period and to a depth to facilitate removal of Slurry A mixture of water, portland cement, sand, and
-

this paste after the GFRC element is otherwise cured (a other additions or admixtures in suspension.
method of producing an exposed aggregate finish).
Spray-up process The simultaneous depositing of glass
-

Return A projection of like cross section that is 90 deg.

-
fibers and slurry by spraying onto a mold followed by ap
to or splayed from the main face or plane of view. propriate compaction.
Reveal (1) Groove in a panel face generally used to cre
-
Strand A number of individual continuous fibers bound
-

ate a desired architectural effect; (2) The depth of exposure together by sizing. Typical AR glass fiber strands contain
of the facing aggregate of an exposed aggregate finish. 102,204, or 408 fibers.
Rib (1) A stiffening member backing the skin; (2) A pro
-
Stripping The process of removing a GFRC element
-

jection from the panel face. from the mold in which it was sprayed.
Roving A group of glass fiber strands gathered together
-
Stud frame See Panel Frame.
-

and wound into a package.

Superplasticizer A high range water reducer (HRWR)
-

Rustication A groove in a panel face for architectural ap

-
admixture producing a cement slurry of significantly
pearance; also reveal.
higher slump without additional water.
Sand Washed and dried silica, complying with composi
-

T (Tensile)* Tensile strength at either yield (Y) or ulti

-
tion requirements of ASTM C 144; passing No. 20 (850
m) sieve with a maximum of 2 percent passing No. 100 mate (U). A uniform stress as contrasted to flexural stress
(0.15-mm) sieve. (herein usually, but not always, modified by A or E and Y
or U).
Sandwich panel A prefabricated panel which is a layered
-

composite formed by attaching two skins separated by an Test board A test sample produced by spraying up simul
-

insulating core. taneously with and alongside the production panel from
which coupons are cut for testing.
Scrim A manufactured fabric having open area construc
-

) using AR
tion (windows) of over 0.062 sq. in., (0.40 cm
2 Thermal movement Volume change of the skin due to-

glass fiber strands. It is laid up by hand to reinforce an temperature change of the skin. Volume change may be
area of the GFRC backing. contraction or expansion.
Sealants (joint sealant)- Material used to exclude water
- Tolerance Specified permissible variation from stated re
-

and solid foreign materials from joints between GFRC quirements such as dimensions and strength.
vii
Trowel surface The surface of a panel away from the
-
Wythe Each continuous vertical section of a wall.
-

form or mold made by smoothing with a trowel or roller. Wythe Equivalent Thickness The thickness of a solid
-

U (Ultimate)” Ultimate strength or failure point at which

- flat wythe having the same volume as the wythe in ques
material is no longer capable of carrying load (herein usu
ally, but not always, modified by A or E and F or T).
UTS Ultimate tensile strength in some literature; replaced
-
herein by TU, tensile ultimate.
tion. For a wythe having a non-uniform cross section
throughout its length, the equivalent thickness is equal to
the cross-sectional area divided by the length of the cross
section.
Y (Yield)* Yield point or strength; point on a stress-strain
-

Vapor Permeance The rate of water vapor transmission

-

curve at which strain ceases to be proportional to stress

per unit of vapor pressure differential; commonly ex
(herein usually, but not always, modified by A or E and F
pressed in perms.
or T).
Volume change An increase or decrease in volume of the
-

skin. It includes initial drying shrinkage, moisture4n-

duced-movement, thermal movement and creep.

viii
 CHAPTER 1 — INTRODUCTION
1.1 —Scope
This Recommended Practice is intended to provide infor
mation relating to the planning, preparation of specifica
tions, design, manufacture and installation of glass fiber re
inforced concrete (GFRC) panels.
Data presented covers portland cement based composites
manufactured by the spray-up process using special alkali
resistant glass fibers that are chopped and sprayed onto a
form with an appropriate cement/aggregate slurry (see Sec
tion 7.7). The premix method of manufacturing concrete
composites is covered in Appendix J. Polymer modified E
glass fiber reinforced concrete (P-GFRC) that uses a mini
mum of 10 percent of a special polymer compound to pro
vide alkali protection for the E-glass is not covered in this
publication.
The primary concern of this publication is thin-walled ar
chitectural panels made of glass fiber reinforced concrete
by the spray-up process under controlled factory condi
tions. These cladding panels are capable of accepting and
transferring wind and self-weight and their own inertial
seismic loads to the building’s load-resisting system, but
are not considered as vertical loadbearing components or as
part of the lateral load-resisting system.
This Recommended Practice reflects the present state of
the art. As significant changes in materials or process tech
nology occur, revisions to this document will be consid
ered.
GFRC is recognized by the four US model codes. See
Section 1.6
12 — General Description
Glass fiber reinforced concrete (GFRC) is the term ap
plied to products manufactured using a cement/aggregate
slurry reinforced throughout with alkali resistant glass
fibers.
GFRC does not consist of a single composition, but can
be manufactured using different combinations of materials
to meet the required properties. Mix composition, degree of
compaction, type of cement, and the proportion, length,
and orientation of glass fibers may all be varied to produce
a specific product. Typically, a GFRC panel consists of 5
percent by weight (of total mix) of alkali resistant glass
fiber (absolute minimum of 4 percent) combined with a
portland cement/sand slurry. Methods of manufacture vary,
but spraying either by hand equipment onto a form of the
desired shape and size, or mechanically on a production
line are most common (Fig. 1).
It is important to understand that the material is a compos
ite with reinforcing elements randomly distributed through
out the matrix, unlike reinforced concrete where the rein
forcing steel is placed primarily in tensile stress areas.
1
Fig. 1. In the spray-up process, a continuous strand of
glass fiber is fed into the compressed-air-powered gun,
where the strand is chopped into predetermined
lengths and combined with a sand and cement slurry.
1.3 — Historic Development
The potential of using glass fiber reinforced concrete sys
tems was recognized during the early development work on
glass fiber reinforced plastics carried out in the 1940’s. A
summary of Russian experience up to 1964 is given in Ref.
2. This early experience indicated that portland cement
composites made with unprotected hE glass (conventional
glass fiber reinforcement used in plastics) were subject to
alkaline attack. Because of this fact, a special glass fiber
product was developed.
Following the successful development of AR (alkali re
sistant) glass fibers in the late 1960’s, test programs were
undertaken to determine the properties of portland cement
and AR glass fiber . 45 AR glass fibers have
’
3
composites
been used in the U.S. since early 1970’s.
1.4 — Plant Certification
The GFRC manufacturing plants shall be certified by the
Precast/Prestressed Concrete Institute, Plant Certification
Program. Manufacturers shall be certified at time of bid
ding. Certification shall be in Product Group G.
The certification of a GFRC producing plant by PCI en
sures that the plant has developed an in-depth quality sys
tem that is based on time-tested industry standards. Every
plant must document their specific practices in a Quality
System Manual. The QSM must be submitted to and ap
proved by PCI; then updated at least annually. In addition,
every company must have at least one year of production
experience prior to the initial audit. Participants may be ei
ther PCI producer members or non-members.
 The glass fiber reinforced concrete products industry has
taken steps to publish standards for design, production, in
spection and testing. These are contained in PCI Manual
for Quality Control for Plants and Production of Glass
Fiber Reinforced Concrete Products, MNL-130. Audits and
grading of GFRC products are based on MNL- 130. A plant
is audited a minimum of twice each year. These are unan
nounced audits. Auditors are independent, specially trained
engineers accredited by PCI. They are employed by a sin
gle consulting engineering firm under contract to PCI
which ensures consistency for every plant.
The audit covers all aspects of production and quality
control as well as engineering and general plant practices.
During each audit, stored products are reviewed. Selected
panels are measured and compared to shop drawings to
verify conformance with tolerances. Product evaluations
performed by in-house quality control personnel are also
reviewed to determine if regular plant quality control pro
cedures are correct and effective.
PCI certification ensures adherence to a pre-approved, in
dustry endorsed, quality assurance program. It does not in
volve inspection and/or judgment of product quality on
specific individual projects. A current listing of all PCI
Certified Plants is published quarterly in PCI’s ASCENT
magazine. A convenient searchable list is regularly updated
on the Internet at: www.pci.org.
1.5— Applications and Advantages
6 tectural expression.
GFRC cladding panels can be designed as wall units, win
dow wall units, spandrels, mullions and column covers.
Custom designed in sizes to suit the modular planning of
the building, their largest dimensions may be vertical or
horizontal. GFRC is also suitable for use as fascia panels,
soffits, sun screens, mansard roofs and interior feature pan
els. GFRC architectural panels will generally weigh from
10 to 25 pounds per square foot (0.5 to 1.2 kPa) depending
on surface finish, panel size and shape, and arrangement of
panel frame.
The lightweight GFRC panels are in general less costly to
transport because more panels can be carried per truckload.
The light weight of GFRC panels allows the contractor to
quickly and efficiently erect panels even in hard-to-reach
areas with smaller, less expensive cranes. High early im
pact strength minimizes handling and erection damage.
The low weight of GFRC panels decreases superimposed
loads on the building’s structural framing and foundation,
usually providing savings in multistory construction and in
areas with poor supporting soil. Its light weight also makes
it ideal for use on low-rise frame buildings where heavier
cladding systems would increase the size of framing mem
bers required. In building rehabilitation or retrofit projects,
the use of GFRC panels for recladding minimizes the load
added to the existing structure.
Currently, GFRC is not considered as a vertical loadbear
ing component or as part of the lateral load-resisting sys
tem, although it can accept and transfer wind and self-
2
weight and its own inertial seismic loads to the building’s
load resisting system. GFRC panels are used primarily as
cladding or fascia panels.
In terms of creative architectural design, the possibilities
of shape variation inherent in the GFRC manufacturing
process provide a wide range of opportunities. The de
signer can choose from deep reveals to complex rectilinear
and curvilinear shapes, such as short radius curves, wide
sweeping arcs or 90-degree angles. Properly designed pan
els with appropriate configurations and multiple skin seg
ments on a single panel frame have been made up to 30 ft
(9 m) in length with 1/2 in. (13 mm) skin thickness.
GFRC systems can be designed to provide a 2-hour fire
resistance rating using fire rated insulation and drywall. In
addition, GFRC does not contribute to the fire load of the
building.
GFRC is recognized by the four US model codes. See
Section 1.6
GFRC panels can be produced with or without a face mix
with decorative aggregates. In either case, the cementitious
material produces a durable, lightweight wall for the struc
ture. With a face mix, GFRC cladding panels are indistin
guishable in exterior appearance from traditional precast
concrete panels.
A wide range of surface finishes may be achieved by us
ing exposed aggregate face mixes, integral color, white ce
ment, textured or featured finishes, or by using veneer-
faced panels; the designer has a wide latitude for free archi
Multiple integral colors and finishes can be achieved
within one panel, expanding design possibilities. Color
transitions can occur in a greater variety of locations within
the panel, and in more intricate detail as compared to other
materials.
Exact replicas of original ornamental work, e.g., terra
cotta, from historic buildings can be made of GFRC.
1.6— Building Codes
GFRC is covered in Section 1903.11 of the Uniform
Building Code
; and in ICBO’s Evaluation Report ER-
49
435949; Section 1406.3 of the National Building Code
;
87
Section 1910 of the Standard Building Code
; and Table
88
719.1(2) items 15-1.10 and 15-1.11 of the International
Building Code
96
1.7 —Types of GFRC Panels
Currently, the single skin GFRC panel is the predomi
nantly used panel in the United States. These panels have a
typical GFRC backing thickness from 1/2 to 5/8 in. (13 to
16 mm), not including the exposed aggregate face mix or
veneer finish, when used. However, design requirements or
panel size may call for a thicker backing or the use of stiff
eners. In no case should the minimum design thickness of
the backing be less than 1/2 in. (13 mm).
Unless the panel has a functionally strengthening shape,
GFRC properties dictate the use of stiffeners on panels of
Fig. 2. Typical panel frame, box, upstand GFRC skin stiffeners.
any appreciable size. Stiffeners commonly used include
prefabricated, plant attached, cold formed steel studs or
structural tubes; upstanding, single skin ribs formed on the
back of the panel; and integral ribs formed on the back of
the panel by spraying over hidden rib formers, such as ex
panded polystyrene sthps (Fig. 2). Each of these methods
reinforce and stiffen the GFRC skin and provide a means
for connecting the panel to the supporting structure.
While each method of stiffening has advantages, use of
panel frames is the most economical and preferred method
for stiffening panels in the United States. Sometimes, com
plex shapes or exposure of the steel panel frame to the
weather dictates the use of self formed ribs (Fig. 2). In ad-
3
dition, the panel frame provides a support for attaching fur
ring elements for the interior finish, drywall, and window
frame. Furthermore, this system provides a cavity for in
stalling insulation and electrical, mechanical and telephone
conduits.
Sandwich panels are usually constructed with two outer
skins of GFRC separated by a lightweight insulating core.
As with the single skin GFRC panel, this panel also has a
GFRC backing thickness for each wythe between 1/2 to 5/8
in. (13 to 16 mm). Specific guidelines need to be developed
to overcome thermal and moisture-induced bowing and
warping of sandwich panels which may cause cracking.
 CHAPTER 2— PROJECT RESPONSIBILITIES
2.1 — Responsibilities
With GFRC panels, as with many construction materials,
there is a potential for overlapping project responsibilities
and subsequent difficulties. Problems may develop when
responsibility for structural design and handling stresses,
manufacturing techniques, installation, connection hard
ware, sealant and its installation, and cleaning are not de
termined in advance. To ensure proper coordination, the
full building team should be involved in defining responsi
bilities.
The PCI Code of Standard Practice for Precast Concrete
7 ance. The manufacturer should call to the architect/engi
is a compilation of practices and recommendations for de
sign, manufacture and erection of precast concrete that also
provides an excellent guide for GFRC panel fabrication
and erection.
2.2 — Contractual Responsibilities
Areas of contractual responsibility that should be clearly
assigned in the contract documents are:
a. Panel design
b. Installing, furnishing, and design of connection
hardware
1. Attached to the building frame
2. Furnished loose
3. Secured to the panel
4. Integral with the panel
c. Panel installation
d. Sealing or coating
e. Joint sealing
f. Panel cleaning
The GFRC manufacturer is responsible for delivering a
clean panel. The general contractor must assume the re
sponsibility of protecting panels from subsequent damage
and soiling after accepting panels from the carrier, or after
the erection of the panels.Specialty items anchored in or at
tached to the panels should be supplied to the manufacturer
by the appropriate trade along with detailed instructions.
2.3 — Design Responsibility
Design calculations should be performed under the super
vision of a registered professional engineer with experience
in GFRC design. The GFRC manufacturer should be pre
pared to assist in the design of panels and connections.
The owner’s designer (architect/engineer) maintains ulti
mate design responsibility. Table 1 offers options as to how
the lines of responsibility can be established within a given
project.
The architect/engineer can benefit from early contact with
experienced manufacturers who can offer constructive ad
vice during preliminary design.
It is common practice for the architect/engineer to rely on
the GFRC manufacturer for handling and erection proce
dures, and for ensuring that the unit is adequately designed
4
for loads incurred during manufacturing, handling, ship
ping, and installation. All procedures should be checked to
ensure that they do not cause: (1) cracking, (2) structural
damage, (3) architectural impairment, or (4) permanent dis
tortion.
Contract drawings prepared by the architect/engineer
should show connections in sufficient detail to permit de
sign, estimating, and bidding. Panel manufacturers, during
the preparation of shop drawings, usually review connec
tions for tolerances, clearances, practicality, and perform
neer’s attention any recognized conflicting conditions.
Responsibility for the architectural design of GFRC
should rest with the architect/engineer who should:
1. Provide clear and concise drawings and specifications
and, where necessary, interpretation of the contract
documents.
2. Establish standard of acceptable surface finish consis
tent with industry capabilities.
3. As part of the design, allow for the effect of differ
ences in material properties, stiffness, temperatures,
and other elements as they might affect requirements
for joints, connections, panel frames, compatibility
with adjacent materials and interaction with the struc
ture.
4. Analyze the water-tightness of wall systems, evaluat
ing joint treatment, including the performance of adja
cent materials for compatibility in joint treatment, and
the proper sealing of windows and other openings.
5.Design the exterior walls with respect to weathering
heat transfer, fire resistance rating, vapor diffusion,
and moist air or rain penetration.
6.Review and approve all GFRC manufacturers shop
drawings as required in the specifications.
Contract drawings should provide a clear interpretation of
the configuration and dimensions of individual units, their
relation to the structure, and to other materials. The draw
ings must supply the following information:
1. All sections and dimensions necessary to define the
size and shape of the unit.
2. Location of all joints, both real (functional) and false
(aesthetic).
3. The materials and finishes required on all surfaces, and
a clear indication of which surfaces are to be exposed
when in place.
4. Details for the corners of the structure.
5. Details for joining to other materials.
6. Details for unusual conditions and fire endurance
requirements.
7. Governing building code and design loads.
8.Deflection limitations.
9. Specified tolerances and clearance requirements for
proper panel installation.
 lO.Support locations for gravity and lateral loads.
11 .Details of connections to the supporting structure, see
Option 1, Table 1.
2.4 Responsibilities of General Contrac
tor/Construction Manager
The general conditions of the construction contract usu
ally state the responsibility of the general contractor/con
struction manager (GC/CM) in coordinating the construc
tion work. The general contractor is responsible for project
schedule, dimension coordination with all other construc
tion trades, and for the adequacy of construction means,
methods, techniques, sequences, and procedures of con
struction, in addition to safety precautions and programs in
connection with the project.
The GC/CM should:
1. Be responsible for supplying all information necessary
to produce the GFRC erection drawings.
2. Review and approve or obtain approval for all GFRC
JJ
5
shop drawings.
3. Be responsible for the coordination of dimensional in
terfacing of the GFRC units with other materials and
construction trades.
4. See that proper tolerances are maintained to guarantee
accurate fit and overall conformity with GFRC erec
tion drawings.
It is the responsibility of the GC/CM to establish and
maintain on each floor control points, benchmarks and
lines in an undisturbed condition for use by the erector un
til final completion and acceptance of a project.
The GC/CM must immediately notify the GFRC manu
facturer of any deviations found in dimensions due to plan
or construction errors or changes to the structure.
The general contractor is usually responsible for the loca
tion of all panel bearing surfaces and connectors on the
building frame. Changes, other than adjustments within
the prescribed tolerances, require coordination with panel
manufacturer and approval by the architect/engineer.
 Table 1. Design Responsibilities.

Responsibility of the
Contract Information Supplied by Manufacturer of GFRC Units
Designer (ArchitectlEngineer)
Option I
(erection
detailing The manufacturer shall make shop drawings
Provide complete drawings and specifications and production draw ings ), as requ ired, with detai ls as
requ irem ents
all aesthetic, functional and structural shown by the desig ner. Mod ifica tions may be sug
plus dimensions, gested that, in manufacturer’s estim ation , wou ld im
s, struc tural soun dnes s or perfo rm
prove the economic
GFR C insta llatio n. The man ufac turer shall
ance of the
. Full re
obtain specific approval for such modifications
pane l desig n, inclu ding such
sponsibility for the GFRC
, shall rema in with the desig ners. Alte rna
modifications
mete rs estab
tive proposals remain within the para
sable to give
lished for the project. It is particularly advi
favorable considera tion to such prop osals if the modifi
are sugg ested so as to conf orm to the manu
cations
facturer’s normal and proven proc edur es.

Option II
but The manufacturer has two alternatives:
requ irem ents all neces
Detail all aesth etic and func tiona l (a) Submit erection and shape drawings with
ce of the approval
specify only the required structural performan sary detai ls and desig n infor mati on for the
rman ce shall inclu de all desig ner.
GFRC units. Specified perfo and ultimate responsibility of the
their points general ap
limiting combinations of loads together with (b) Submit erection and shape drawings for
icati on. This infor mati on shall be supp lied in me respo nsib ility for part of the struc
of appl proval and assu
unit can be desig ned but not their effect
such a way that all details of the tural design, i.e., the individual units
beha vior of othe r parts of the pting this prac tice may ei
without reference to the on the building. Firms acce
The divisio n of respo nsib ility for the design ) draw ings them selve s, or com miss ion
structure. ther stamp (seal
stamp the
shall be clearly stated in the contract. engineering firms to perform the design and
drawings.
shall be
The choice between alternatives (a) and (b)
een the desig ner and the man ufac turer
decided betw
clear ly state d in
prior to bidding with either approach
er alloc ation of desig n re
the specifications for prop
sponsibility.
responsibil
Experience has shown that divided design
lems . It is essen tial that
ity can create contractual prob
n respo nsib ility is unde rstood
the allocation of desig
ly expr essed in the cont ract docu men ts.
and clear
where the
The second alternative is normally adopted
desig n engi neer to assist
architect does not engage a
in the design.

Option III
e in the prelim
ce require- The GFRC Manufacturer shall participat
Cover general aesthetic and performan mary design stage and the deve lopm ent of the final de
prov ide enou gh detai l to define the and shall
ments only and tails and spec ifica tions for the GFR C units
of work. an effic ient de
scope work with the design team to provide
ides the engi neer ing de
sign. The manufacturer prov
units and their conn ectio ns to the
sign of the GFRC
shall work with the desig n profe ssion als
structure and
inter facin g work . The
on the team to coordinate the
at various
manufacturer shall submit shop drawings
pleti on for coor dina tion with othe r work.
stages of com

I-
 CHAPTER 3— MATERIALS
Materials should conform to the requirements of this
Chapter. Nonconforming materials having a history of sat
isfactory performance are permitted with approval of the
architect/engineer when acceptable evidence of satisfactory
short and long term performance is provided.
3.1 — Face Mix and GFRC Backing
Materials
3.1.1 —General
Limiting stresses used in design are based on test data
supplied by the manufacturer. Any departure from estab
lished materials and proportions will usually require a new
series of tests as described in Chapter 5.
3.1.2— Cement
Portland cements, conforming to ASTM C150 , are rec
8 of contaminants and lumps, and should meet the composi
ommended for use in GFRC. The producer should have the
choice of the type and kind of cement to use to achieve the
specified properties of the project. Cements shall be se
lected to provide predictable strength and durability as well
as proper color. Cement performance can be influenced by
atmospheric conditions, and cement has an influence on
finishing techniques, mix design requirements and spray-
up procedures.
Cement used in face mixes or mist coats must be con
trolled for color uniformity. Cement should be provided
from one manufacturer using one color, brand and type
throughout a given project. The use of white portland ce
ment will provide the most color uniformity.
New cements are coming on the market, which have been
developed specifically for GFRC. They have unique prop
erties for the enhancement of GFRC long term properties.
See Appendix I for additional information.
3.1.3 — Facing Materials
With GFRC, any change in face mix materials or propor
tions will affect the surface appearance. If the face mix is
exposed by sandblasting, retarders or other means, the
color becomes increasingly dependent on the fine and
coarse aggregates. A change in aggregate proportions, color
or gradation will affect the uniformity of the finish, particu
larly where the aggregate is exposed.
Where sand and facing aggregates are used for exposed
fmishes on the face of GFRC panels, they should be clean,
hard, strong, durable and inert, and free of staining or dele
terious material. Aggregates should conform to ASTM
9 except for gradation, which can deviate to achieve the
C33
texture mutually agreed to by the architect and panel manu
facturer. Facing aggregate should not exceed 1/4 in. (6
mm) in size. Aggregates should be non-reactive with ce
ment and available in particle shapes required for GFRC.
The method used to expose the aggregate in the finished
product may influence the final appearance. Weathering of
certain aggregates may influence their appearance over
7
time.
Moisture and/or thermal movements of facing materials
could subject the GFRC to strains it may not tolerate. Com
patibility of the facing material to the backing should be
considered when developing mix designs. (See Section
5.10) Veneers such as natural stone, thin brick, ceramic tile
or terra cotta may be used as facing materials with special
consideration. A bond breaker with flexible mechanical an
chors is recommended with natural stone to minimize panel
bowing or high stresses in the GFRC skin.
3.1.4— Sand for GFRC Backing
The use of a properly graded silica sand (see Section
4.1.4, Ref. 1) in the GFRC slurry reduces drying shrinkage,
thereby reducing the possibility of cracking and bowing
due to shrinkage. Sands should be washed and dried, free
tional requirements of ASTM C144’°.
A typical acceptable silica sand composition is:
Silica 96-98 Percent
Soluble salts 1 percent maximum
Loss on ignition 0.5 percent maximum
Clay and organic matter 0.5 percent maximum
To minimize clogging of the spray nozzle, all of the parti
cles should pass a US. No. 20 (850 pm) sieve. Fines should
be limited to a maximum of 2 percent passing a US. No.
100 (150 pm) sieve. Natural sands with rounded particles
are easier to pump and cause less sand blockages than do
crushed sands.
3.1.5 — Mixing Water
Potable water free from deleterious matter that may inter
fere with the color, setting or strength of the GFRC backing
or face mix is recommended.
3.1.6— Admixtures and Curing Agents
Standard commercially available admixtures such as wa
ter reducers, accelerators, retarders and air entraining
agents may be used to impart specific properties to GFRC.
Admixtures should conform to the requirements of ASTM
C494”, Types A, B, D, F and G or ASTM C260’ . Fly ash
2
or other pozzolans used as admixtures should conform to
ASTM C618’. Coloring agents should be stable at high
3
temperature, alkali resistant, sunlight fast, and harmless to
backing mix and face mix set and strength. Colored and
white pigments should conform to the requirements of
ASTM C979 . It is advisable to order all the color for one
4
project from one lot. Set accelerators containing calcium
chloride may cause severe shrinkage in the cement rich
GFRC mixes and corrosion of embedded items and should
not be used.
Thixotropic agents, such as carboxy methyl cellulose,
may be used when spraying vertical sides to reduce slump
and hold sand in suspension.
The polymer curing admixture used to replace the moist
cure shall conform to the curing agent specification in
Appendix L. Only polymers shown to eliminate the need
for moist curing through published independent laboratory
test data should be used.
GFRC water-cement ratios are lower than those normally
used for precast concrete. Conventional water-reducing
agents or high range water reducers (superplasticizers) are
often used. The polymer curing admixture also reduces the
added water of the mix since they contain water.
3.2 — Reinforcement
3.2.1 — Alkali Resistant Glass Fiber
Only high zirconia (minimum 16 percent) alkali resistant
glass fibers specifically designed for alkali resistance and
use in concrete should be used (Fig. 3). (See Appendix K.)
Specifically, unprotected “E’ glass, the type designed for
use in reinforced plastic should not be used.
Alkali resistant glass fiber reinforcement is available in
roving, chopped strand and scrim forms. The use of roving
for spray-up and chopped strands for premix is most com
mon, with scrim being used for selective reinforcement in
areas of high stress concentrations.
Glass fiber lengths of 1 to 2 in. (25 to 51 mm) are most
common in GFRC production. Lengths less than 1 inch (25
mm) are used for special situations.
3.3 — Panel Frame and Hardware
3.3.1 — Panel Frame
The panel frame for a GFRC panel may be fabricated
from light gage steel and/or structural steel shapes. Light
gage steel materials should be either painted or galvanized
to inhibit corrosion. Hot dip galvanizing of the frame after
fabrication is not recommended, as it can cause distortion.
The necessity for corrosion protection of the panel frame
members depends on the thickness of the material and the
aggressiveness of the atmosphere. Under normal circum
stances, structural steel sections equal to or greater than
3/16 inch (5 mm) in thickness will not require corrosion
protection.
Light gage steel should conform to ASTM A1011 15 or
A1008’ Grades A, B, C, or D, of
,
6 Sectio n A3.1 of the AISI
Specifications’ and should be prime-
7 painted with a rust-in
hibitive paint conforming to MPI 79 or SSCP- Paint
galvanized in accordance with ASTM A653’ 8 or
with a minimum G-60 coating. Gage, yield strength and
size of studs, tubes and tracks should be shown on the ap
proved shop drawings.
Structural steel tubes should conform to ASTM A500
Grade B or ASTM A5 1321. Other structu ral shapes
confor m to ASTM .
22
A36 Memb er size and yield
should be shown on the approv ed shop drawin gs.
3.3.2 — Anchors and Inserts
Steel bars for anchors should conform to the appropriate
require ments of ASTM A29 23 or A108 . Yield strength
24
should confor m to design minim um and maximum.
Anchors incorp orated into the GFRC skin should be cor
Alkali resistant glass fiber properties
Property Value
Density 170 pcf
Tensile Strength 185-355 X 10 psi
Young’s Modulus 11,400 X 1 0 psi
Elongation at break 2 ± 0.5%
Fig. 3. Glass fiber roving
rosion resistant. Materials that are galvanized should con
form to the requirements of ASTM A153 . Materials that
25
are cadmium plated should conform to the requirements of
ASTM B766 . Materials that are zinc plated should con
26
form to the requirements of ASTM B633 . Inserts should
27
be compatible with or isolated from the other materials
with which they will come in contact in order to avoid un
wanted chemical or electrochemical reactions. Ductile ma
terials should be used. Hardware, which is specified to be
protected with paint, galvanizing or plating should be
touched up if the coating is damaged. If welding is required
as part of the field assembly, the welded area should be
cleaned and touched up with zinc-rich paint if galvanized,
or if painted, with matching paint.
The allowable load on any anchor or insert molded into
the GFRC skin should be determined by the results of con
25 or trolled tests duplicating the loading condition in which it is
19
A924 used. Many inserts used in GFRC panels that have been de
signed and tested by the insert manufacturer for use in pre
cast or cast-in-place concrete will develop different
strengths in GFRC. Anchors and inserts for use in GFRC
.
20 require testing to determine their suitability, see Sections
should 5 .7.2.3 5 .8, and 8 .6.
,
strengt h 3.3.3— Handling and Lifting Devices
Handling and lifting devices should be fabricated from
ductile material because they are subjected to dynamic
loads. They should be designed to lift and transport the
GFRC panel in its various positions considering special
loadings such as wind or impact with an appropriate factor
of safety. When permanent connection hardware is used for
8
handling, it should be properly designed for such additional
service without any danger of subsequent damage to such
connections or their performance.
3.3.4 — Connection Hardware
Miscellaneous structural shapes used to support or attach
GFRC panels to the structure should be fabricated from
steel conforming to ASTM A36 or A500. Light gage shapes
should conform to ASTM AlOll or A1008 and A653,
A924, with MPI 79 or SSPC Paint 25. Under normal cir
cumstances, connection hardware equal to, or greater than
3/16 inch (5 mm) thick wifi not require corrosion protec
tion.
3.4 — Integral Rib Farmers
Rib formers may be used to produce ribs, which provide
strength and stiffness for the GFRC panels. Expanded poly
styrene foam and polyurethane foam are the most common
materials used. Care should be exercised when these mate
rials are used where ambient service temperatures are
greater than 140 deg. F (60 deg. C). Hollow sections can be
made by using GFRC or cardboard shapes to form the void
and then overspraying with GFRC backing mix. If GFRC
forms are to be incorporated into a panel they should be
prevented from drying prior to their incorporation to mini
mize restraints due to differential drying shririlcage.
3.5 —Welding
The welding of panel frame members should be in accor
dance with the most recent AWS welding codes; AWS
for structural steel and AWS Dl 329 for sheet steel.
Dl .l
28
Frames can be welded using the shielded metal arc welding
(SMAW), flux cored arc welding (FCAW) or gas metal arc
welding (GMAW).
Electrodes for SMAW should conform to the requirements
of AWS AS .1 or AS .5. Electrodes (wires) for FCAW should
conform to the requirements of AWS AS .20. Electrodes
(wires) for GMAW should conform to the requirements of
AWS A5 .18. The type and grade of electrode should be as
recommended by AWS for the grade of material being
welded
9
3.6 — Joint Sealants and Backer Rods
The most commonly used sealants with GFRC wall panels
are field molded sealants. For a complete reference to these
. The recommendations of
sealants refer to ASTM C1193
30
the sealant manufacturer should always be followed re
garding mixing, surface preparation, priming, application
life and application procedure.
Only high performance one- or two-part sealants meeting
ASTM C920, such as polysufides, urethanes, silicones, or
3
other sealants that can meet Federal Specifications TT-S
00227e (polysulfides) Type II, non-sag: TT-S-00230c (ure
thanes) Type II, non-sag: or TT-S-001543a (siicones) are
recommended for sealing joints in GFRC panels. Sealants
should withstand joint movements of at least ± 25 percent
of specified joint width. Where greater movement capabil
ity may be required, manufactures of low modulus sealants
should be consulted.
Joints are usually primed and primers require careful ap
plications. Some will leave a stain on the face of the panel
if brushed along the joint edge.
The backup rod or bondbreaker should be as recom
mended by the sealant manufacturer.
The contractor responsible for sealing should test the
sealant for adhesion to on-site installed panels or to panels
in the plant prior to proceeding with the whole job.
3.7 — Coatings
Coatings may be applied to GFRC panels. Latex masonry
paints and water-resistant stains in a methylmethacrylate
base offer a wide range of color choices. A clear coating of
silane or siloxane may be applied to the face and back sur
faces of a panel to reduce moisture absorption (moisture
movement) and efflorescence. It is important that the coat
ing be water vapor permeable to allow the panel to
“breathe. Manufacturers of coatings should be consulted
for details of application, performance and testing of coat
ings prior to use on GFRC panels. In most cases, except for
the silanes or siloxanes, it will be necessary to adequately
roughen the surface in order to obtain good adhesion of the
coating. One method is to lightly sandblast the surface to
be coated.

CHAPTER 4— PHYSICAL PROPERTIES
The physical properties of GFRC depend greatly on the
mix composition, glass fiber content and its length or on
entation in the composite, polymer content, and the overall
quality of workmanship incorporated during the manufac
turing process. Therefore physical properties of GFRC to
be used in design must be determined for each individual
manufacturer and each mix design used.
Early (28-day) properties of GFRC are typically used to
determine appropriate design parameters and to monitor
quality control throughout manufacturing. Unaged GFRC
is a relatively strong, tough, pseudo-ductile material. It
must be anticipated that GFRC will exhibit gradual and
permanent reductions in strength and strain capacity when
exposed to an outdoor environment (natural aging). The
rate at which natural aging of GFRC occurs is environ
ment-dependent. GFRC products exposed to an outdoor en
vironment will, in most cases, reach a fully-aged condition
within the intended life span of the product. Therefore,
GFRC products must be designed to ensure that stresses re
sulting from in-service conditions are kept within the
strength and strain limits of the fully-aged material.
4.1 — Factors Affecting Physical
Properties
Variations in mix composition can result in variations in
composite physical properties. Cement/sand ratios ranging
from 1:1 to 3:1 have been used within the industry. Grada
tion of the sand used for slurry mixes is also not standard
ized. Performance of ordinary portland cements typically
used can vary from one source of supply to another. Sev
eral different polymer curing admixtures are currently
available and in use. Therefore, composite mix proportions,
constituents, and physical properties, can vary from one
manufacturer’s plant to another. Manufacturers should be
aware of the potential variations in the physical properties
of GFRC resulting from changes or modifications in mix
composition.
Fiber content, length, and orientation primarily affect the
strengths A glass fiber
early tensile and flexural ultimate 4 .
is the optimum for GFRC
conten t of 5 percen t by weight
ts in lower early ulti
mix design s. Lower fiber conten result
mate strengths and higher fiber conten ts can lead to com
posite compaction and consol idation proble ms. Composite
glass fiber content is contro lled and monito red during
GFRC production by perform ing the bag, bucket and wash
out tests.
Fiber length also affects composite ultimate strengths and
compaction and consolidation. For GFRC spray-up, the op
timum fiber length is 1 to 2 in. (25 to 51 mm). Shorter
lengths, although easier to spray, will not provide maxi
mum reinforcement efficiency. Longer fiber lengths may
10
I
cause problems with fiber and slurry laydown as well as
compaction and consolidation during rolling.
The orientation of reinforcing fibers also affects compos
ite physical ’
proper
3
32 3 ties 34 Sprayed-up GFRC composites
are intended to have a two-dimensional random fiber orien
tation. However, if care is not taken during production,
fibers can become unintentionally aligned parallel in one
direction or another, resulting in a composite with sigriifi
cantly different properties when tested along different axes.
GFRC composites must also be compacted and consoli
dated to achieve adequate fiber embedment and composite
density, as well as the required design thickness. Failure to
achieve adequate composite compaction and consolidation
will have adverse affects on strength properties and can
cause changes in the material response to both temperature
and moisture. GFRC skin permeability may also be ad
versely affected. Flexural and tensile strength and modulus
. Poor consolidation can
of elasticity vary with density
35
also lead to composite deterioration due to freeze/thaw cy
cles.
The required (design) thickness for GFRC is determined
by the panel design engineer. Since GFRC is a relatively
thin material to begin with, even small thickness variations
will have significant effects on skin stresses. Therefore
GFRC thicknesses should always be within thickness toler
ances specified. In production, GFRC backing is often
manufactured with a target thickness 1/8 in. greater than
the design thickness in order to meet the specified thick
ness tolerances.
Proper curing results in adequate hydration of the cement
and is necessary to achieve desired fiber- and matrix-de
pendent properties. Prior to the introduction of polymer
curing admixtures to the GFRC industry, adequate curing
of GFRC composites was both time consuming and incon
venient. Today, curing of GFRC has become greatly simpli
fied by using polymer admixtures in the cement matrix.
Use of polymer admixtures, in appropriate amounts, has
been shown to eliminate the need for the 7-day moist cure.
Sprayed up GFRC is a man-made material, which de
mands ongoing quality control and quality assurance moni
toring. Therefore, an ongoing quality control and quality
I
assurance program is recommended.
4.2 —Tensile and Flexural Strengths
The primary properties of GFRC used to establish limiting
design stresses are the 28-day flexural yield and ultimate
strengths. As discussed in Chapter 5, the limiting design
stress in GFRC is based on an assumed aged flexural ulti
mate strength. The assumed aged flexural ultimate strength
is determined based on the average 28-day flexural yield
and ultimate strength of 20 consecutive tests (6 specimens
each) performed by the manufacturer prior to design.
 4000

3000
(0
0
0
0
0
0
ii
C,)
C,) 2000 AFU

AFY
1000 IATY=ATU
#
( I I
Aged

I I
I
0.5 1.0 0 0.1 0.2 0.3 0.4 0.5
Strain, %
Strain, %

Fig. 4. Representative stress-strain behavior of GFRC subjected to flexure and tension.

Representative stress-strain behavior of 28-day (unaged) —

Fibers Lying in In-plane F In-plane
Plane of Sheet Shear Compression
GFRC material is shown in Fig. 4. Early tensile yield
strength (ETY) and early flexural yield strength (EFY) are
primarily influenced by the matrix composition, density,
polymer content, and curing procedures. Early tensile ulti
mate strength (ETU) and early flexural ultimate strength
(EFU) are affected primarily by glass fiber content, fiber
length and orientation, polymer content, and composite
“
density. As GFRC ages, a loss in composite strength and Interlaminar Cross-plane
strain to failure occurs as shown in Fig. 4, while the modu Shear Compression
lus of elasticity increases. In the fully aged condition, the
ultimate strengths (ATU or AFU) are at least equal to the Fig. 5. Compressive and shear strengths.
yield strengths (ATY or AFY). In addition, aged ultimate
strengths are also equal to or greater than the early yield 4.5 — Impact Resistance
The impact resistance of GFRC is influenced strongly by
strengths.
. Increasing fiber length from, for ex
the reinforcing fibers
4
ample, 1 to 2 in. (25 to 51 mm) or using alkali resistant
4.3 — Modulus of Elasticity glass fibers with improved sizing, increases impact
Flexural stress-strain curves are used to determine values strength. Cured GFRC at 28 days has higher impact
of modulus of elasticity for design purposes. Values of strengths than either unreinforced cement paste or asbestos
flexural modulus of elasticity will vary with matrix compo cement. Impact properties relate to the area under the ten
sile or flexural stress-strain curve. As these curves alter
sition, density, polymer content and curing procedures.
with time, the impact properties are reduced. Normally, im
Therefore, each manufacturer must determine, through test pact strength is not a design parameter.
ing, appropriate values for modulus of elasticity to be used
in design. 4.6 — Shear Strength
Panels made by the spray-up method have fibers ran
4.4 — Compressive Strength domly distributed in the plane of the section. Therefore,
Compressive strength is essentially matrix . 5 2
3
dependent
3
’ shear values (Fig. 5)32. 33, vary with the type of load appli
In-plane (edgewise) compressive strength will be some cation as follows:
what lower than cross-plane (“flatwise’) strength due to the a. Interlaminar shear. The value of shear strength is es
layers of glass fibers affecting the continuity of the matrix sentially that of the matrix. This type of shear stress is
(Fig. 5). Cross-plane compressive strength is not influ encountered in the bending of single skins and in-
plane load-carrying bonding pads.
enced by the presence of glass fibers and will be about the
b. In-plane shear. In-plane shear strength and ultimate
same as the compressive strength measured in cube or
tensile strength for a range of formulations of hand-
cylinder tests.
11
 sprayed GFRC after a variety of aging treatments are 0
identic
3
’
32
. 3 al Therefore, in the absence of direct in-
plane shear measurements, tensile strength values may
be used with confidence. In-plane shear stress can be
generated by bolted connections near the edge of a
sheet.

4.7 — Shrinkage and Other

Moisture-Induced Movement G)

As with all concrete, GFRC is subject to shrinkage on C

drying and partial recovery on wetting. Moisture-induced Cl)

movement is dependent upon several factors including the

water/cement ratio, the cement/sand ratio, polymer cohtent,
curing, density and the age of the .compo
32
3
’ 3
8
9 site
The effects of moisture on GFRC are shown in Fig. 6. Ir
reversible drying shrinkage occurs during the initial drying
stage, and is largely dependent on the cement/sand ratio
and the water/cement ratio. Subsequent moisture content
changes cause a reversible dimensional (or volume)
Cement/Sand Ratio by Weight
change. Volume change is largely governed by the ce
ment/sand ratio and decreases somewhat with age. Fig. 7. Effect of cementlsand on shrinkage behavior.
The incorporation of sand, a standard practice, reduces the
amount of shrinkage; but shrinkage is still greater in GFRC to gradually reduce with exposure to outdoor environment
than most concrete products because of the higher cement (natural aging).
content. Fig. 7 shows typical relationship between sand The extent of any dimensional change depends upon the
content and . shrink
32
3
’ 3
9 age Experience has shown that ce particular GFRC formulation and conditions of exposure.
ment/sand ratios as low as 1:1 can be accommodated with Therefore, each manufacturer should determine initial
out appreciable deterioration of the strength of the compos shrinkage and other moisture-induced movement character
33 Larger proportions of sand in the GFRC matrix may
’
32
ite
. istics of GFRC for each formulation and the lowest
lead to a reduction in strength and other mechanical prop monthly ambient relative humidity to be encountered. De
erties. termination of these characteristics should take place prior
Restrained shrinkage induces stresses, which can lead to to design of GFRC elements. Shrinkage and other mois
cracking, particularly in components constrained by shape, ture-induced movement measurements should be made on
variable section thickness, embedded materials, or external unrestrained test samples. Measurements cannot be made
restraint. Shrinkage cracking in unaged GFRC panels, that on actual panels because restraint from facing materials
have been designed and manufactured properly, can be and the frame system could cause inaccuracies in data.
controlled with adequate fiber content and random fiber When facing materials are bonded to GFRC, tests must be
orientation. Although the addition of glass fiber to the ce performed on these materials to determine shrinkage and
mentitious matrix does not materially reduce its drying other moisture-induced movement characteristics. Facing
shrinkage, it does increase strength and reduce the risk of materials should have shrinkage and moisture-induced
propagating shrinkage cracking in unaged GFRC. How movement characteristics as close as possible to those of
ever, as with strength, the strain capacity and ability to in the GFRC backing. Significant differences in the character
hibit propagation of shrinkage cracking must be anticipated istics of these materials can cause significant panel skin
stresses as a result of one material restraining the other
from moving. It should be understood that some facing ma
terials should not be bonded to GFRC due to volume
change incompatibility.
C
Co
C) 4.8 — Thermal Movement
Co
C
0 As with most materials, GFRC expands with increasing
(9
C
‘8)
temperature. This normal thermal expansion may be coun
E teracted by shrinkage due to moisture loss during the heat
ing of the GFRC panel. Response to thermal and moisture
changes is time-dependent and complex, and depends on
Fig. 6. Dimensional stability: Moisture induced move conditions such as moisture content.
ment of GFRC. Thermal expansion and contraction is governed by matrix
12
properties, primarily the density and amount of sand or ce
32 33 Thermal expansion characteristics
ment/sand ratio
should be considered in the design of GFRC elements.
Each manufacturer should evaluate thermal expansion
characteristics for each GFRC formulation typically used.
Facing materials should have thermal expansion charac
teristics as close as possible to those of the GFRC backing.
Significant differences in the characteristics of these mate
rials can cause significant panel skin stresses as a result of
one material restraining the other from moving. It should
be understood that some facing materials should not be
bonded to GFRC due to thermal expansion incompatibility.
49—Creep
GFRC is capable of sustaining load over prolonged peri
ods. Creep behavior is similar to that of other cement-based
materials. Initial elastic deformation is followed by a slow
creep deformation under sustained load. The creep rate de
creases with time on a logarithniic basis, i.e., the creep de
formation occurring from 100 to 1,000 hours is usually
about equal to that occurring from 10 to 100 hours. An ex
ception to this general rule is found when load is applied to
a saturated GFRC specimen. Higher creep deformation is
observed in the first hour of loading of saturated specimens
than in subsequent logarithmic increments. After this time,
the creep rate parallels that of materials loaded in other en
vironments. Typical creep curves are shown in Fig. 8 for
bending stresses below flexural yield (the normal range of
. Under dry
working stress) under saturated conditions
32
conditions, creep is initially greater but approaches the
creep strain under saturated conditions at later ages. Creep
strain in flexure or direct tension are proportional to the ini
tial strain, and are substantially smaller than
expansion/contraction strains due to moisture changes.
Studies with composites indicate that creep properties are
controlled by the matrix. This is expected because of the
small proportion (typically 5 percent by weight) of the
ui 4
oe
——
Co
a.
Co
C)
C
5)
:s 0.5 Note:
5)
0 Specimens Loaded at 28 Days
C.) Tested in Water
0
5) Fiber Content = 5% by Weight
5)
W/C Ratio = 0.3
C-)
0 1 10 52100
Time After Loading, weeks
Fig. 8. Flexural creep of GFRC.
13
fiber in the composite. Both water content and sand content
have a significant effect on creep rates. There has been no
indication of any creep effects in the composite resulting
from the interaction between the matrix and the fiber.
4.10 — Freeze-Thaw Resistance
Experience with GFRC in natural freeze-thaw environ
ments has been good. In order to study the mechanism of
behavior, a series of laboratory studies have been per
formed.
ASTM C666, Procedure A, gives the most severe expo
40
sure of standard unrestrained freeze-thaw tests. In this test,
specimens were subjected to alternating cycles of freezing
in water at 0 deg. F (-18 deg. C) for approximately 2 hours
and thawing in water at 40 deg. F (4 deg. C) for approxi
mately 1-1/2 hours. GFRC specimens were subjected to
freeze-thaw cycles after 0, 8, and 26 weeks of accelerated
aging. Unreinforced mortar specimens were subjected to
freeze-thaw cycles after 0 and 26 weeks of accelerated ag
ing. For each of these accelerated aging periods, six speci
mens were tested in flexure after 0, 100, 200, and 300 cy
’ 42 [Note: Accelerated aging
cles of freezing and thawing
41
was achieved by immersing specimens in lime-saturated
water at 122 deg. F (50 deg. C)].
Flexural yield strength versus freeze-thaw cycles are plot
ted with solid lines in Fig. 9 for the GFRC specimens and
by dashed lines for the companion unreinfOrced mortar
specimens. All curves in Fig. 9 represent matrix cracking
strength. Numbers next to each curve indicate the number
of weeks in accelerated aging conditions prior to exposure
to freezing and thawing.
As shown in the figure, presence of the glass fibers effec
tively preserved the cement matrix against significant
freeze-thaw deterioration. Without fibers, mortar speci
mens were observed to completely deteriorate before
reaching 200 freeze-thaw cycles. In addition, the effect of
accelerated aging prior to freeze-thaw exposure had very
little effect on the resulting freeze-thaw resistance of the
GFRC specimens as indicated by the relatively flat slope of
the line for each accelerated aging period
.
442
Flexural ultimate strength versus freeze-thaw cycles are
— GFRC Composites
Co
Urireinforced Mortar Composites
a.
Note:
0) Fiber Content = 5% by Weight
C
5) Cement/Sand Ratio = 2 to 1
Cl) W/C Ratio = 0.35
0
5)
>.
:3
L1
0 100 200 300
Freeze-Thaw Cycles
Fig. 9. Flexural yield strength versus freeze-thaw cy
cles.

Note:
Fiber Content = 5% by Weight
Ratio=2to1
0
and
3000 = .35
Weeks ofA
26
0 index is zero. In addition, tests for non-combustibility, ig
iz
0 100 200 300
Freeze-Thaw Cycles
Fig. 10. Flexural ultimate strength versus freeze-thaw
cycles.
plotted in Fig. 10 for the GFRC specimens. Numbers next
to each curve indicate the number of weeks in accelerated
aging conditions prior to freeze-thaw exposure. As shown
in the figure, regardless of the number of weeks in acceler
ated aging prior to freeze-thaw exiosure, the flexural ulti
mate strength decreases to approximately 1500 psi (10.4
MPa) after 100 cycles and approximately 1000 psi (6.9
MPa) after 300 . 42
’
4
cycles
After 300 cycles the GFRC showed slight flaking and
fiber prominence on the form side. There was severe flak
ing of the ‘trowel’ face and delamination cracks along the
edges. The flakes, about 5/32 to 13/64 in. (4 to 5 mm)
across and 3/64 in. (1 mm) thick, generally remained at
tached to the main body of the specimen by the glass
fibers.
Freeze-thaw tests have been made on test samples cut
from sprayed boards containing 5 percent AR glass fiber by
weight and 20 percent sand by total ’.43 The tests
’
32
weight
were based on the British Standard Test for Asbestos and
Asbestos Cement Building Products, BS 4624; 1970 (50
freeze-thaw cycles). These involved samples that were arti
ficially aged by soaking in 122 deg. F (50 deg. C) water for
90 days then subjected to 50 cycles of 16 hours at -4 deg. F
(-20 deg. C) in air and 8 hours at 68 deg. F (20 deg. C) in
air, followed by soaking in water for 48 hours.
There was no visible change in the appearance of the sam
ples after the tests, and the mechanical properties of flex
ural ultimate and yield strengths, modulus of elasticity, and
impact strength were not affected.
In practice, the form side of GFRC would usually be the
exterior of a component with the more vulnerable trowel
face protected from the weather. GFRC is of low perme
ability and the trowel face would be unlikely to become
saturated with water and susceptible to the action of freeze-
thaw. Where an integral concrete face mix is used, the ag
gregates in the finish must be compatible with the antici
pated weathering exposure as determined by tests or
proven performance.
ASTM C666, Procedure A (freezing and thawing im
mersed in water), provides a very severe freeze-thaw con
dition and most materials show some degradation. GFRC is
14
no exception but it still compares favorably with other ce
ment-based materials and the conclusion is that freeze-
thaw conditions do not pose a problem in the use of GFRC.
4.11 — Fire Endurance
GFRC made of cement, glass fibers, sand and water is
non-combustible and meets the requirements of ASTM
. When used as a surface material, its flame spread
45
E136
nitability, and fire propagation have been conducted in
England in accordance with the appropriate British Stan
dard on “Fire Tests on Building Materials and Structures,”
BS 476, Parts 4,5, and 65.32
GFRC made with a polymer curing admixture will meet
the requirements of NFPA Class A and UBC Class I when
tested according to ASTM E84 , resulting in a “0” Flame
46
47 and less than 5 smoke density.
Spread Rating
GFRC panels can be designed to provide one and two
hour fire rating. The rating as defined in ASTM El l9 is
primarily dependent upon the fire endurance of the insula
tion and sheetrock materials field applied to the panels by
other trades. Fire tests conducted in the U.S .A. (Table 2) on
GFRC wall panels with panel frames are summarized in
the 1997 Uniform Building Code , Table 7-B items 18-
49
1.10 and 18-1.11, and the International Building Code 96
items 15-1.10 and 15-1.11.
It should be noted that the tests were conducted in accor
dance with ASTM El 19, which requires hose stream tests
in addition to fire resistance tests.
4.11.1 Joint Treatments: One-Stage Buft Joints. One of
the assemblies listed in Table 2 consisted of GFRC panels
with 1-1/2 in. (38 mm) returns. In that assembly, the joints
were 3/4 in. (19 mm) wide, but instead of using ceramic
fiber felt to firestop the joints (Table 3), a 5-in. (127 mm)
thickness of TFB insulation (Fig. 11) was placed between
the steel studs across the backs of the returns. The same in
sulation was used between the other studs in the assembly.
The joints in the assemblies with 6-in. (152 mm) returns
listed in Table 2 were 1/2 in. (13 mm) wide and were pro-
Fig. 11. Use of TFB insulation behind one-stage butt
joint.
Table 2 Description of wall panel assemblies fire tested in the U.S.A.

Fire Steel Studs or GFRC Ribs Overall

Endurance* Outside Wythe Type Maximum Spacing Insulation Inside Wythe Thickness

2 hr
56 3/8 in. GFRC; 6 in. Returns 5 in. Ribs 24 in. (nominal) 5 in. TFB 5/8 in. GWB-C 7-3/8 in.

2 hr5
7 1/2 in. GFRC; 4 in. Studs 24 in. (nominal) 5 in. TFB 1/2 in. + 1/2 in. 6-1/2 in.
1-1/2 in. Returns GWB-C

2 hr 1/2 in. GFRC;** 6 in. Studs 24 in. (nominal) 5 in. TFB 1/2 in. + 1/2 in. 9 in.
1-1/2 in. Returns GWB-X

1 hr
59 1/2 in. GFRC; 5 in. Returns 4 in. Studs 24 in. (nominal) 5 in. TFB 5/8 in. GWB-C 6-1/8 in.

*Surface of inside wythe exposed to fire.

**Contained 5 percent polymer curing admixture by volume of GFRC.

Explanation of Symbols and Terms Used in Table 2

GFRC = Glass fiber reinforced concrete
GWB-X Type X gypsum wallboard
GWB-C = Sheetrock brand Firecode C gypsum wall panels produced by United States Gypsum Co.
TFB = Thermafiber CW 40 batts produced by United States Gypsum Co.

tected with a 5-in. (127 mm) initial depth of the same TFB sity offers good attenuation characteristics. A 3/8 in. (10
insulation as that used in the assemblies. mm) sheet of GFRC at 4 psf (0.2 kPa) provides a STC of
4.11.2 Fire Safing. Fire safing is used to close the gap be 34 (see Fig. 13)3233. However, a complete panel assembly
tween the edge of the floor slab and the GFRC skin. The will provide greater sound reduction conforming to most
gap varies due to the profile of the skin. The gap is filled code requirements.
with mineral wool batt insulation and a sealant is applied to
the top of the insulation. See Fig. 12. Table 3. Calculated depth of ceramic fiber felt
and joint width for various tire endurances.
4.12 — Acoustical Properties Depth (c)
GFRC follows the mass law for sound reduction. For Fire Joint of Ceramic
skins of similar design, but different weights, the sound Endurance Width Fiber Felt
transmission class (STC) increases approximately 6 units
1 hr 3/8 in. 1/2 in.
for each doubling of weight. GFRC’s relatively high den-
2hr 3/8 in. 3/4 in.
Band No.
lhr un. un.
2 hr 1 in. 2-1/4 in.

Note: 1 in. = 25.4 mm.

Sealant

Ceramic
Fiber Felt

Joint Width
I
Frequency in Hertz
Fire Side
Fig. 13. Relationship of sound reduction and frequency.
15
 GFRC Panel

i— Sealant-Mm. Ye” Thickness - Sealant-Miri. Ya Thickness

/ Of Modified Latex Elastorner* Of Modified Latex Elastomer
Applied Over The Packing Applied Over The Packing

i-Shaped Clips

:•.

Impaling Pins
;:t
1_____ Packing Material-Mm. 4
Pking MateriaMin. 4
Thickness Of 4 PCF Thickness Of 4 PCF
Mineral Wool BaIt Mineral Wool BaIt
Insulation Insulation

Gap Width-Il Max,

Gap Width-l9 Max.
* 5100SF - Sprayable Mastic
a) Fire And Smoke Stop Sealant b)
By Firestop Systems Inc.

Fig. 12. Fire sating details.

4.13 — Density spectively.

The dry density of spray-up GFRC depends primarily on Most formulations of the material have a vapor permeance
fiber content, water-cement ratio, polymer content, sand ), making the
of less than 3 perms (1.7 x 10 gml Pa•s•m
2
content, compaction, and spray techniques. These factors need for an additional vapor barrier subject to vapor flow
35 The typical range of dry density
also influence .
’
4
porosity calculations .

). A knowledge of the
is 120 to 140 pcf (1920 to 2240 kg/rn
3 Air permeability of GFRC ranges from 4.6 penn-in. (6.7 x
density gives information on the general quality of manu
facture and is used as a measure of plant quality control
procedures.
4.14 —Thermal Properties
Thermal conductivity of the GFRC skin is dependent
5 The typical
upon composite density and moisture content.
range of thermal conductivity is 3.5 to 7.0 BTU/in ./ ft?/
hr./deg. F (0.5 to 1.0 WmIm
/deg. C).
2 materials ‘
The resistance, R value, per inch of skin thickness ranges
between 0.18 and 0.10 hr. ftZ deg. F/Btu (1.23 and 0.71 m
K/W).
4.15 — Permeability
The GFRC matrix tends to absorb and distribute water
throughout the composite uniformly and rapidly but does
not seem to allow passage of water through the skin thick
ness. Laboratory tests have shown that no signs of moisture
would appear on the inside of a 3/8 in. (10 mm) sheet of
GFRC with rain blown onto it by a 73 mph (117 km/h)
50 Water vapor permeability of GFRC will range from
wind.
5 to 11 penn-in. (7.3 to 16 x l0 gm/Pa•s•m) for GFRC
materials made at 0.25 and 0.35 water-cement ratios, re
10 gmlPa•s.m) for GFRC exposed to 40 percent relative
humidity to 0.2 penn-in. (0.3 x 10 gmlPa•s•m) for GFRC
exposed to 90 percent relative humidity.
5
The air and water vapor permeances of GFRC decrease as
a function of time and storage under natural weather condi
tions. These properties are largely those of the cement ma
trix and compare favorably with those of other building
4.16 — Moisture Absorption
Moisture absorption varies according to the density and
polymer content of GFRC but will normally be in the range
. Moisture content in an envi
of 8 to 16 percent by weight
52
ronment of 65 deg. F and 60 percent relative humidity will
reach equilibrium in the range of 4 to 8 percent by weight.
4.17 — Property Summary
Different manufacturers may achieve different ranges of
values of physical properties of GFRC. Specific values of
properties should be supplied by the manufacturer to the
designer. For general information, Table 4 gives ranges of
material properties.

16
Table 4. Typical Range of GFRC Properties*
Property 28-day, (E) Aged, (A)
Density (dry) 120 to 140 (pcf) 120 to 140 (pcf)

Compressive strength 7,000 to 12,000 (psi) 10,000 to 12,000 (psi)

Flexural: Yield (FY) 900 to 1,500 (psi) 1000 to 1600 (psi)

Ultimate strength (EU) 2000 to 3500 (psi) 1,300 to 2,000 (psi)
Modulus of elasticity 1 .Oxl 06 to 3.Oxl 06 (psi) 2.5x1 06 to 4.Oxl 06 (psi)

Direct tension: Yield (TY) 700 to 1,000 (psi) 700 to 1,100 (psi)
Ultimate strength (TU) 1,000 to 1,600 (psi) 725 to 1,100 (psi)
Strain to failure 0.6 to 1.2 (percent) 0.03 to 0.08 (percent)

Shear: Interlaminar 400 to 800 (psi) 400 to 800 (psi)

In-plane 1,000 to 1,600 (psi) 725 to 1,100 (psi)

Coefficient of thermal expansion 8 (in./in./deg F)

Approx.12x10 (in./in./deg F)
Approx. 12x10
6

Thermal conductivity 3.5 to 7.0 2 deg F)

(Btu/in./hr/ft
/ 3.5 to 7.0 2 deg F)
(Btu/in./hr/ft
/

; 1 psi = 6.895 kPa, 145 psi = iN/mm

Note: 1 pcf= 16.02 kg/rn
3 2 = 1MPa: 1 in-lb/in? = 0.175 N-mm/mm2
*These are typical values and are not to be used for design or control purposes. Each manufacturer must test production composites to es
tablish physical properties for design. The values achieved in practice will be dependent on mix design, quality control of materials, fabri
cation process and curing. Cement/sand ratios are between 1:1 to 3:1.
**Developed from accelerated testing programs on GFRC specimens immersed in 50 to 80 deg. C (122 and 175 deg. F) water. On the ba
sis of comparisons between behavior in real weather and accelerated tests, predictions can be made of properties for 50+ years in different
’
53
climates ‘

17
 CHAPTER 5— DESIGN
The following notation is used in this Chapter:
f = limiting GFRC skin flexural stress for factored
loads
= average 28 day flexural ultimate strength (EFU)
fyr = average 28 day flexural yield strength (EFY)
f’,,= maximum allowable designf’
design strength [f’J determinant if fur is less
f’ =
than 3 times fyr
= design strength [f’1 determinant if fyr is more
than 1/3 of fur
f’ = assumed aged ultimate flexural strength for design
and quality control purposes
= average 28 day anchor strength
= limiting factored load per anchor
s = shape factor, to account for stress redistribution
in different cross sections
t = students t, a statistical value to allow for the
number of expected low tests
V = coefficient of variation, ie. standard deviation /
average
0 = strength reduction factor
a = sample standard deviation (n-i)
5.1—Scope
The design of GFRC cladding panels is based on the ma
terial properties, and their change with time, and on per
formance in installations in a variety of climates. Panels are
subjected to a variety of loads and environmental condi
tions, producing significant external and internal forces. A
major consideration in the design of GFRC, in addition to
external loads such as wind or gravity, is the reduction of
restraint of volume change, due to changes in moisture or
temperature.
In reinforced concrete, the concrete strength f’) is tradi
tionally specified, and the required average strength f’cr)
is based on each supplier’s test data and its variability. Due
to variables in manufacturing techniques, this is not practi
cal for GFRC; so the situation is reversed. Determination
of the design strength f’) must be based on test data pro
vided by the specific manufacturer. The procedure for de
termining the ratio of test data to strength used in design is
similar to concrete.
5.2—Background
Even with special alkali-resistant glass compositions, if
moisture is present for cement hydration, the GFRC com
posite still loses significant strength and ductility with
time. The leading theory to explain this phenomena is that
ongoing cement hydration results in products, primarily
calcium hydroxide, which penetrate the fiber bundles and
fill the interstitial spaces between the glass filaments. This
increases the bond of the glass fiber to the cement matrix
and leads to a reduction in fiber pull-out, and in turn a re
18
duction in strain to failure. There is also an associated de
crease in tensile strength with time’
. This phenomenon
61
is called embrittlement. There is also a, not widely held,
theory, that chemical attack by hydroxyl ions on surface of
the glass fiber may result in a reduction in the strength of
the fiber”
. Researchers are not fully in agreement as to
62
the mechanism responsible for the observed decrease in
GFRC strength and ductility
’.
6
It should be noted, however, that in dry, indoor environ
ments where cement hydration and chemical attack is
slowed significantly, early composite properties are main
tained longer. However, in usual environments, using cur
rent portland cements; there remain very significant reduc
tions in strength and strain to failure, which must be recog
nized by the designer and user. The length of time over
which these reductions take place, and the degree to which
they take place, depend on the type and content of the fiber
and polymer curing admixture, and upon the environment.
Tests on laboratory coupons and coupons from actual
building panels indicate that the aged ultimate strength of
GFRC exposed to outdoor natural weathering is at least
equal to the yield strength at 28-days as shown in Fig. 14
4563.74. 89
and Table
Developments in AR glass manufacturing techniques, and
the use of higher polymer contents have resulted in im
tions .‘ ‘
proved long-term properties; including better retention of
strain to failure and strength, compared to earlier formula
New cements and formulations are being developed and
some are currently in use overseas. With AR glass fiber re
inforcement, these systems exhibit substantially less loss of
ductility in the fully aged condition. As this technology de
velops it is expected that it will lead to changes in the de
sign and application of GFRC.
Nothing in this publication is intended to limit develop
ment and utilization of these or other improvements in the
system. The intent of this publication is to establish proce
dures to maintain adequate safety factors that are consistent
with the reliability and lifetime properties of GFRC and the
associated components. These principles and procedures
should be maintained in the evaluation of new develop
ments and their application.
EFU EFU = Early Flexural Ultimate
AFU = Aged Flexural Ultimate
EFY = Early Flexural Yield
AFY = Aged Flexural Yield
El
‘ EFY Assumed AFUEFY
28 days Time —
Fig. 14. Long-term GFRC composite strength behavior
under typical weathering conditions.
5.2.1—Design Philosophy
The procedure for the design of GFRC panels is based on
both the assumption that the aged ultimate strength is at
least equivalent to the 28-day yield strength, to ensure that
in-service panel stresses are kept below the cracking
strength at all times. Demolding and other handling
stresses should also be kept as low as possible; and ideally,
below the yield strength of the material at all times.
Changes in GFRC properties with aging may affect con
nections to a lesser degree, but must be considered when
designing connections and evaluating load tests, see Sec
tion 5.7.2.3. Aged properties of GFRC are usually deter
mined in the laboratory by subjecting samples to a hot wa
ter bath, or some other regime that has been shown to sim
ulate, at an accelerated rate, the effects of real time in a nat
ural environment. It is generally impractical to test full
sized panels that have been artificially aged. The following
minimum ratios of test load to service load have been sug
gested for unaged panels: 1.5 to yield, and at least 4 to ulti
mate 65
The intent of the design procedures herein is to keep the
GFRC backing stresses below the cracking strength by an
adequate margin. This is done by keeping factored strength
greater than factored loads. Strength is assessed by com
puting the stresses by the straight line theory- that is; flex
ural stress and strain are both proportional to distance from
the neutral axis.
Structural performance is also a function of configuration.
Recognition should be given to the effects of shape, re
turns, recesses, plate action, and solid, hollow, or foam-
filled stiffening ribs (Fig. 2) on structural performance.
It should be recognized that the design procedures in this
chapter primarily address panelized wall systems. As with
many other materials, including precast concrete and terra
cotta, many applications, such as ornamental and historic
replications, are designed and fabricated based on experi
ence and previous successful use, rather than rigorous
mathematical procedures. This practice has been followed
for centuries, particularly with developing materials, and is
not to be discouraged through rigid application of the pro
cedures in this publication. Architects and engineers, how
ever, should be aware of the material behavior related to
aged strength, ductility, and volume change characteristics
discussed in this publication when considering these types
of applications for GFRC.
This chapter emphasizes those aspects of panel design re
lated to the panel skin and its anchorage to a panel frame.
The design of the panel frame is treated in Section 5.7. For
more information on the connection of the panel frame to
the structure see Refs. 66 and 67.
5.2.2—Panel Stiffeners and Methods of Support
It is not practical to make the panel skin very thick. To al
low larger panels, stiffening is used. This is usually accom
plished by anchoring the skin to a steel panel frame, by the
introduction of stiffening with panel shape, or with integral
ribs incorporated into the back of the panel.
19
Maintain Frame
Clearance = 1/2 Mm.
Fig. 15. Reveal and frame clearance.
Presently, GFRC panels are usually made with a panel
frame stiffening system. Currently, there are two methods
of attaching the skin to the panel frame, see Section 5.7.2.
One method uses flex anchors alone to transfer loads from
the panel skin to the frame, which is described in Section
5.7.2. The second and preferred method, uses flex anchors,
for wind load; but transfers the weight of the skin to the
frame with separate gravity anchors. The anchors are
welded to the panel frame, and bonded to the skin with ad
ditional GFRC called a bonding pad.
When designing and detailing GFRC panels, it is impor
tant to keep the panel frame isolated from the skin, so that
it does not create undue resistance to in-plane volume
changes. The distance between the skin and the frame often
varies due to the profile of the panel. The distance must be
adequate to permit unrestricted access by the workers for
thorough integration of the bonding pad to the panel skin.
Panel edge returns and surface recesses (Figs. 15 and 38c)
often control the dimension from the panel skin to the
panel frame, and in turn to the building frame.
5.3—Design Loads
GFRC panels are designed for stripping, handling, and in
stallation loads; usually by the panel manufacturer. Service
loads are set by the governing building code, and are multi
plied by the appropriate load factor. Minimum load factors
are set by the governing building code, but they should not
be less than those in Section 5.3.2.
5.3.1—Panel Service Loads
Panel design must consider dead, live, and environmental
loads; including wind, earthquake (if applicable), tempera
ture, and moisture effects
.Service loads set by the govern
68
ing building code should be considered only as minimum
requirements. There may be situations where additional
considerations with respect to loads should be considered,
such as:
Gravity Load Effects: Gravity loads associated with the
weight of GFRC panels. Three-dimensional panels often do
not result in pure in-plane stresses. Skin bending stresseses
associated with gravity loads should be considered in de
sign. See Fig. 16.
Wind Load Effects: Variation in wind load due to sur
rounding structures, or to the geometry of the structure
should be considered in design. Since GFRC panels are
light in weight, wind load is a more significant part of the
total design load than it is with heavier concrete panels.
 Struts

a) b)

Fig. 16. Struts for dead load skin stress reduction.

Earthquake Load Effects: Inertial forces developed in (b) Cyclic moisture changes in the panel skin.
panels during seismic events must be resisted. Special con (c) Differential shrinkage caused by unequal shrinkage
sideration should be given to three-dimensional panels coefficient between two different materials such as
where inertial forces can result in skin bending stresses. GFRC backing and architectural face mixes (if used),
Use of seismic anchors reduces load on flex anchors, see see Section 5.10.
Section 5.7.2.2 and Fig. 28.
5.3.2—Load Factors and Combinations
Volume Change Effects Thermal And Moisture: Ex
— GFRC uses strength design concepts where both the
--

pansion and contraction due to changes in temperature and material strength and the loads are factored. Minimum
moisture content are three dimensional or volumetric. In service loads stated in the governing building code, along
many respects their effects are the same and can be as with the additional load conditions and considerations
sessed similarly. Panels should be designed for horizontal stated in this Recommended Practice, should be considered
and vertical contraction and expansion without buckling, when assessing various load combinations. The following
opening of sealed joints, excessive stresses within panel load factor combinations should be considered as mini
components or fasteners, or other detrimental effects. Due mums:
to the thinness of the panel skin its response to temperature
or moisture change is usually faster, and the effect often 1.4 D 1.7 L
+ (5-1)
greater, than in thicker concrete panels. Volume change ef
fects are usually greater than wind load, and often control 0.75 [1.4D+ 1.7 L+ 1.7 (greater of Wor 1.1 E)j (5-2)
the design of the panel; especially if the panel has an archi 0.9D+1.3(greaterof Worl.1E) (5-3)
tectural face mix. Panels with architectural face mixes re
quire special considerations as described in Section 5.10. 1.4 D + 1.7 (greater of M or T) (5-4)
0.75 [1.4D+1.7(greaterof L,Worl.1E)
Temperature considerations should include:
+ 1.6 (greater of M or T)] (5-5)
(a) Gross thermal movement of panel for temperature
changes, consistent with geographical location. 1.1[1.2D + l.OE+0.5L] (56)*
Depending on weather, exposure, panel color, etc. (5.7)*
1.1[1.2D + 1.OE + 1.6(greater ofM or T)]
facade surface temperature can be 20 to 80 deg. F.
(11 to 45 deg. C.) greater than ambient temperature where:
due to solar heat gain.
(b) Differential thermal movement characteristics D = Dead Load
between the GFRC backing and architectural face E = Earthquake Load
mixes (if used), see Section 5.10. L = Live Load

Moisture considerations should include: *Note: Equations 5-6 and 5-7 apply only where 1997
(a) Initial drying shrinkage in the panel skin. Uniform Building Code is in effect.
20
 M = Effects of Moisture Change
T = Effects of Temperature Change
W = Wind Load
Depending on local conditions, where the International
Building Code is in effect, if its provisions are more strin
gent they may govern the design.
The first four load factor combinations are the same as in
ACT 318. For cladding panels there is seldom a live load,
however window washing procedures may be a considera
tion, but would probably not occur with higher wind load.
The factor for moisture and temperature is greater than in
ACT 318 due to the uncertainties in values and calculation
procedures, and the potential effect if underestimated. If
there is a reasonable probability of a higher volume ‘change
effect due to a combination of the two, especially initial
drying shrinkage and temperature, that is greater than ei
ther maximum alone, judgment may indicate that a combi
nation be used. In some circumstances, creep can reduce
these effects, but the rates at which moisture and tempera
ture changes and creep occur are difficult to define, see
Section 5.10.
54—Limiting Stresses (Strength)
In determining design conditions, service and environ
mental loads (or stresses) should be factored and combined
to establish the highest applicable value, see Appendix H.
In addition, panel geometry should be considered when de
termining the effects of gravity, wind, earthquake, tempera
ture, and moisture induced stresses. Three dimensional
panel configurations can cause differential conditions with
respect to temperature, moisture, and wind effects, as well
as gravity induced bending conditions in the skin. Changes
in panel geometry, especially thickened sections, ribs, stiff
eners, returns and architectural face mixes can cause in
creased stiffness that may restrain the panel skin and create
additional stress.
Stresses imposed on the panel skin during stripping of the
panel from the mold, handling, transporting, or erecting
should be kept as low as possible; and ideally, below the
yield strength of the material at all times.
It is the intent of this procedure that skin forces be resisted
only by the glass fiber reinforced portion (backing) of the
skin. For design purposes, mist coat or architectural finish
layers of a two material skin are not considered as adding
to the strength; nor included in test specimens for strength
determination or quality control.
5.4.1—Flexure
Stresses due to factored loads, computed by the straight
line theory of stress and strain, should be limited to:
f = 4)5f’ (5-8)
where:
4) = 0.75, strength reduction factor. The derivation of this
factor is based on experience and judgment and is not in
tended to be precise. The purpose of the strength reduction
factor, 4) is: (1) to allow for the probability of under
strength members due variations in material strengths and
21
dimensions; (2) to allow for variability in test methods; (3)
to allow for inaccuracies in the design equations; (4) to re
flect the degree of ductility, and required reliability, of the
member under the load effects being considered; and (5) to
reflect the importance of the member in the structure.
s = shape factor. The basic strength test for GFRC is a
flexure test on a solid rectangular specimen. Stress redistri
bution occurs to different degrees in other cross sections, at
times approaching a tensile condition. To account for this,
the following shape factors are suggested: solid rectangular
(including single skins with or without facing), 1; flange,
box, or I sections, 0.5. Other values may be used if sub
stantiated by test.
f’ = the lesser of:
f’ =fyr (1t V) (5-9)
f’uy = 113 fur (1t V) (5-10)
f’ max=
20 (5-11)
and:
f’ = assumed aged ultimate flexural strength for de
sign and quality control purposes. It is taken as
that value which, statistically, no more than 1%
of the tests will fall below. See Appendix B for
a sample determination.
f’ = design strength [f’ul determinant if ur is less
than 3 times fyr
f’, = design strength [f’i determinant if fyr is more
than 1/3 of fur
fur = 28-day flexural ultimate strength
(EFU).
fyr = average* 28-day flexural yield strength (EFY).
t = students t, a statistical value to allow for the
number of tests expected to fall belowf’. See
Appendix A.
V.,, ,V = coefficient of variation of the yield, ultimate
flexural test values.
VyUy/fyr and Vu=Uu/fur
°y’ u = sample standard deviation (n-i) of the yield,
ultimate flexural test values.
A maximum effective flange width of 24 times design
thickness beyond corners or intersections may be used for
stress calculations, as in Appendix C.
5.4.2—Shear and Tension
Direct shear seldom controls the design of GFRC panels.
Interlaminar shear, likewise, seldom controls the design of
flat GFRC elements unless the span-depth ratio is less than
16. However, interlaminar shear may control design of con
nections. While in-plane shear occurring in the diaphragms
and webs seldom controls design, it should be considered
and the principal tension stresses limited. Diligence is re
quired to maintain the continuity of webs at intersecting
box ribs. The tensile strength of GFRC is less than the flex-
*
Note: ‘Average’ strength test values should be based on
a minimum of twenty tests of six specimens each; half of
which are tested with the mold side in tension and half of
which are tested with the mold side in compression. All
tests shall conform to Appendix F of Ref. 1.
 Small Openings Large Openings

*(a)
Poor Panel
TI T (b)
Good Panel
(C)
Poor Panel
Layout
(d)
Poor Panel
Layout
(e)
Good Panel
Layout Options
Layout Layout
Jambs too Narrow

Fig. 17. Small and large window openingsIpanel jQint relationship.

ural strength. Due to impracticality of tests to determine umn covers are vertical panels covering columns. Some
tensile strength on a specific job basis, it should be limited times column cover type panels are used where columns do
to 40 percent of the flexural strength or 0.4 not actually occur, to achieve an effect. They may be con
tinuous or interrupted by spandrels. All three types may be
5.5—Deflection flat or have returns. Column covers, particularly at lower
Panels should have adequate stiffness to limit deflections floors, may be in sets to completely surround a column.
or any deformations that may affect serviceability or cause Beams are often similarly covered.
cracking. 5.6.1—Panel Layouts
Deflections due to service loads are sometimes limited to When possible, it is preferable to have small windows, or
L/240 but may need to be less in some conditions. The in
, other openings, occur entirely within one panel to mini
terior finish systems or windows that are attached to the mize fit and joint sealing concerns. For large openings,
panel frame should be compatible with this deflection. panels should be configured so that openings are least af
fected by movement of the structure. The panel configura
tions in Figs. I 7a, 1 7c, and 1 7d are poor layouts for open
5.6—Panel Types
ings. Figs. 17b and 17e show good layouts for openings.
Three types of panels (panel frame, integral rib, and sand
Panel layouts must be coordinated with the connections to
wich) based on their internal makeup are discussed in Sec
the structure, so story drift is not in conflict with panel
tion 1.6. These are essentially different in their stiffening
jointing. Generally, this is best facilitated if horizontal
systems. By far, the predominant system now used in the
joints are continuous, as in Fig. 17e, not interrupted as in
United States is the panel frame. The integral rib is used in
Fig. 17d. If a continuous column cover effect is desired, it
smaller panels; or where space limitations do not allow for
may be advisable to simulate it with panel shape and false
a panel frame, such as in column covers. The integral rib
joints.
can take a variety of shapes depending on space available
The panel manufacturer should be consulted for panel
and extent of stiffening required. It can approach a sand
size. For long panels, over 20 ft (6 m), it is usually neces
wich panel in appearance. However, in a sandwich panel,
sary to segment the skin with control joints, as in Fig. 18,
internal forces are transmitted between the two faces by the
to minimize restraint of the skin. Sometimes panel returns,
filler between them, so the properties of the filler, and its
or other shapes, are detached from the main skin as in Fig.
installation, are critical. With a box rib the filler’s only
19 to limit differential volume change stresses. Each skin
function is to form the desired shape. It should be noted
segment usually requires its own gravity anchors. Often
that it is difficult to resolve the high calculated stresses in
more than one skin segment is attached to a single large
integral rib and sandwich panels and panels with returns,
panel frame.
when rigorous mathematical modeling is carried out for
Due to the spray up methods used to manufacture GFRC
significant differential volume changes.
panels, integral returns are usually vertical in the mold, so
Panels can also be categorized by application. Terminol
should generally be less than one foot to prevent the fresh
ogy varies to some extent throughout the country, with
GFRC from sagging, see Fig. 19. Since circumstances vary,
‘panel’. ‘cladding’, ‘wall’, or ‘curtain wall’ being applied as a
the manufacturer should be consulted for the maximum di
general term to all types. Wall generally applies to panels
mension of returns.
that extend from one floor to the next. They may be solid,
or have ‘punched’ window openings. The horizontal joints
need not occur at the floor line, and the panels may even be 5.7—Panel Frame System
more than one story high. Spandrels are horizontal band The panel frame system is by far the most common type
panels, less than story height, separated by windows. They of panel in use today in the US. It is also gaining in popu
may be continuous or interrupted by column covers. Col larity world wide, even where light gage steel members are

22
 a)

F
0 Q) (0

VI ,L1..

b)
Fig. 18. Skin segments separated with sealed control
joint.
not as common. Because of its popular appeal and ability
to adapt to many conditions it is given greater coverage in [LF
this publication.
The system consists of four distinct parts: the panel skin
(which may include an architectural face mix), the anchors
that attach the skin to the panel frame, the panel frame it
self, and the connectors that attach the panel frame to the
structure. The anchors are intended to be flexible in the
plane of the panel (except as required to carry gravity or
seismic load) so that they provide minimum in plane re
straint against the volume change of the skin. They must,
[LJ C)

of course, transmit wind loads to the panel frame. The

panel frame must accumulate all the loads and transfer
them to the structure via the connectors. With this system
the skin is never attached directly to the main building
structure.
The panel frame concept is truly a system. All loads must
have a positive path from their origin to the main building d)
structure. Figs. 20 and 21 show some of the more common
approaches. For illustrative purposes, spandrel panels are 4-

shown in these figures; but the concepts apply to other ap
plications as well, even though the details may differ. In all
cases, the wind load is transferred from the skin to the
studs (or other frame members) by the flex anchors, by the
studs to the upper and lower tracks, by the tracks to the
connector studs (or tubes) and then to the connectors.
There are two methods of transferring the gravity load of
the skin to the frame. Fig. 20 is only for small panels where
the flex anchors can be stiff enough to carry the gravity
load without being so rigid that they unduly restrain the
skin against in-plane volume changes. Figs. 20 and 21b
have the gravity loads distributed to the panel frame uni
formly along its length. This requires the frame to have suf
ficient in-plane rigidity to pick up the load and transfer it to
the connection system. In Fig. 21a the gravity anchors
transfer the weight of the skin to the panel frame at two
discreet points. If these points are at the connector studs
23
Fig. 19. Corner panel skin joint and frame options.
(or tubes), the rest of the frame has little participation in the
gravity load transfer.
5.7.1—Skin Design
If the skin has an architectural facing that has volume
change characteristics that are not equal to the GFRC back
ing, the differential stress must be considered. If the panel
skin includes an architectural face mix, see Section 5.10 for
additional considerations.
Typically, face mixes are not reinforced with glass fiber
so, for design purposes, they are not considered as con
tributing to the strength of the skin. The design of the skin
for wind load is straight forward. The panel skin spans be
tween the anchors. It can be modeled as a beam on a row of
flex anchors, or as a two-way slab system, with the bond
ing pads acting similar to a column capital, as in Appendix
 Wind Load from Window
(Top & Bottom)

Gravity Load from Skin

Carried by Flex Anchors
to Studs Load is Delivered to
Building Connections
Wind Load from Skin
Carried by Flex Anchors
to Studs
• Bearing Connection
(may act as top tie-back

or Structural Tube

Tie-Back Connection
• Track Carries Wind Load
to Connector Studs

Stud Carries Load to This system is the same as (a) except that the
Top & Bottom Tracks top and bottom tracks are heavier members that
are designed to support the panel for vertical
a) • Diagonal Brace Transfers
Gravity Load to Connector ‘ dead load and eliminate the diagonal braces.
Studs

Fig. 20. Optional methods of stiffening frame for panels without gravity anchors for small panels only.

Gravity Skin Load Carried

Gravity Skin Load Carried by by Trussed Round Bar
Flat Plate Tee Gravity Anchor Gravity Anchor to Stud-

to Connector Studs

-Flat Plate Tee Gravtty

Anchor Welded to
Panel Connector Studs

Wind Load Carried by I Load Carried by

Flex Anchor to Stud Flex Anchor to Stud

- Trussed Round Bar Gravity

a) Anchor Welded to Each Stud

b) Braces or Heavier
Track (Alternates)

Flex anchors support skin wind loads;Trussed round bar

anchors support skin gravity load. Gravity loads trans
Flex anchors support skin wind loads; Flat plate tee an fered with diagonal straps or heavy top and bottom mem
chors support skin gravity load. bers similar to Fig. 20.
-

Fig. 21. Optional gravity anchor and panel framing systems.

24

Small Edge Large Edge Distance
Distance (panel may warp)
Fig. 22. Effect of edge distance on bowing or warping of
panel.
D, this is dependent on skin configuration. Consideration
should be given to non-typical anchor spacing and edge
conditions, as they will affect skin load capacity. Unsup
ported edges of GFRC panels can bow or warp. This can
present a problem with panel alignment, as well as an un
sightly joint. It is recommended that the distances from the
edges of the skin to the anchors be kept equal, and small to
minimize warping, see Fig. 2269,70, 71 This is especially im
portant with two material skins with unequal properties of
the layers.
Variable stiffness of the members within the panel frame
should be considered, as it could result in their carrying
load that is disproportionate to their tributary area, which
may also have an effect on the skin design.
The highest wind load is often suction. At corners eddy
currents may create a negative pressure on one face while
the other face has positive pressure.
Panels with deep returns and integral rib or sandwich pan-
Skin
I Frame
I Member
A
Length of Flex-Anchor for
b) Vertical Movement from
a) --
Neutral Point
(also must carry wind load)
Better
d) e)
Fig. 23. Flex anchor variations to reduce restraint.
els should be investigated for the effect of sun or rain on
one surface and not the other. Experience has shown, how
ever, that rigorous mathematical modeling of potential
moisture or thermal volume changes may lead to calculated
stresses significantly larger than the limiting stress of
GFRC; however empirical designs are often used success
fully. In some cases, Potentially high stresses have been
eliminated by detachment of the return with control joints,
as in Fig. 19a.
Panel shapes can be such that the skin weight above or be
low gravity anchors could create high axial stresses. Even
with low stress creep could in time distort the panel. Fig.
16 shows some examples where this is controlled with C
shaped bars similar to flex anchors, except with feet at both
ends. Fig. 23 shows ways to reduce restraint while still pro
viding load capacity at returns.
Analysis of the skin must consider all sources of stress
with the appropriate factored load combinations from Sec
tion 5.3.2. Some of these stresses will be flexural and some
will be axial. Since the tensile strength is smaller than the
flexural strength, and since different loads use different
load factors, neither loads nor stresses can be added di
rectly. They should be combined with a procedure such as
in Appendix H.
5.7.2 — Anchorage of Skin to Panel Frame
It is imperative that the anchorage of the skin to the panel
frame be accomplished in such a manner as to minimize re
straint of the in-plane volume changes of the skin. Each an-
Restrains Skin
Movement
Length of Flex-Anchor for
Horizontal Movement
from Neutral Point
(also must carry wind load)
C)
Side
Return
Length of Flex-Anchor
for Horizontal Movement from
Neutral Point
(also must carry wind load)
Length of Flex-Anchor
for Vertical Movement
from Neutral Point
(also must carry wind load)
25
chor should be examined for its action in all three axes;
perpendicular to the skin, in-plane vertical, and in-plane
horizontal. Typically all anchors carry wind and perpendi
cular seismic loads, so they are rigid on the axis perpendi
cular to the skin. Gravity anchors carry load vertically, but
are flexible to allow in-plane horizontal movement. Seis
mic anchors carry in-plane horizontal forces, but should
provide minimum vertical restraint.
Volume change movement of the skin is usually consid
ered to be zero at its center and to increase in proportion to
the distance from this ‘neutral’ point.
The skin should not act, or be assumed to act, as part of a
composite system in conjunction with the panel frame; so
horizontal shear capacity of a well designed anchorage sys
tem is very low, except as noted above.
5.7.2.1—Flex Anchors
The primary flex anchor load is typically due to wind; but
for skins with architectural face mixes, if volume change
properties of the layers are unequal, there will also be
forces on the anchor and the bonding pad to restrict bow
ing, see Section 5.7.2.5. With all skins, the flex anchors
should provide minimum restraint against in-plane volume
change.
In one method of attaching the panel skin to the panel
frame, the weight of the skin is transferred to the frame
through bending of the flex anchors, as in Fig. 20. To as
sure structural integrity, the anchors must be of ample
rigidity and strength to carry their thbutary weight, as well
as wind loads; while still remaining flexible enough to al
low in-plane volume change movements of the skin with
out excess restraint. This method is recommended only for
panels small enough that flex anchor restraint stresses,
when combined with other stresses, are within acceptable
limits.
Fig. 24 shows the most common type of flex anchor. Al
though there are many variations, they are usually made
with a smooth round rod. Diameter is determined by the
wind load, spacing, the distance from the skin to the frame,
and by whether or not a separate gravity anchor is pro
vided. Column strength and lateral buckling of the anchors
should be investigated. They are welded, at the top of the
leg for flexibility, with flare bevel groove welds.
Regardless of which anchors are used, the principle of
strength with minimum in-plane restraint must remain the
primary considerations. This is important in both design
and construction. Designers and workmen should guard
against inadvertently creating excess restraint while trying
to assure strength.
If the flex anchors are in the yield range, low cycle fatigue
may need to be considered in their design for wind load or
other cyclic movements.
It is recommended that anchors be oriented with the toes
pointing toward the ‘neutral’ center of the panel, so that ini
tial drying shrinkage will tend to pull the anchor leg away
from the stud, where pressure could reduce the effective
length of the leg. Any rigid fire protection or thermal insu
26
lation (see Fig. 37) should be installed in a manner that
does not restrict movement. The movement of the GFRC
skin is provided for by the flexing of the flex anchors and
the gravity anchors. On a few projects a plastic sleeve has
been put over the anchor foot to allow the bonding pad to
slide, as a means of reducing restraint.
5.7.2.2 Gravity and Seismic Anchors
In larger, heavier panels, if the skin is attached to the
panel frame with flex anchors only, they may become so
stiff, that restraint creates high skin stress. If the dead load
is carried separately by gravity anchors, the flex anchors
can be small (1/4 in. or 6 mm diameter) to substantially re
duce their in-plane restraint.
In its plane, the skin is quite rigid. If the panel frame is
made sufficiently rigid, with diagonals or stiff upper and/or
lower tracks, as in Fig. 25, the load of the skin can be trans
ferred with a series of gravity anchors. This is usually ac
complished with the trussed rod gravity anchors, as shown
in Figs. 21b and 26, located on every, or every other, stud.
If the frame is supported at two connector studs (or tubes),
it is often advantageous to support the skin’s dead weight at
the same two members. This allows the in-plane rigidity of
the panel frame to be lower, since the skin’s weight is car
ried by the connector studs directly to the structure connec
tions. The connector studs (or tubes) may need strengthen
ing at the anchors or at the connectors. This two point grav
ity transfer is usually accomplished with the plate gravity
anchor shown in Figs. 21a and 27. By adjusting the plate
height and thickness, vertical strength of the anchor is
achieved without sacrificing horizontal flexibility. Addi
tional flexibility can be achieved by slotting the leg plate as
in Fig. 16a. Additional load capacity can be achieved by
putting holes or notches in the cross plate to increase its
bearing area in the bonding pad.
Gravity anchors should be placed on one horizontal line,
so they don’t act against each other to restrict the vertical
movement caused by temperature and moisture variations.
Gravity anchors should be positioned so that skin bending
stresses of three-dimensional panels (i.e., with returns or
Panel
Weld at End of Leg
Foot
Bonding Pad
— 3Mm.
Fig. 24. Typical flex anchor.
 Track Spans
Horizontally Between Diagonal Brace
Connector Studs (7 (may be required)

L rKL-1l
Studs Connector Studs at
Add Stud or Conn. to Bldg. Studs
Rolled Structural Welded Together or
Shape When Rolled Structural Shape
Required for
Greater Strength

Note: Welding is all done from one side to allow prefabrication

Fig. 25. Optional methods of stiffening panel frames.
recesses) are minimized. It is preferable to locate gravity
anchors near the bottom of the skin, so its own weight puts
it in compression; however other considerations may dic
tate otherwise. Since the gravity anchors set the location of
the vertical neutral point, from which movement radiates,
it is sometimes advantageous to put the gravity anchors at
mid-height. While it is preferable to have permanent
stresses compressive, the tensile stresses produced by the
bottom half of the panel hanging from the gravity anchors
are usually low, though localized at the anchors.
Where the panel shape creates a seat, it can be fit to a
shelf on the panel frame to carry the weight of the skin, in
stead of using a gravity anchor. This can also be accom
plished with the addition of GFRC corbels to the panel
skin. These must both be used in a manner that do not re
sthct volume change.
In seismic areas, the in-plane seismic force resistance
must be achieved without excess restraint of volume
change. If seismic force is taken by typical studs, their
weak axis stiffness may need to be investigated. With a flat
plate gravity anchor system, one, not both, of the gravity
anchors can be strengthened to carry the seismic load. A
flat plate anchor with a horizontally oriented leg may be
used to carry the longitudinal seismic force to the panel
frame, as shown in Fig. 28. The seismic anchor will usually
set the location of the horizontal neutral point, so it should
preferably be at the mid-length of the panel. There will be
rotational forces, which the anchor system must carry, if
the seismic anchors are not on the same horizontal line as
the center of mass of the skin.
5.7.2.3—Anchor Evaluation
In addition to material variables, the strength and per
formance of the skin anchors are highly dependent on the
technique of the individual applying the bonding pads. The
properties achieved in practice will be dependent on type

Skin

Slots to Reduce
Restraint Optional

Fig. 26. Trussed rod gravity anchor. Fig. 27. Plate gravity anchor.
27

Fig. 28. Plate and trussed seismic anchors.
of anchors used, quality of materials, degree of com
paction, thickness and area of bonding pads, and adequacy
of curing.
It is necessary that each manufacturer perform a sufficient
number of tests, to develop a data base from which a limit
ing anchor load can be determined. All specimens must be
made in a manner identical to the production anchors. A
minimum of twenty specimens are to be tested for the
manufacturer’s typical anchor.
It is crucial that all anchor tests and conditions simulate
those on production units as closely as possible and accu
rately simulate in service conditions, and in accordance
with relevant portions of Refs. 1 and ASTM C1230 . Test
85
reports must include details of all materials and procedures
used for the anchor tests.
Factored load per anchor should be limited to:
= çbP(l-tV) (512)
where:
0.6, strength reduction factor
a = average 28 day anchor strength
1 ble at the stud ends. It is suggested in recognition of the
Pu = limiting factored load per anchor
students t, a statistical value to allow for the
number of tests expected to fall below assumed
minimum. See Appendix A.
Va = coefficient of variation of the anchor test values.
Va = a’
1a
0
a =sample standard deviation (n-i) of the appropri
ate anchor test values.
Tests of artificially aged embedments and bonding pads
have indicated strength reductions varying from 10 to 50
28
percent, with the failure in the bonding pads.
Tests have indicated the following unaged ultimate
strength ranges for various types of anchors.
Type of Anchor and Load Ultimate Load unaged
--
TENSION
Flex Anchor (Fig. 24) . .500 1200 lbs. (2 5 kN)
. - -
SHEAR
Trussed Rod Gravity Anchor (Fig. 26)
1000-2000lbs. (4-8kN)
Flat Plate Gravity Anchor (Fig. 27)
2000 4000 lbs. (8 -16 kN)
-
These are sample values and are not to be used for
design purposes!
5.7.2.4—In-Plane Anchor Restraint Stresses
The purpose of the flexible anchorage of the panel skin to
the panel frame is to transfer perpendicular (e.g., wind)
loads from the skin to the frame, while allowing independ
ent in-plane movements between the two.
There are substantial panel skin movements caused by
temperature and moisture changes. If the flex anchor legs
are too rigid, the restraint can induce high in-plane stresses
in the skin.
Considerations in the determination of the panel skin at
tachment include: thicknesses and mix design for both the
GFRC backing and face mix, size and shape of the panel,
location of openings or irregularities, and movements due
to temperature and moisture variations.
Flex anchor spacing, and orientation, and the panel di
mension from the ‘neutral’ point all have a significant effect
on the dimensional change of the skin.
The most significant and easiest parameters to control are
the diameter, length, and yield strength of the anchors. If
the anchor toes are perpendicular to the studs, and point
away from them and toward the middle of the panel, the
initial drying shrinkage tends to pull the anchors away
from the studs rather than making them bear against the
studs, where pressure could reduce the effective length of
the leg. Some manufacturers put a small bend in the an
chors so that their only frame contact is at the weld.
In many instances the flex anchors are stressed to their
yield level. For simplicity in skin stress analysis, all an
chors can be assumed to exert a restraining tensile stress in
the panel skin equivalent to that which develops when their
yield strength is reached. This simplified approach ignores
stud twisting and weak axis bending, since they are negligi
difficulty in quantifying all factors and is conservative for
skin stresses. See Appendix E for suggestions for calculat
ing in-plane skin stresses due to anchor restraint.
Since these stresses are a function of the yield strength of
the anchor, and steel often has a yield point higher than (the
minimum) specified, it is prudent to use a conservatively
high value for design. In order for this analysis to be valid,
the yield strength used in the analysis must not be exceeded
in practice (which may require that a maximum be speci
fied), and the bonding pads can not extend up the anchor
leg to shorten its design length. Excessively long or mislo
cated welds of the flex anchors to the studs can also
shorten the intended design length.
For skins with architectural face mixes, all stresses due to
in-plane volume change, or any other source, should be as
sumed to be resisted entirely by the GFRC backing alone.
5.7.2.5—Out-of-Plane Restraint Stresses
Every effort should be made to make the layers of a two
material skin have similar thermal and moisture volume
change properties, see Section 5.10.
Even though the skin is quite flexible, it does tend to bow
with differential inter laminar volume changes, which cre
ate out-of-plane forces, in addition to the in-plane forces
discussed in Sections 5.7.2.4 and 5.10 and Appendices E
through G.
The skin bow, if unsupported, could be computed from its
properties, dimensions, and differential volume change.
The force to remove the bow would then be exerted on the
skin, anchors, and frame, which could be appropriately an
alyzed. Section 3.3.2 of Ref. 72 presents a method of
analysis of such a procedure.
5.7.3—Panel Frame Design
Panel frames are usually made up of cold-formed steel
studs, and/or structural tubes, but may contain any struc
tural shape. They are prefabricated, usually including the
skin anchors, and set into place over the just sprayed skin,
with jigs for precise location with respect to the skin. The
frame should be designed for stripping, handling, and in-
place loads in accordance with Refs. 17 and 73. Welding
should conform to Ref. 28 for structural steel and Ref. 29
for sheet steel.
Prefabrication, panelization, and handling induce loads
that studs do not traditionally encounter. The skin should
not be relied on to provide bracing for stud stability. De
pending on stud gage, dimensions, support conditions, inte
rior finish, etc., bridging may be required to prevent buck
ling.
Due to the low restraint requirement of the skin anchors,
the skin can not be assumed to add to the stud strength as
in some composite masonry/stud applications. Since there
is an interconnection between the skin and the panel frame;
when the skin shrinks and the frame doesn’t, the panel may
tend to bow. The frame must have sufficient rigidity per
pendicular to its plane to resist this bowing, as well as any
bowing due to differences in volume change properties of
two material skins. A panel frame is usually designed to
support a panel with two bearing connections (which also
function as tie-backs) and two tie-back connections. Tie
back connections are those used to resist loads perpendicu
lar to the panel. This requires sufficient frame strength to
span between the connections.
The load from the panel skin is transmitted through the
gravity and flex anchors to the studs. From the studs, the
load is transmitted via horizontal tracks, diagonal bracing,
and vertical connector studs to the structure connections,
and then to the structure, see Figs. 20 and 21. If the skin’s
29
gravity anchors are at every, or every other stud, diagonal
braces or stiffening of the horizontal track may be required
as illustrated in Fig. 25 and 21b to provide sufficient in-
plane frame rigidity so that each stud supports its tributary
portion of vertical loads.
Greater member capacity is required at the structure con
nection locations since they will carry the loads collected
by the horizontal tracks. Increased capacity of these con
nector studs is usually accomplished by using double or
boxed studs, tubes, or rolled structural shapes as in Fig. 29.
See Section 5.7.1 for discussion of increased load resulting
from increased stiffness of connector studs.
It is common to reinforce light gage connector studs by
welding heavier plate or angle assemblies to them in order
to achieve better transfer of the loads, as in Fig. 29a. Field
welding to steel with thicknesses lighter than 12 gage
should be done by qualified welders under controlled con
ditions.
Often panel to panel alignment connections as in Fig. 33
are beneficial. They can usually be added as a field modifi
cation without changing the action of the panel connection
system.
Deflection perpendicular to the plane of the panel is
sometimes limited to L/240. The interior finish systems or
windows that are attached to the panel frame must be com
patible with this deflection.
The panel frame should have sufficient in-plane rigidity
so that the force in the panel tie-backs due to story drift, is
not transferred to the skin anchors.
5.7.4—Connection of Panel Frame to the
Building Structure
Since most of the requirements for connecting GFRC
panel frames to the structure are the same as those for ar
chitectural precast concrete, the designer is urged to see
Refs. 66 and 67 for a more complete treatment of panel
connections. Typical connections are shown in Figs. 30, 31,
32, and 33.
Panel loads are carried through the panel frame to the
panel connection points. The connection location, as well
as panel joints, should be determined jointly by the archi
tect, structural engineer of record, and the GFRC panel
manufacturer during the design stage. It is essential that the
building frame and the GFRC panel joint locations be coor
dinated; so that the engineer of record can design the build
ing frame to accommodate the panels, and the GFRC panel
manufacturer can design the panel and its connections to
accommodate building movements.
A typical panel is attached to the structure with two bear
ing connections at one level. More than two are undesirable
because their reactions would be indeterminate. Panel con
nection loads are point loads, not uniform loads. Flexible,
non-bearing, tie-back connections are provided at another
level to accommodate drift resulting from wind or seismic
loads. Typical connection arrangements are shown in Figs.
20,21,34, and 35. On story height wall panels, the bearing
connections are traditionally near the bottom and the tie-

Fig. 29. Panel frame connector members.
backs near the top, although they can be reversed. Span
drels usually have the bearing connections at the floor,
above the tie-backs. Often panels have additional upper
and lower tie-backs for wind load or alignment, which may
be installed during or after alignment. Loads perpendicular
to the panel are shared by the load bearing and the tie-back
connections. Seismic loads parallel to the face produce hor
izontal loads on any inflexible connections (such as typical
30
bearing connectors), and often vertical loads, to resist in
plane overturn, that add to or subtract from the gravity load
as indicated in Fig. 34.
The seismic response and story drift accommodation are
dependent on the panel connection system, and the manner
in which it isolates the panel from the structure movement.
Tall panels (Fig. 34) can be subject to large, vertical loads
on the bearing connections, due to seismic overturn. To off
set this, if the load bearing connectors provide the horizon
tal resistance, and if they are placed as near to a horizontal
line through the panels center of mass as possible, the
overturn loads are minimized. Story drift accommodation
may require wide panel joints, as shown in Fig. 35.
Tie-backs must be flexible enough so that when the struc
ture deflects, they do not transfer undue load to the panel
frame.
5.8—Inserts and Embedments
There are sometimes requirements for attachments of
other items to GFRC panels. They may be required for ex
ample, on a framed panel skin for a sign, or sprayed in at
the inside of an integral rib panel for its connection to the
structure as in Fig. 36. The same principles apply all con
—
nections should be tested for capacity and be utilized in
such a way as to minimize unwanted restraint. See Section
5.7.2.3 regarding strength evaluation guidelines.
Fastening details should be designed to distribute the
force to as large an area of the GFRC as possible. Encapsu
lated inserts should be set with jigs to protrude slightly
above the surface of the GFRC so they do not become in
advertently recessed. Attachments to inserts should bear di
rectly upon the insert, not the GFRC surface, to prevent ex
cess load on the insert if the bolt is over-tightened. Very
high loads can be exerted when bolts are over-tightened,
leading to bolt failure or local failure of the GFRC. The use
of over-sized washers is recommended when direct bolting
is used. Elastomeric washers may be used, particularly
when the GFRC bearing area is not smooth, flat, and per
pendicular to the bolt.
Many fasteners used with precast concrete panels are also
suitable for GFRC panels. Corrosion resistant inserts and
embedments are recommended. They must be properly em
bedded in built-up homogeneous GFRC bosses or bonding
pads to develop their strength and distribute the load. As
care is needed to encapsulate inserts, the area should be
easily accessible during manufacture. Good quality GFRC
must be used around the embedments. Waste material, such
as over-spray, is not acceptable.
Flexural tension in the area of embedments may reduce
their pull-out capacity.
Rigid embedded items that are bonded to the GFRC, such
as steel more than 6 to 12 in. (150 to 300 mm) long, may
create undesirable restraint to volume change and cause
over stressing of the GFRC. With adequate precautions,
over stressing can be avoided. These precautions include;
isolation of embedded items, use of a bond-breaker, discon
Fig. 30. Spandrel connections.
tinuity of a rigid item, or an increased section of GFRC.
Exterior items, such as small signs, should have sliding
hardware or be set to stand off on long bolts that can flex.
Preferably items should connect to the panel frame, or the
main structure, not the panel skin. The fastening system
must not prevent the movement between the skin and the
panel frame or between the panels and the main structure,
as determined by the connection system.
It is preferable in connection design for integral rib pan
els, to have the main support at the bottom of the panel so
that the panel is put into compression under its own weight.
If panels are excessively restrained, such as by over-tight
ening of nuts and bolts, large or sharp changes in section
Threaded
Rod
ELEVATION
Fig. 31. Tie-back connections.
31
thickness, or by attachment of adjacent components (e.g.,
window frames), movement of the panel skin due to tem
perature or moisture change is restricted. As the panel ages,
any unrelieved strains could exceed the strain capacity of
the GFRC, resulting in cracking.
The fastening detail must provide sufficient three-dimen
sional adjustment for construction tolerance and sufficient
movement ability to accommodate volume changes and al
low for structure movements. Slotted and/or oversize holes
in connections, or special fasteners, are the usual means to
accommodate these requirements. Usually, integral rib pan
els are fixed at one connection while the others have the
freedom to move.
Boxed Studs or Tube
(gage metal OK when
welding is light)
Fig. 32. Bearing connections (combined with tie-back).
 — Tie-back
if Rigid Panels rotates as in (a)
if Flexible Panels Translates as in (b)

— Bearing

& Bottom Tie-backs

Story Drift
Greatly Exaggerated
II I
- Bridging TI I
I
II
if Required
Stiff Tie-backs EeHei
/
\ \ Slottedor
Flexible /
/
\ \ lie-backs--”
-Shims if
Required

a) Rotating b) Translating

Fig. 33. Alignment connections. Fig. 35. Story drift of tall narrow panels.

Consideration should also be given to environmental con
ditions, such as corrosive atmosphere, as well as to fire
protection requirements. Corrosion protection of connec
tion elements should be provided to prevent loss of move
ment. One technique to avoid a corrosion-fused connection
is the use of plastic or fiber washers. Dissimilar metals that
could lead to galvanic corrosion should be avoided.
5.9—Finishes — One and Two Material
Skins
GFRC has been made with all the traditional concrete fin
ishes: paint, sandblasted, exposed aggregate, stone, and ce
ramic veneer. There are limitations, which are discussed
more fully in Section 5.10. Also, see Sections 3.1 and 7.8
for other considerations.
Panel skins are considered one material if they consist en
tirely of glass reinforced material or have only a thin mist
coat. If it has a facing (tile, stone, concrete face mix, etc.),
it is considered a two material skin.
The fine particle sizes in a cement-sand slurry mist coat
can accurately reproduce the textural characteristics of the
mold surface. However, the extent to which the glass fibers
are able to penetrate surface detail depends on the scale of
the detail and the length of the fiber. The surface layer of a
panel is usually unreinforced and such layers are not to be
included in the effective thickness when determining panel

f Short Bearing Angle at Two

/ Locations Only

Gravity • Tie-back Connection

Reaction
÷. Denotes Tie-back Connection
Tie-back Connection Which Can Slide or Flex in
as Required Direction of Arrow
SECTION A
v Denotes Bearing Connection
SECTION A
Fig. 34. Panel connection concepts.
32

Embedded
a) Typical Attachment Detail
\Hidden Box Former
Pocket Type
Insert —‘
/ GFRC Pocket Sprayed Up\
and Compacted In Layers—
b) Typical Box Rib Insert Embedment Detail Pocket Type
Ii
Embedment Depth
Rear Surface of /
/
I
Surface Type Insert
OFRC Skin L GFRC Bonding Pad
—,
c) Typical Insert Embedment Detail Surface Type
Fig. 36. Embedded insert connectors.
strength.
Test specimens used in detennining limiting stress, like
wise, should not include face mix. However, total panel
thickness (including surface finishes) should be considered
when calculating temperature and moisture effects, and
weights. Exposed aggregate or veneer facings can substan
tially increase the weight of a panel and must be allowed
for in the design of the panel, anchors, connectors and lift
ing hardware.
Clay product veneers, which are rigidly bonded to the
GFRC backing, are discouraged due to volume change
considerations. With stone, current practice is to use me
chanical anchors and prevent bond to the GFRC backing.
Volume changes due to moisture content or temperature
variations may cause bowing or cracking when the product
is faced with a material that has significantly different vol
ume change characteristics than the GFRC.
Most materials expand when wetted or heated, and con
tract when dried or cooled but at different rates. The ef
--
fect of their differences, should be minimized by making
the face mix thin and using materials that approximate the
GFRC backing properties as closely as possible, as in Sec
tion 5.10, and by reducing the size of the panel skin seg
33
ments with control and panel joints.
5.1 0—Facing/Backing Interaction
Two material skins, that have a decorative face mix with
properties different than the GFRC backing, should be ana
lyzed in order to give satisfactory results. GFRC mixes
have a cement content in the range of three times that of
conventional concrete mixes. This results in high initial
drying shrinkage, high reversible shrinkage, and high ther
mal expansion coefficients. If a bonded facing has different
volume change characteristics, the skin tends to act like a
bi-metallic thermostat element, developing internal stresses
and curvature. Using proper consideration, a wide variety
of materials have been used successfully. Some problems
have occurred with some materials when inadequately in
vestigated. Architectural concrete face mix, with small ag
gregate, has been the most common and satisfactory.
With face mixes, smaller aggregate sizes give the greatest
leeway for mix adjustment and flexibility of design.
Method of placement is also important. Facing in general
should be thin and of uniform thickness with proper con
sideration given to recesses, projections and changes in
plane Small aggregate concrete can be sprayed. If it has a
water and cement content as close to the backing as is fea
sible, it has the best prospects for compatible properties, al
though larger aggregate mixes can tolerate less cement than
smaller aggregate facing mixes. Sealing the surface or us
ing a polymer curing admixture will also be of benefit by
reducing water absorption, and its associated expansion
and contraction and its effect on the thermal expansion co
efficient.
One rule of thumb for compatibility is that if the backing
has a 1:1 cement/sand ratio the face mix can have a ce
ment/aggregate ratio of from 1:1 to 1:2.5, with coarser
mixes at the leaner end of the range.
There has been some work that indicates that if the ce
ment to aggregate ratio of the face mix is no less than half
(as rich as) that of the backing, satisfactory performance
may be anticipated. By this theory, if the cement to sand ra
tio of the backing is 1:0.8 (=1.25); the cement to (total) ag
gregate ratio of the face mix should be no less than 1:1.6
(=0.625). There has been a limited amount of work done on
this ‘ratio of ratios?, and it should not be expected to take
the place of the more rigorous procedures discussed herein.
It could, however, provide a good starting point.
Tile or ceramic veneer usually have no shrinkage -- or
even expand as they come back to ambient moisture con
tent after firing. Though expensive, if such products are ad
hered to the GFRC backing after the panel is removed from
the mold, and after the initial GFRC drying shrinkage has
occurred, the potential for satisfactory performance is
likely to improve. Use of an elastomeric joint sealant in ve
neer joints should also be beneficial.
Two material skins, in addition to having very significant
stresses, may produce bowing if the layers have signifi
cantly different properties. If this must be resisted by the
panel frame, permanent loads in the anchors and frame
members may need to be considered.
Regardless of what facing is used, tests should be con
ducted on both it and the specific GFRC mix to determine
their volume change characteristics. Even different cements
can have a considerable effect on volume changes.
The majority of GFRC has performed very well, and de
signs have evolved with experience, material, and system
improvements. These many good experiences have resulted
in bolder designs, a few of which have led to the need for
greater consideration of material properties, and their com
patibility. The test data should be analyzed for environmen
tal conditions appropriate to the site. Unfortunately, there is
no standard procedure for this.
Creep (relaxation) will help to relieve the stresses, but the
rates of creep, shrinkage, and change in GFRC strength and
strain to failure, are dependent on many variables and not
always accurately predictable. Its effect is greatest with
sustained loads, such as initial drying shrinkage. It is less
effective with seasonal variations, and almost negligible
with daily cycles. Since face mixes, to a degree, protect the
GFRC backing from outside exposure, the effect of envi
ronmental changes sometimes do not even reach the back
ing.
If the ultimate strength of either the facing or backing is
exceeded, cracking could occur. This may reduce its ability
to resist wind loads and moisture penetration, so panels
should be designed to reduce the probability of cracking.
Crazing, small discontinuous random cracking, is expected
to some extent in most concrete products and should not be
cause for alarm. Any cracking that may occur should be
evaluated on an individual basis.
Although temperature variations could put the GFRC
backing in compression, most commonly, due to initial dry
ing shrinkage, it is in tension. Even though measurements
have shown there is sometimes a small through skin tem
perature gradient, volume change is considered uniform
through each layer of the skin. This simplification is made
in the appendices procedures. In these procedures the skin
stresses, in both face mix and backing, are assumed to be
axial; and due to a differential volume change between the
two layers. The procedure is taken to be the same whether
the variation is due to a difference in moisture induced or
thermal movement or a combination of the two.
See Appendices F and G for further discussion and some
sample calculations of these phenomena.
5.11—Joints
The design of the joints between GFRC cladding panels is
an integral part of the total wall design. Requirements for
joints should be assessed with respect to both performance
and cost. A joint width should not be chosen for reasons of
it must relate to panel size, structure
appearance alone
--
tolerance, anticipated movement, story drift, joint materi
als, and adjacent surfaces. The joint can be expected to ex
pand and contract up to 1/8 in. per 10 ft. of panel width
(1:1000) as a result of moisture and thermal effects.
Movement capability is expressed as a function of the
joint width when installed. Joint width should be four times
the anticipated movement; unless a low modulus sealant is
used, in which case joint width may be as narrow as twice
the anticipated movement. For example, if a joint is ex
pected to move 1/4 in. (6 mm), the joint width, when in
stalled, should be a least 1 in. (25 mm), unless low modu
lus sealant is used. The minimum design joint width should
be 3/4 in. (20 mm). The minimum panel edge return for
proper application of a joint sealant is 1-1/2 in. (38 mm)
with 2 in. (50 mm) preferred. See Section 10.5 and Ref. 66
for additional information on panel joints.
5.12—Condensation Control
The U-value of a wall must be such that the interior sur
face temperature will not fall below the dew-point tempera
ture of the room air, in order to prevent condensation on the
interior surface of the wall. In many designs, the desire to
conserve energy will dictate the use of lower U-values than
those required to avoid condensation.
Water vapor in air behaves as a gas, and will diffuse
through building materials at rates dependent on the vapor
permeability of the materials and vapor pressure differen
tials. GFRC has low water vapor permeance. Permeance is
a function of the water-cement ratio and polymer content of
the GFRC. A low water-cement ratio, such as that used in
GFRC panels results in low permeance.
The colder the outside temperature the greater the pres
sure of the water vapor in the warm inside air to reach the
cooler, dry outside air. Leakage of moisture laden air into
an assembly through small cracks when outdoor air pres
sures are lower than interior pressures, may be a greater
problem than vapor diffusion.
Where climatic conditions require insulation, a vapor bar
rier may be necessary to prevent condensation, and venting
of the wall is recommended. Water vapor entering a cool
panel frame panel cavity may condense, and over an ex
tended period of time, may reduce the effectiveness of fiber
insulation. Water droplets thus formed may also corrode
unprotected steel. If the vapor condenses at or near the ex
terior surfaces, salts in the concrete face mix may be car
ried to the surface and deposited, as efflorescence.
Insulation, if used, should be kept away from the skin
thereby creating a void space between the back of the skin
and the face of the insulation (see Fig.37). This cavity al
lows air circulation, which reduces the presence of mois
ture in the skin. This in turn, will reduce telegraphing of
the panel frame to the outer surface finish.
The analysis of an assembly for the potential problem of
water vapor condensation should consider: (1) the differen
tials between inside and outside temperatures, water vapor
pressures, and relative humidities; (2) temperature gradi
ents through the assembly, the dew point location under de
sign temperatures, and relative humidities; (3) resistance to
vapor transmission of the components of the assembly; and
(4) venting to allow water vapor to escape. Warm air holds
more moisture than cold air and moves from areas of high
34
 to areas of low vapor pressure. In cold climates a vapor
Panel barrier is installed on the building side of the insulation and
in warm climates it is installed on the weather side the in
Skin
_ Air Space
sulation. For a more complete treatment of the subject of
condensation within wall assemblies, see Refs. 66 and 75.
..— Flex Anchor

Batt Insulation 5.13—Architectural Details

Architectural details, such as the control of water run-off to
_— Panel Frame
minimize staining, affect the facade appearance over time
Restraining Straps as much as the material and its finish. Section 3.6 of Ref.
to Maintain Space 66 has a good treatment of this subject and other considera
From Insulation tions that the designer may wish to review.
to Back of Panel Skin
Fig. 38 shows some typical architectural details. These
should be modified to satisfy specific project requirements.
aries 3’ Mm.
Recommended

Fig. 37. Ventilation space between skin and insulation.

Panel
Skin

11
Rounded

a) Typical Panel Edge Detail

Galvanized Or Painted
Sheet Metal Cap By
)uirk Miter
Others (no attachment ci,
C
tOGFRC)_NS__ a

Sealant
Sealant
c) Optional Edge or Control Joint

Sheathing And/ Or
Roofing By Others

Galvanized Or Painted
Sheet Metal Cap By
Others (no attachment
Slope toGFRC)—
Slope Shim Equal
Sealant
to Joint
Sealant Width

Sealant

Flashing By Others
Sheathing And/ Or
‘—Sealant Roofing By Others

z— Sheathing And/ Or g) False Joint

+ - Roofing By Others

Fig. 38. Typical architectural details.

35
 CHAPTER 6—TOLERANCES

6.1 — GENERAL 6.2 — PRODUCT TOLERANCES

Tolerance is a specified permissible variation from re Product tolerances are needed in any manufacturing
quirements of the contract documents. Tolerances should process. They are normally determined by economical and
practical production considerations, as well as functional
be provided for dimensions, locations, and other relation
and appearance requirements. Manufacturing tolerances are
ships. Erection and manufacturing tolerances apply to
applied to physical dimensions of units such as thickness,
GFRC as they do to other building materials.
length, width, squareness, and openings. Tolerances should
Tolerances should be established for the following rea
not be set any smaller than necessary for proper function
sons:
and appearance as doing so will adversely affect cost and
1 .Structural — To ensure that structural design ‘properly
schedule.
accounts for factors sensitive to variations in dimen
The product tolerances for GFRC panels have the follow
sional control. Examples include eccentric loading
ing significance:
condition, bearing areas, hardware and hardware an
1. Length or width dimensions and straightness of the
chorage locations. GFRC unit will affect the joint dimension, opening di
2.Feasibility To ensure acceptable performance of
mensions between panels, and perhaps the overall
—

joints and interfacing materials in the finished struc
ture.
3 .Visual— To ensure that the variations will be control
lable and result in an aesthetically acceptable looking
structure.
4 Economic — To ensure ease and speed of production
and erection by having a known degree of accuracy in
the dimensions of products.
5 .Legal— To avoid encroaching on property lines and to
establish a standard against which the work can be
compared in the event of a dispute.
6.Contractual — To establish a known acceptability
range, and also to establish responsibility for develop
ing, achieving and maintaining mutually agreed upon
tolerances.
The architect should be primarily responsible for coordi
nating the tolerances for all work with the requirements of
other trades whose work adjoins the GFRC units.
It should be understood by those involved in the design
and construction process that tolerances shown in this Rec
ommended Practice must be considered as guidelines for
an acceptability range and not limits for rejection. If these
tolerances are met, the member should be accepted. If these
tolerances are exceeded, the member may still be accept
able if it meets any of the following criteria:
1. Exceeding the tolerances does not affect the structural
integrity or architectural performance of the member.
2. The member can be brought within tolerance by struc
turally and architecturally satisfactory means.
3. The total erected assembly can be modified economi
cally to meet all structural and architectural require
ments.
The enforcement of tolerances should be based on the
technical judgment of the designer. In so doing, the design
professional should decide whether a deviation from the al
lowable tolerances affects safety, appearance, performance
or other trades. In construction very little work is rejected
and removed solely because it is out of T tolerance.’
36
length of the structure. Tolerances must relate to unit
size and increase as unit dimensions increase.
2. Panels that are out-of-tolerance can cause tapered
joints and make alignment of adjacent panels
extremely difficult.
3. Thickness variation of the GFRC panels requires the
use of shimmed furring channels when interior fin
ishes are attached to the panel frame.
Warping and bowing tolerances have an important effect
on the edge match up during erection and on the visual ap
pearance of the erected panels, both individually and when
viewed together.
Warping is generally an overall variation from planeness
in which the corners of the panel do not all fall within the
same plane. Warping tolerances are stated in terms of the
magnitude of the corner variation, as shown in Fig. 39.
Bowing is an overall out-of-planeness condition that dif
fers from warping in that while the corners of the panel
may fall in the same plane, the portion of the panel be
tween two parallel edges is out of plane, as shown in Fig.
40. Differential temperature effects and differential mois
ture absorption between the inside and outside faces of a
panel should be considered in design to both minimize
Fig. 39. Warping definition for panels.
 b. Edge return +1/2 in., 0 in. (+13 mm, 0mm)
- -

c. Thickness:
LEEEE 1. Architectural face mix thickness +1/8 in., -0 in.
(+3 mm, -0 mm.)
2. GFRC backing +1/4in.,-Oin.
Fig. 40. Possible bowing condition. (+ mm, 0 mm)
6 -

3. Panel depth from face of skin to back of panel

frame or integral rib + 3/8 in., -1/4 in.
GFRC Panels
7
(+ lOmm,-6mm)
d Angular variation of plane of side mold
± 1/32 in. per 3 in. (± 1 mm per 75 mm) depth or

Cross Section of Facade
Fig. 41. Differential bowing of panels.
bowing and warping and ensure that the resulting stresses
are kept within acceptable limits.
Bowing and warping tolerances are of primary interest at
the time the panel is erected and should be checked prior to
panel delivery. Careful attention to pre-erection storage of
panels is necessary since storage conditions can be an im
portant factor in achieving and maintaining panel bowing
and warping tolerances.
Differential bowing is a consideration for panels that are
±1/16 in.(± 1.5 mm) total, whichever is greater.
e. Variation from square or designated skew (difference
in length of two diagonal measurements)
1/8 in. per 6 ft (3 mm per 2 m) or 1/4 in. (6 mm) total,
whichever is greater.
f. Local smoothness 1/4 in. per 10 ft
(6 mm per3 m)
g. Bowing: Bowing shall not exceed L/240 unless it can
be shown that the member can meet erection toler
ances using connection adjustments.
h. Length and width of blockouts and openings within
one unit ± 1/4 in. (± 6 mm)
i Location of window opening within panel .± 1/4 in.
..

viewed together on the completed structure, Fig. 41. (±6 mm)

The likelihood that a panel will bow or warp depends on
the design of the panel and its relative stiffness or ability to
resist deflection as a plate member. Panels that are rela
tively shallow or have a ‘flexible” frame, when compared
to their overall plan dimensions, are more likely to warp or
bow.
GFRC panels shall be fabricated within tolerances shown
in Fig. 42.
j. Warpage: Maximum permissible warpage of one cor
ner out of the plane of the other three shall be 1/16 in.
per ft (5 mm per m) of distance from the nearest adja
cent corner, unless it can be shown that the member
can meet erection tolerances using connection adjust
ments. This requirement is illustrated in Fig. 39.
k Position of integral items

— =11_IF—
lIII
2
L
t
Fig. 42. Tolerance locations.

a. Overall height and width of units measured at the face

z
adjacent to the mold:
1. lOft(3m)orunder ± 1/8in.(±3mm)
2.lOft(3m)andover ±1/8 in.per lOft — .---. -

(± 3 mm per 3 m); 1/4 in. (6 mm) maximum Fig. 43. Location of panel frame tolerances.
37
 1. Panel frame and track
2. Flashing reglets at edge of panel
3. Inserts
4. Special handling devices
5. Location of bearing devices
1/4 in. (6 mm)
.±
± 1/4 in.
(±6 mm)
± 1/2 in. (± 12 mm)
± 3 in. (± 75 mm)
± 1/4 in.
(± 6 mm)
6. Blockouts ± 3/8 in. (± 10 mm)
1. Panel frames shall be fabricated within the follow
ing tolerances shown in Fig. 43.
1. Vertical and horizontal alignment.. 1/4 in. in 10 ft.
(6 mm in 3 m)
2. Spacing of framing members . .± 3/8 in.
. .
(± 10 nun)
3. Squareness of frame (difference in diagonals)
3/8 in. (10 mm)
4. Overall size of frame ± 3/8 in. (± 10 mm)
6.3 — ERECTION TOLERANCES
Manufacturing and erection tolerances and the interface
with adjoining trades must be taken into account during the
design phase of each project to assure satisfactory panel in
stallation. Erection tolerances are those required for proper
fit with the building structure. Erection tolerances are de
termined by the characteristics of the building structure and
are provided to achieve uniform joints and plane wall con
ditions. They should be determined on the basis of individ
ual unit design, shape, thickness, composition of materials,
and overall scale of the unit in relation to the building. The
specified erection tolerances affect the work of adjoining
trades and must be consistent with the tolerances as speci
fied for those trades. Where GFRC units connect to site
work, such as footings or foundation walls, sufficient erec
tion tolerances are required.
Erection tolerances are by necessity largely determined by
the actual alignment and dimensional accuracy of the
building foundation and frame. The general contractor is
responsible for the plumbness, level and alignment of the
foundation and building frame including the location of all
bearing surfaces and anchorage points for the GFRC units.
The architect should recognize the critical importance of
controffing foundation and building frame alignment toler
ances and should include, in the contract documents, clear
ance dimensions that allow for building frame tolerances.
If the GFRC units are to be installed reasonably “plumb,
level, square, and true,” the “as-built” location of all ele
ments affecting their alignment, including the levels of
floor slabs and beams, the vertical alignment of floor slab
edges and the plumbness of columns or walls must be
known before erection begins.
The architect/engineer should clearly define in the con
tract documents the maximum tolerances to be permitted in
the building frame alignment, and require verification by
the general contractor that these tolerances are being held.
In addition, the architect/engineer should ensure that the
details in the contract documents allow for the specified
38
tolerances. Lack of attention to these matters often necessi
tates changes and adjustments in the field, not only delay
ing the work but usually resulting in unnecessary extra
cost, and sometimes impairing the appearance of the units
and the completed structure.
Tolerances of the building frame must be adequate to pre
I
vent obstructions that may impact the panel installation
procedure. The building frame should also provide for the
use of standardized connections, i.e. beam elevations and
column locations should be uniform in relation to the
GFRC units with a constant clear distance between the
GFRC units and the support elements.
Tolerances for structural steel framing should be specified
. Particular atten
to conform to the AISC Code of Practice
73
tion is directed to the “Commentary” included with this
Code, which provides a detailed explanation of the speci
fied erection tolerances. The combination of milling, fabri
cation, and erection tolerances result in the final dimen
sional accuracy of the structural steel frame.
The allowable tolerances for steel frame structures can
make it impractical, on tall structures, to maintain GFRC
panels in a true vertical plane. Based on the allowable steel
frame tolerances, it would be necessary to provide for a 3
in. (76 mm) adjustment in connections up to the 20th story
and a 5 in. (127 mm) adjustment in connections above the
20th story if the architectlengineer insists on a true vertical
plane. These adjustments in connections are not economi
cally feasible. Therefore, walls should follow the steel
frame.
For a cast-in-place concrete frame, the maximum toler
ances that should be permitted, unless otherwise stated in
the contract documents, are those given in ACT 117 These
.
tolerances are not realistic for tall buildings when com
pared to AISC Code tolerances and to tolerances actually
obtained on concrete buildings. Also, greater variations in
heights of floors are more prevalent in cast-in-place frames
than in other types of building frames. This will affect loca
tion or mating of the connector in the panel with the cast-in
connection devices. Tolerances for cast-in-place structures
may need to be increased further to account for local trade
practices, the complexity of the structure, and climatic con
ditions. As a result, it is recommended that walls should
follow concrete frames in the same manner as for steel
frames.
It should also be noted that ACT 117 standard tolerances
for concrete construction and material applies only to cast-
in-place reinforced concrete buildings, and the AISC Code
only to steel building frames. Neither of these standards ap
ply to buildings of composite construction (i.e. concrete
floor slabs carried by steel columns or concrete encased
structural steel members). It should also be noted that fire-
proofing and masonry are not controlled by referencing
these standards and the architect/engineer should require
the location of all such materials adjacent to the GFRC
units be within tolerances which are, at most, no more than
those specified in ACT 117. Should there be any doubt as to
what these tolerances should be the GFRC manufacturer
should be consulted for his recommendation. control points and bench marks in an undisturbed condition
In the determination of erection tolerances, attention until final completion and acceptance of the project.
should also be given to possible deflection and/or rotation Non-cumulative tolerances for the location of GFRC units
of structural members supporting GFRC panels. This is are as shown in Fig. 44.
particularly important for bearing on flexible members, a = Plan location from building grid datum*
such as open web joists, or cantilevered structural mem ± 1/2 in. (± 13 mm)
bers. If the deflection of the building frame is sensitive to 1 = Plan location from centerline of steel+
a
the location or eccentricity of the connection, limits should ± l/2in.(± 13mm)
be provided on the erection drawings. Consideration should b = Top elevation from nominal top elevation
be given to both initial deflection and to long-term deflec Exposed individual panel ± 1/4 in. (± 6 mm)
tion caused by creep of the supporting structural members. Nonexposed individual panel ± 1/2 in.
A structural steel building frame presents different erec
(± 13 mm)
tion and connection problems from a cast-in-place concrete Exposed relative to adjacent panel ± 1/4 in.
building frame. For example, structural steel beams, being (6 mm)
relatively flexible in torsion, compared to concrete, may re Nonexposed relative to adjacent panel. .± 1/2 in.
. .

quire that the load be applied directly over the web or that
additional bracing be provided to resist the effects of tor
sion. Problems during erection with rolling of steel beams
may occur if they are not adequately braced. Also, al
lowances must be made when detailing connections of
GFRC panels to steel structures for sway in tall, slender
steel structures with uneven loading, and movements due
to sun or wind on one side or seasonal thermal expansions
and contractions.
Final erection tolerances should be verified and agreed to
prior to the beginning of erection and, if different from
those originally specified, stated in writing or noted in the
contract documents.
Appropriate procedures should be followed to ensure ap
propriate and accurate application of tolerances. The gen
eral contractor should be required to establish and maintain
Bldg. Y Grid Datum
GFRC Panel
XGrid Datum
PLAN
ioj
Building
Elevation
Datum
-naI
ELEVATION
Fig. 44. Tolerance locations for GFRC elements to pre
cast or cast-in-place concrete, masonry, or structural
steel.
39
(13 mm)
c = Support elevation from nominal elevation
1/2 in. (13 mm)
Maximum low
Maximum high 1/4 in. (6 mm)
d = Maximum variation from plumb over height of
structure or 100 ft. (30 m) whichever is less*
1 in. (25 mm)
e = Plumb in any 10 ft. (3 m) of element height
1/4 in. (6 mm)
f = Maximum jog in alignment of matching edges
1/4in.(6mm)
g = Joint width (governs over joint taper) (See Section
10.5.1)
Panel dimension less than 20 ft. (6 m)
± 1/4 in.(± 6 mm)
Panel dimension over 20 ft. (6 m) ± 3/8 in.
(± 10 mm)
h = Joint taper maximum 3/8 in. (9 mm)
10 Joint taper in 10 ft.(3 m)
h 1/4 in. (6 mm)
i = Maximum jog in alignment of matching faces
1/4 in. (6 mm)
j = Differential bowing as erected between adjacent
member of the same design 1/4 in. (6mm)
These tolerances are intended as guidelines only. Consid
eration should be given to the stated tolerances to ensure
that they are applicable to a given project. Upon comple
tion of GFRC panel alignment and before other trades in
terface any materials with the GFRC units, it should be
verified that the GFRC panels are erected within the speci
fied tolerances.
A nominal amount of bowing and warpage can often be
removed during panel alignment. Care shall be taken to en
sure that neither the GFRC skin or the panel frame is over-
stressed when attempting to remove bowing and warpage.
*
For precast buildings in excess of 100 ft. (30 m) tall, tol
erances a and ‘d’ can increase at the rate of 1/8 in. (3
mm) per story over 100 ft. (30 m) to a maximum of 2 in.
(50 mm).
+ For GFRC elements erected on a steel frame, this toler
ance takes precedence over tolerance on dimension ‘a.’
 Limits on the amount of bowing or warping which can be
removed during alignment should be established by the
panel design engineer. Maximum permissible warpage of
one corner out of plane of the other three corners shall be
1/16 in. per ft. (5 mm per m) of distance from the nearest
adjacent corner, or 1/4 in. (6 mm) total after installation.
Bowing shall not be over L/360 with a maximum of 1 in.
(25 mm), where L is the panel length in the direction of the
bow.
Clearance is the space provided between adjacent materi
als. It is one of the most important factors to consider in
erection. The clearance should provide a buffer area where
frame, erection and manufacturing tolerance variatiois can
be absorbed.
The designer should provide adequate clearance space be
tween the theoretical face of the structure and the back face
of the GFRC panel frame in detailing the wall and its rela
tionship to the building structure. Adjacent materials may
include products such as glass or subframes that are in
stalled after the GFRC panels are in place. If sufficient
clearance is not provided, alignment of the wall as speci
fied will likely cause delays and extra costs, and may be
impossible.
The failure to provide adequate clearances is an all-too-
common deficiency of cladding designs. They are ab
solutely essential for any of several reasons:
1. To accommodate movement between adjacent mem
bers.
2. To provide for possible size variation or misalignment.
3. To provide working space to make the connections, suf
ficient room for welding or adequate space to place a
wrench to tighten bolts.
The clearance between the structure and the GFRC panel
is an important detail and impacts the final appearance of
the structure. Clearances should be reviewed during the de
sign stages of the project to assure they are appropriate
from both erection and aesthetic points of view.
The clearance necessary for erection of the GFRC panels
will depend on their design, the dimensional accuracy of
the building frame or other construction to which the
GFRC panels are connected and the limits of adjustment
permitted by the connection details.
A good rule of thumb is that at least 1-1/2 in. (38 mm)
clearance be required between GFRC panels and precast
concrete members; 2 in. (51 mm) is the minimum clearance
between the GFRC panels and cast-in-place concrete, For
steel structures, 1-1/2 in. (38 mm) is the minimum clear
ance between the back of the GFRC panel frame and the
surface of the fireproofing. If there is no fireproofing re
quired on the steel, then 1-1/2 in. (38 mm) minimum clear
ance should be maintained. At least 2 in. (51 mm) clearance
should be allowed in tall, irregular structures regardless of
the structural framing materials. The minimum clearance
between column covers and column should be 2 in. (51
mm), with 3 in. (76 mm) preferred because of the possibil
ity of columns being out of plumb or a column dimension
interfering with the completion of the connection. If clear-
40
ances are realistically assessed, they will prevent many tol
erance problems. Where large tolerances have been al
lowed for a supporting structure, or where no tolerances are
given, the clearance must be increased.
The maximum variation from the specified clearance be
tween adjacent independent members of separate building
parts or components should be ± 1/4 in. (± 6 mm). Adjacent
independent members are members that are close together
but are not connected structurally. These members may be
GFRC and cast-in-place concrete, masonry, or steel. Typi
cally, this clearance situation develops at an expansion joint
or at the interface between a stair tower and a larger struc
ture when the two are joined only by an expansion joint.
All connections should be designed with the maximum
adjustability in all directions that is structurally and archi
tecturally feasible. To accommodate any misalignment of
the building frame, connections should provide for vertical,
horizontal, and lateral adjustments of at least 1 in. (25
mm). Tolerance of hardware items cast into, or fastened to
the structure should be ± 1/4 in. (± 6 mm) in all directions.
Connection details should consider the possibility of bear
ing surfaces being sloped or warped from the desired plane,
which would necessitate field adjustments.
The minimum shim space between various connection el
ements should be 1 in. (25 mm) for steel structures or 1- 1/2
in. (38 mm) for cast-in-place concrete structures.
Where a unit is not erected within the tolerances of the
connection design, the structural adequacy of the installa
tion should be checked and the connection design modi
fied, if required.
No unit should be left in an unsafe support condition. Any
adjustments affecting structural performance, other than
adjustments within the prescribed tolerances, should only
be made after approval by the connection design engineer.
Units should not be forced into place or installed by any
method that would impose undue stress on the unit or the
connections.
The GFRC panels should be located in the center of their
theoretical location on the structure and adjusted to accom
modate adjacent materials, proper joint width, and align
ment with adjacent GFRC panels. Width variations be
tween adjacent joints can be minimized by laying out joint
centerlines along an elevation and centering the units be
tween them. Variations from true length or width dimen
sions of the overall structure are normally accommodated
in the joints or, where this is not feasible or desirable, at the
corner units, in expansion joints, or in joints adjacent to
other wall materials.
During panel installation, priority is given to aligning the
exterior face of the panels to meet aesthetic requirements.
This will result in the interior panel frame face not being in
a true plane. Panel design usually prevents spacing of the
panel frame members from being coordinated with interior
drywall modules. If the panel frame is to receive interior
drywall or similar treatment, the interior finish should be
mounted on a separate stud system or on shimmed
transverse furring elements rather than directly to the panel
frame.
A liberal joint width should be allowed if variations in
overall building dimensions are to be absorbed in the
Theoretical
joints. This may be coupled with a closer tolerance for vari Location (±1/4”)
ations from one joint to the next for uniformity of appear
ance purposes. The individual joint width tolerance should
relate to the number of joints over a given building dimen
sion. For example, to accommodate reasonable variations
in actual site dimensions, a 3/4 in. (19 mm) joint may be
specified with a tolerance of ± 1/4 in. (± 6 mm) but with
only a 3/16 in. (5 mm) differential variation allowed be
tween joint widths on any one floor, or between adjacent
floors. Alternatively, the jog in alignment of edge my be Theoretical
Location (±1I4)
specified.
The performance characteristics of the joint sealant should
also be taken into account when selecting a joint size.
Joints between GFRC units should be wide enough to ac
commodate anticipated wall movements.
In a situation where a joint has to match an architectural Fig. 45. Spandrel (window) rough opening.
feature (such as a false joint), a large variation from the ance) for differential volume changes between the materi
theoretical joint width may not be acceptable and tolerance als. A case in point would be the glazing of an opening
for building lengths will have to be accommodated else completely formed within a GFRC panel. Such openings
where. -
can be made to normal manufacturing tolerances. However,
openings for aluminum windows should allow room for
6.4 — Interfacing Tolerances some temperature expansion of the sash.
Interfacing tolerances and clearances are those required A critical interface area is between the GFRC spandrel
for joining of different materials in contact with or in close panel and the spandrel glazing system. Vertical dimensions
proximity to GFRC panels and for accommodating the rel between spandrels should be checked with a story polel or
ative movements expected between such materials during similar device to ensure that opening size is within allow
the life of the building. Typical examples include toler able tolerances. The interface tolerance between these two
ances for window and door openings, joints, flashing and systems is as shown in Fig. 45. Windows between open
reglets. shape units where they will intersect a joint between units
Where matching of the different materials is dependent on also require interface erection tolerances.
work executed at the construction site, interface tolerances Fabrication and erection tolerances of other materials
should be related to erection tolerances. Consideration must be considered in design as the GFRC panels must be
should also be given to provision for adjustment of the ma coordinated with, and must accommodate the other struc
terials after installation. Where tolerances are independent tural and functional elements comprising the total structure.
of site conditions, they will depend solely on normal manu Unusual requirements or allowances for interfacing should
facturing tolerances plus an appropriate allowance (clear- be stated in the contract documents.

41
 CHAPTER 7— MANUFACTURING
7.1 — Panel Manufacture
GFRC panels should be obtained from manufacturers who
possess a demonstrated capability to produce products of
reliable and consistent quality. These manufacturers must
show that they have the required physical plant and equip
ment, experienced production personnel, and the quality
control procedures necessary to manufacture panels of a
given size with the designed performance characteristics at
the required rate of production. Manufacturing, facilities
and quality control procedures should comply with Ref. 1.
The GFRC manufacturing plant shall be certified by the
Precast/Prestressed Concrete Institute, Plant Certification
Program. Manufacturers shall be certified at time of bid
ding. Certification shall be in Product Group G.
7.2 — Plant Facilities
The facilities required depend on the size, complexity, and
quantity of items to be manufactured at a given time.
GFRC plants shall provide the following:
1. An enclosed area for the dry storage of raw materi
als, as necessary.
2. A storage area that maintains the temperature of the
curing agent above 32 deg. F (0 deg. C) and below
115 deg. F(38 deg. C).
3. Area for mold fabrication and storage.
4. Area for fabricating panel frames and connection
hardware.
5. An enclosed or covered area for the spray operation
that is protected from wind, dust, and direct sunlight.
Temperature extremes that dry the sprayed material
or delay the cure shall be avoided. Strong air cur
rents, which cause plastic shrinkage cracks due to
rapid moisture loss, shall be avoided.
6. Equipment for controlled proportioning and mixing
of the matrix should be of sufficient capacity to per
mit continuous spray operation.
7. Spray equipment for simultaneous deposition of
controlled proportions of matrix and chopping glass
fibers into the molds.
8. Equipment to compact the GFRC composite in the
mold.
9. When a polymer curing admixture is used, a moist
curing facility is not required. The panel temperature
shall be maintained at or above 60 deg. F (16 deg.
C) for 12 to 16 hours. When a polymer curing ad
mixture is not used, a moist environment curing fa
cility with adequate temperature control to achieve
required strength within the curing period.
l0.Equipment to strip the newly manufactured units
from the mold without overstressing them.
11. Handling equipment for rotating, stacking and load
ing finished units for inspection and transportation
42
without marking the finished surfaces or causing ex
cessive .stress in the units.
12.Plant or yard space for finishing operations, and ade
quate space for convenient and proper storage.
13. Area for sample preparation and laboratory testing
unless the services of a testing agency are retained.
7.3 — Molds
The appearance of the finished panel surface is directly
related to the choice of mold material and the quality of the
mold itself. The in-service life of a mold is also a function
of the choice of mold material. All molds, regardless of
material, should conform to the profiles, dimensions and
tolerances indicated by the contract documents and the ap
proved shop drawings.
Molds for GFRC can be made of various materials such as
plywood, concrete, steel, plastics, polyester resins rein
forced with glass fibers (FRP), GFRC, or a combination of
these materials. For complicated details, molds of plaster,
rubber, foam plastic, or sculptured sand may be used.
These molds are often combined or reinforced with wood
or steel depending on the size of the panel to be produced.
Molds should be dimensionally stable to produce the re
quired finish and tolerance. Repeated use of molds shall
not affect the dimensions or planes of the molds beyond
permissible tolerances. Mold materials should not warp or
buckle due to temperature change or moisture, which can
cause unsightly depressions and uneven swells in the fin
ished surface. The mold materials should be non-absorbent
or sealed to prevent excessive moisture absorption in order
to minimize variations in finish.
All corners should have fillets, chamfers or rounded cor
ners (Figs. 15, 38a). Built-in air connections and/or jacking
points help to increase mold life by making stripping eas
ier. Generally, the minimum draft which will enable a unit
to be stripped easily from a mold is 1:8. This draft should
be increased for narrower sections or delicate units as the
suction between the unit and the mold then becomes a ma
jor factor in both design and stripping. The draft should be
increased to 1:6 for screen units with many openings, or for
ribbed panels. Drafts for ribbed panels should be related to
the depth and spacing of the ribs. In instances where verti
cal faces are required, molds should be designed so that the
vertical portion of the mold is removable or collapsible.
Molds should be coated with release agents that will per
mit release without damaging or staining the GFRC, and
without affecting subsequent coating, painting or joint
sealant operations
7.4 — Proportioning and Mixing
Mix design will depend upon strength requirements, the
amount of detail, the form surface, density, fire rating, and
other physical properties. Records should be kept of actual
mixes used. This enables correlation of the properties of
cured products to the specified requirements.
Mix proportions must be left to producer’s discretion to
achieve proper workability, property characteristics and
surface finish under the specific circumstances and with
available materials. Physical properties for use as design
parameters will vary and must be determined from trial
runs and testing prior to establishing mix proportions and
control limits.
7.4.1 — Face Mix
The following factors should be considered in preparing
the mix design:
1. Volume change compatibility with GFRC backing mix.
2. 28 day compressive strength, f > 4000 psi (28 MPa).
3. Absorption < 10% by weight.
4. Entrained air (non-polymer containing mixes) in freeze
thaw areas = 3 to 10%.
5. Maximum aggregate size = 1/4 in. (6 mm)
In proportioning face mixes, attention should be given to
assure sufficient compatibility with the GFRC backing
reasonably similar cement, aggregate, and water contents
should be used. Large differences in physical properties,
such as shrinkage and thermal coefficient of expansion, of
the face mix and GFRC backing mix may cause cracking
and/or delamination.
GFRC backing mixes have a much higher cement content
than conventional concrete. Consequently, integral face
mixes should be compatible with GFRC backing mixes in
the following areas:
1. Initial shrinkage.
2. Moisture induced volume changes.
3. Thermal induced volume changes.
Panels made with one piece corner returns will have dif
ferent exposure of aggregate finish. One side of the panel
will be fabricated flat while the return will be fabricated
vertical. The vertical surface could have a different appear
ance due to this manufacturing process.
7.4.2 — GFRC Backing Mix
The spray process requires a mix that is fluid enough for
continuous pumping, spraying without blockages and
proper compaction. Low water contents give high cured
strength and simplify the spraying of near vertical mold
surfaces.
The following factors should be considered in preparing
the mix design:
1. Fiber content.
2. Fiber length.
3. Desired physical properties.
4. CementJsand ratio.
5. Water/cement ratio.
6. Polymer curing admixture content (if used).
7. Any other admixtures.
In general, nominal fiber content of 5% by weight of total
mix, using 1 in. (25 mm) to 2 in. (51 mm) fiber lengths,
cement-sand ratios of approximately 1:1 to 1:2, water/ce
ment ratio of approximately 0.3, and a polymer curing ad
mixture of 6 to 7% by weight of polymer solids to dry ce
ment, provide a blend of acceptable composite properties
and processability
’
7778
Mixing equipment should be capable of thoroughly blend
ing the materials. Mixes must be free of lumps to avoid
spray blockages. To assure proper proportioning and mix
ing, the polymer curing admixture should be homogeneous
dispersion free from lumps. This is achieved by mild stir
ring, if required, of the polymer prior to proportioning and
mixing. Consideration should be given to the pot life and
mix temperature to avoid blockage of the spray equipment.
It is important to maintain proper cleanliness of the equip
ment.
7.5 — Spray Application of Mist Coat
After application of a form release agent, a mist coat is
sometimes applied directly to the surface of the mold prior
to spray-up, where the surface of the unit will not have a
face mix. The mist coat is a fine coat of cement/sand slurry.
-
The mist coat should be just thick enough to cover mold
details and surfaces. The mist coat should not be too thin,
as fibers might be exposed, nor be too thick, as crazing
might occur as well as adding excess weight. Thickness of
the mist coat may be up to a nominal thickness of 1/8 in. (3
mm). Mixes that contain a polymer curing admixture may
help to reduce crazing of the mist coat surface. The GFRC
backing must be applied prior to drying or set of the mist
coat.
7.6 — Placing and Consolidating of
Face Mix
Face mixes should be sprayed or placed to the required
thickness. The primary concern with the face mix is unifor
mity and thickness. Thickness control of this unreinforced
layer is important to ensure that sufficient material is avail
able for sandblasting or other surface treatments. However,
it is important that the face mix thickness be controlled and
uniform since the thickness of the GFRC backing, to be
subsequently applied on top of the face mix, will be deter
mined based on a measurement of the total thickness of the
skin. Face mixes are generally applied 1/8 in. (3 mm)
thicker than the largest aggregate size.
Sprayable face mixes should be applied in one uniform
layer. Consolidation of face mixes is achieved by trowel
ing, tamping, rolling, or vibrating. Thickness shall be
checked to ensure uniformity over the entire panel. Special
attention shall be given to placement thickness over re
veals, corners and sides. Thickness shall generally be the
minimum possible to achieve the desired finish but shall be
sufficient to prevent bleeding through of the sprayed-up
glass fiber backing mix.
Face mixes should generally be compacted to remove ex
cess air. All corners, recesses, and reveals should be com
pacted with special tools made for each condition to ensure
43
all areas have been compacted. Mold vibration or the use
of vibrating trowels is successful on flat panels. This some
times requires a two step face mix application on profile
molds.
The same face mix applied or consolidated by different
methods may result in varying colors and textures on the
finished product. Therefore, the methods of applying and
consolidating the face mix should remain the same
throughout a project.
The GFRC backing must be applied prior to drying or set
of the face mix.
7.7— Spray Application of GFRC Backing
GFRC manufactured by a spray process, either manual or
automated, is a demanding operation requiring trained op
erators using specialized equipment. The proper spray-up
of GFRC will provide a strong and durable product. The
GFRC backing must be applied prior to drying or set of the
face mix.
In spray processing, simultaneous sprays of cement-sand-
water slurry and chopped glass fibers are deposited from a
spray-gun onto a mold. Slurry is fed to the spray gun from
a metering pump unit and is atomized by compressed air.
The glass fiber roving is fed to a chopper/feeder, mounted
on the slurry gun, which chops the fiber to predetermined
lengths and injects the chopped strands into the slurry
spray which premixes the materials in the air so that a uni
form layer of fiber and slurry is deposited on the mold.
(See Fig. 1, page 1) The operator moves the spray-head
back and forth across the mold, directing the stream of ma
terial normal to the mold surface, until the required thick
ness is achieved.
Each layer is compacted and additional layers are sprayed
while the composite is still wet and plastic (before initial
set) until the design thickness is achieved. Roller com
paction ensures conformation with the form face and re
moval of entrapped air (Fig. 46). A good rolling process
will assure consistent compaction and contact of the slurry
with the fibers and a maximum density. Special care is re
quired to avoid planes of weakness caused by improper
rolling.
Fig. 46. Roller compaction of sprayed-up GFRC.
44
Each layer should be approximately 1/8 in. to 1/4 in. (3 to
6 mm) thick and sprayed in a direction perpendicular to the
previous layer. Thickness checks are required during spray
up. GFRC backing thickness should be 1/2 in. (13 mm) or
design thickness, whichever is greater.
Particular care must be taken to maintain uniform and
proper thickness. This is important in both flat and corner
areas (see Fig. 15) where rolling tends to move material
away from raised corners. Thin areas produce stress risers
and locations for potential cracks.
Scrim may be used to reinforce areas subjected to high lo
calized stress, for example, at corners of openings, at grav
ity anchors, around transitions and shapes such as deep re
veal lines.
7.8 — Surface Finishes
Many types of surface finishes successful with architec
tural precast concrete will be acceptable on GFRC panels.
The absence of large coarse aggregate in the GFRC mix al
lows it to follow closely the surface texture or pattern of
the mold and a wide variety of surface patterns and textures
can be provided. It is advisable to avoid sharp angles and
thin projections whenever possible and incorporate cham
fers or radii at inside corners of the form due to the possi
bility of fiber bridging.
Combination finishes involving the use of more than one
basic finishing method are almost infinite. A demarcation
feature, change of plane or a skin joint should be incorpo
rated into the surface of a GFRC panel having two or more
different mixes or finishes (Fig. 47). The different face
mixes shall have reasonably similar behavior with respect
to shrinkage in order to avoid cracking at the demarcation
feature due to differential shrinkage.
Multiple integral colors and finishes can be achieved
within one panel, expanding design possibilities. Crisp
color transitions can occur in a greater variety of locations
within the panel, and in more intricate detail as compared
to other materials.
The cement matrix also offers a wide choice of color vari
ations through the use of white, gray or buff-colored Port
land cements or through the use of color pigments. It
should be noted that color variation between panels will be
directly proportional to the color intensity. The darker the
color the greater the color variation.
Sample panels of adequate size may be necessary to trans
Demarcation
Between Finishes
and/or Colors
Fig. 47. Demarcation groove between finishes.
late design concepts into realistic production requirements.
With any integral or attached finish material, and its attach
ment, consideration must be given to the thermal and mois
ture-induced volume changes and the compatibility of the
volume changes or stresses with the aged properties of the
GFRC.
The fine particle size of the cement-sand slurry matrix al
lows it to closely follow the surface texture or pattern of
the mold. However, the extent to which the glass fibers are
able to penetrate surface detail depends on the scale of the
detail. The surface layer of a heavily textured panel may
consist of unreinforced cement/sand mortar or it may be
exposed aggregate concrete.
7.8.1 — Mist Coats
A smooth or light textured off-the-form finish, using a
mist coat, may be one of the most economical, but is diffi
cult to produce, as color uniformity of gray, buff, or pig
mented surfaces may be difficult to achieve. Some produc
ers have achieved acceptable uniformity in form finishes
that are white or other pale colors. The cement exerts the
primary color influence on a smooth finish because it coats
the exposed GFRC surface. Many of the aesthetic limita
tions of smooth GFRC may be minimized by the shading
and depth provided by profiled surfaces (fluted, sculptured,
board finishes, etc.), subdividing the panel into smaller sur
face areas, using white cement, or by use of applied coat
ings.
The smooth cement film on the GFRC may be susceptible
to surface crazing, i.e. fine and random hairline cracks.
This is, in most cases, a surface phenomenon and will not
affect structural properties or durability. In some environ
ments, crazing will be accentuated by dirt collecting in
these minute cracks. This will be more apparent in white
than gray finishes and in horizontal more than in vertical
surfaces. The use of polymer curing admixtures in the mist
coat or face mix may minimize crazing.
It is advisable to vary the color or tone of the matrix to
match or blend in with the color of the aggregate. This
match can be achieved by careful selection of cement and
sand colors, and the use of coloring agents. Good matrix to
aggregate match will minimize “patchy” effects (minor
segregation of aggregate) from being noticeable.
7.8.3 — Veneers
Materials such as natural cut stone, (granite, limestone,
marble,) thin brick, ceramic or quarry tile, and architectural
terra cotta, provide a great variety of textures for GFRC
units. Quality requirements (design and production proce
dures) for these finishes should be based on previous
records with the identical materials, or sufficient testing of
sample and mockup units to establish performance criteria
under the service conditions. Particular attention should be
paid to compatibility of materials with respect to differen
tial expansion and contraction caused by thermal and mois
ture changes. It is necessary to consider the differential vol
ume change of veneer facings and GFRC backing.
A complete bondbreaker between natural stone veneer and
GFRC should be used. Bondbreakers may be a polyethyl
ene sheet or a polyethylene foam pad or sheet. Connection
of the natural stone to the GFRC should be with mechani
a)
1/16” Oversize Typ.
5/32ø or 3/I 6ø
Stainless Steel
Spring Clip
Rubber Sleeve
1/2 Mm.

7.8.2 Face Mixes 3/4” Mi

::...
:•

r
— ..:
Generally GFRC panels are produced with a face mix that
. :. :
consists of sands, aggregates or color pigments specifically b)

selected for appearance reasons. The size of coarse aggre

/fd4q////
gate varies from 3/16 in. (5 mm) to 1/4 in. (6 mm).
Exposing the aggregates may be achieved by removing Bondbreaker / - 1/4” Mm.
1/4e
surrounding paste through chemical processes, such as us
ing retarders or acid etching, or mechanically through abra
L 3/1 6o or 5/320
Stainless Steel Clip
Hole Filleri
w/Epoxy

sive blasting. Each method will uniquely influence the ap

pearance of the exposed surface.
1/8-31160
Light or medium exposure of aggregates is possible. Sam Stainless Steel Clip
ples should be made to define the depth of sandblast for the
desired finish. With a light sandblast finish, surface imper
fections in the mold or repairs will tend to be more notice
C)
able than with a medium or heavy sandblast finish.
Exposed aggregates can be brightened by washing with
diluted murjatjc acid. This removes the dull cement film,
1/4” Mm.
which remains when exposure techniques such as washing
and brushing are used. Fig. 48. Stone anchor details.
45
cal anchors which can accommodate some relative move
ment due to differential volume change.
Cracking can occur in the GFRC backing if the veneer an
chorage provides excessive restraint. This is particularly
critical where the face materials are large (cut stone). The
introduction of skin joints in the GFRC andlor the limita
tion of the size of the stone pieces may be necessary to pro
vide a properly functioning system. Attention to details
during design and fabrication is critical to ensure that dif
ferential volume change is accounted for. Problems can oc
cur if the interaction characteristics of the veneer-GFRC
backing system are not examined
74
There are several different styles of stone veneer anchors
available. Three examples are shown in Fig. 48. The an
chors are Type 302 or 304 stainless steel with a diameter of
1/8 in. (3 mm) to 3/16 in. (5 mm). They are commonly the
same as those used in veneer-faced precast concrete, but
may be modified to account for the thin section of GFRC.
The spacing and quantity of anchors are dependent on
many factors:
1. Flexural strength of the stone.
2. Thickness of the stone.
3. Strength of the GFRC backing.
4. Strength of the anchor assembly.
Anchor placement can vary based on the results of the
tests performed on the stone and anchor assembly. The
minimum ratio of test load to service load should be five to
one.
When terra cotta is used, the application should be the
same as natural stone veneer. Terra cotta should have a
bondbreaker between it and the GFRC and be attached
with mechanical anchors.
Coatings
7.8.4 —
Coatings may be used for purely decorative reasons.
Every coating is formulated to give certain performance
under specific conditions. Since there are vast differences
in coating types, brands, prices, and performances; knowl
edge of composition and performance standards are neces
sary for obtaining a satisfactory GFRC coating.
GFRC is sometimes so smooth that it makes adhesion of
coatings difficult to obtain. Such surfaces should be lightly
sandblasted or acid etched, to provide a slightly roughened
surface.
Coatings applied to exterior surfaces should be of the
breathing type, (permeable to water vapor but impermeable
to liquid water), or wall cavities should be well vented
when a non-breathable coating is used. Typically, latex or
fluorene coatings are suitable for most exterior applica
tions. When decorative colored coatings are applied to the
exterior surface, the interior surface of exterior walls
should have a vapor barrier to prevent water vapor inside
the building from entering the wall. The paint manufac
turer’s instructions regarding mixing, thinning, tinting, and
application should be strictly followed.
46
7.9 — Panel Frame
Most GFRC panels are fabricated using a panel frame to
provide stiffening and structural support. The frame is gen
erally made using light gage steel or a combination of
structural shapes and light gage steel.
Loads from the panel skin are transferred to the panel
frame through flex, gravity and, in some cases, seismic an
chors.
The panel frame transfers panel loads to the building
frame, supports the panel skin, supports the window and
acts as a grid support for interior insulation, fire stops and
wall coverings. The studs and anchors are based on design
and are generally placed at 24 in. (610 mm) on center.
The anchors must be designed and welded to the frame to
accommodate moisture and thermal movement of the skin
without imposing excess restraint. Oversized, incorrectly
welded, incorrectly positioned or embedded anchors can
cause undue restraint resulting in stresses sufficient to
crack the skin.
The prefabricated panel frame will be moved several
times both before and after skin attachment, therefore,
welded rather than screw connections are more desirable,
although both systems are acceptable.
When light gage steel is welded, it should be a minimum
of 16 gage [0.0598 inch (1.52 mm) nominal, 0.0566 inch
(1.44mm) design, 0.0538 (1.37mm) minimum uncoated
thickness] material. Care should be taken when welding
plates and angles to the light gage steel to prevent burn-
through, since bum-through can significantly alter the sec
tion properties of the member and the strength of the
welded connection. If thick hardware, such as plates or an
gles for bearing connections, is required, supplementary
thin plates or angles should first be welded to the studs as a
base for welding the thick hardware to the panel frame.
Welding should comply with AWS Dl .1 and AWS Dl .3.
Wire feed welding with Gas Metal Arc Welding (GMAW)
(MIG welding) and Shielded Metal Arc Welding (SMAW)
(stick welding) are commonly used.
Accessible welds on corrosion protected material (galva
nized or painted) should be slagged and touched up after
welding.
After fabrication, the panel frame is attached to the
GFRC. After the GFRC is sprayed and roller compacted to
its design thickness, the panel frame is positioned over the
skin by jigs or brackets. The panel frame must be installed
before the GFRC backing reaches initial set.
The flex anchors should not protrude into the GFRC back
ing. The pressure of the anchor compresses the GFRC and
changes it’s density and water/cement ratio in that area and
may cause a blemish or shadow mark on the exterior fin
ished face.
For production convenience, the flex anchors are usually
set from 1/8 to 3/8 in. (3 to 10 mm) away from the surface
of the GFRC backing. With some finishes, they may touch
the surface of the GFRC backing.
Contact between the panel skin and the panel frame will

Ia) IE
Ica
a)
C
c
0 backing and there could be a possible delamination prob
Fig. 49. Clearance between GFRC backing and panel
frame.
impose restraint to movements of the skin. Therefore, the
clearance between the skin and the panel frame at all loca
tions should be a minimum of 1/2 in. (13 mm), Fig. 49, or
extra care should be employed during manufacturing to en
sure an unrestrained skin.
Immediately following placement of the frame, GFRC
bonding pads are placed over the foot of each anchor and
integrated into the GFRC backing. Thickness of the bond
ing pad over the top of the flex-anchor should be a mini
mum of 1/2 in. (13 mm). The effective area of the bonding
pad (effective length x effective width) should be a mini
mum of 24 sq. in. (155 sq. cm), Fig. 50.
The bonding pad is usually manufactured by the hand
pack method. The hand pack method is accomplished by
tween the final roller compaction of the GFRC backing and
the placement of the frame and the bonding pads should be
kept to a minimum. This is necessary to ensure bonding of
the overlay. If there is a significant time delay, initial set of
the backing could prevent the overlay from bonding to the
lem. Care must be taken not to build up the bonding pad
over the heel of the anchor and thus add undue restraint to
the skin.
Bonding pad installation procedures must remain the
same as were used in tests to determine design values.
Broken bonding pads sometimes need to be repaired in
the plant or in the field. In order to repair a broken bonding
pad, the surface of the GFRC skin should be roughened,
and some glass fibers exposed. This area then should be
cleaned of any loose debris. A latex (acrylic copolymer) or
epoxy bonding agent should then be applied to the area and
a fresh bonding pad attached to the GFRC skin. As with
standard flex anchors, each manufacturer should test the
bonding pad repair procedure to establish data for use in
design. Due to creep considerations, the aforementioned re
pair technique is limited to repairing not more than 10% of
the total anchors on a panel.
7.10 — Curing
Mixes with Polymer Curing Admixtures The poly
—

the operator spraying the GFRC composite into a suitable mer curing admixture in the mix creates a film in the back
container or premixing the composite. The material is then ing and on the air exposed surfaces which holds the mois
deposited (by hand) over the flex anchor foot and the oper tire in the panel and eliminates the need for 7 days moist
ators knead them into the GFRC backing. Time delay be- ’ 79 All polymer curing admixtures have a mini
7778
curing
mum film formation temperature (MFT) below which the
Effective Width polymer spheres will not coalesce to form a tough, durable
film. Initial curing temperatures must be maintained above
the MFT until the film formation process is complete. The
recommended minimum panel curing temperature is 60
deg. F (16 deg. C) which should be maintained for 12 to 16
hours. The GFRC temperature should not exceed 120 deg.
F (50 deg. C).
After the GFRC backing has been sprayed, compacted,
the panel frame set and the bonding pads applied, the panel
should be covered with plastic or tarpaulin until stripping.
This will maintain at least a 65 percent RH environment
during initial cure and protect the panel from excessive air
movement. The film formation process is not disturbed by
-
Effective Length covering since the cement hydration and moisture evapora
3Mm.
tion into the space between the backing and the covering is
:
ongoing. Covering of the panel may also accelerate initial
1/8 Heel strength development of the GFRC backing.
to 3/8 Cover
— GFRC Care must be used when using overhead heaters in cold
Backing climate production. Excessive heat or hot molds coupled
* with low relative humidity can create situations where the
panels are subjected to rapid moisture loss which can lead
to drying shrinkage cracks. This can be eliminated by cov
ering the panels with plastic or tarpaulins as soon as possi
Facing Material ble after production.
Fig. 50. Bonding pad details. Moist Curing — Proper curing of fresh GFRC without

-“....--
polymer curing admixtures requires moist atmosphere so
that moisture is retained to assure adequate hydration of ce
ment and to prevent formation of cracks due to rapid loss
of water. Curing procedures should be well established and
properly controlled to develop the required GFRC quality
and strength, as well as to minimize any surface blemishes,
such as non-uniformity of color, staining or cracking.
Immediately after spray-up operations are completed or•
panel frame has been installed, the panel should be covered
with a polyethylene sheet. It should remain covered
overnight to avoid drying and to achieve adequate strength
for stripping. During this period, the temperature of the
GFRC should be maintained above 60 deg. F (16 deg. C) to
aid early strength development.
After initial overnight curing, the panel should be re
moved from the mold and placed in a controlled curing en
vironment. Panels should be kept in a surface-damp condi
tion at a temperature above 60 deg. F (16 deg. C) in a mini
mum of 95% relative humidity for a period of 7 days. Con
sistent and uniform curing conditions should be provided.
GFRC units should be cured as long as possible with a
minimum of seven days. At no time after spray-up and be
fore the end of the minimum seven days wet cure should
any portion of the unit be allowed to dry. GFRC panels are
usually thin and are susceptible to rapid drying. Curing ma
terials or methods that allow one portion of a unit to cure or
dry out faster than other portions may produce color varia
tions in the finished product and differential shrinkage
which can lead to warping or cracking of the unit.
Accelerated curing systems with temperatures over 120
deg. F (50 deg. C) are not recommended and may be detri
mental to strength.
7.11 — Stripping
The panel does not achieve its fully cured properties at the
time of stripping. Therefore, panel and mold design should
allow sufficient lifting points and easy release from the
mold without overstressing.
Stresses imposed on the panel skin during stripping of the
panel from the mold, handling, transporting or erecting
should remain as low as possible, and ideally below the
yield strength at the specific time of that operation.
The panel frame usually acts as a lifting frame for the
panel during stripping, handling and erection. Depending
on the weight of the panel and the location of the pickup
points, the panel may be sthpped with or without an auxil
iary spreader beam.
Localized panel frame deformations due to lift cable or
hook attachment are usually of negligible significance.
7.12 — Cutting and Grinding
When cutting or grinding GFRC panels, appropriate per-
48
sonal protective equipment should be worn to avoid respi
ration of fine silica dust.
7.13 — Handling
Each manufacturer should develop specific panel handling
procedures. These procedures should include
demolding/lifting, storage, preparing panels for transport
and tie-down of panels during transportation. When panels
are handled and/or shipped in orientations other than their
final orientation on the building, special considerations
may be required for frame and flex-anchor design.
Panels should be handled to avoid structural damage,
cracking, architectural impairment or permanent distortion.
The number and location of lifting points for handling of
elements and details of lifting devices should be considered
integral parts of the design of GFRC units and should be
shown on the shop drawings. Lifting points may also serve
as fastening points for connection to the building structure,
provided they are designed for that application also.
7.14 —Yard Storage
A general rule of thumb regarding panel storage and trans
port preparation procedures is to not subject the panel skin
to any loads. Panels should be supported and tied down by
the panel frame and should not be stacked without special
precautions.
GFRC panels should be stored on unyielding supports at
designated locations on a firm, level and smooth surface
with identification marks visible. Dunnage and storage
racks, such as A-frames and vertical racks, should be well
constructed and aligned to minimize warping, bowing,
chipping or cracking of the GFRC panels. Protective mate
rial should be provided at points of contact with exposed
surfaces. All blocking, packing, and protective materials
should be of a type that will not cause damage, staining, or
objectionable disfigurement of the panels. Staggered or un
even blocking should be avoided. When setting one panel
against another, non-staining protective blocks should be
placed immediately in line with the supports of the first
panel.
When long panels are stored vertically, horizontal support
should be provided at each end.
The GFRC panels should be protected from contact with
earth, oil, gas, tar or smoke. Any soiling or weathering of
units, which would result in a pattern different from the
normal weathering as finally installed, shall be avoided by
storing in a manner similar to their final position, or by
suitable protection from such soiling or weathering. Em
bedded items should be protected from penetration of water
or snow during cold weather.
 CHAPTER 8— QUALITY CONTROL
8.1 — General
The manufacture of GFRC products requires a greater de
gree of craftsmanship than conventional precast concrete.
Therefore, it is important for manufacturers to implement
an active Quality Control program that conforms to recog
nized standards. Ref. I is a comprehensive manual includ
ing both a standard and commentary covering all aspects of
Quality Control.
The Quality Control program should include inspections,
tests of raw materials and tests of the cured GFRC. These
tests are required to ensure a consistent and uniform manu
facturing process. Properties of all materials used in the
manufacture of GFRC panels should be verified by appro
priate tests performed by either the material supplier or the
panel manufacturer.
In order to establish evidence of proper manufacture and
conformance with plant standards and project specifica
tions, a system of records should be kept to provide full in
formation on material tests, mix designs, GFRC tests, in
spections, and any other information specified for the proj
ect.
Each GFRC panel should be marked with an identification
number referenced to the production and erection drawings
and testing records. The date of manufacture should be in
cluded. In the absence of specification requirements,
records should be kept for a minimum of two years after
acceptance of the structure.
8.2 — Acceptance Testing of Materials
Cement. Plant testing of cement is not required if mill
certificates are supplied with each shipment. All cement
should meet the requirements of the specified type in
ASTM C 150. Mill certificates should be kept on file.
Glass Fiber. Plant testing of glass fiber is not required if
the glass fiber strand is certified as being manufactured
with an alkali-resistant glass produced using a minimum of
16% Zirconia and conforms to the specification require
ments contained in Appendix K. Certificates should be kept
on file.
Sand. Sieve analyses (ASTM C l36’) should be con
ducted on samples taken from each shipment received at
the plant.
Facing Aggregates. Fine and coarse aggregates should be
regarded as separate ingredients and each should conform
to the requirements for facing aggregates specified in Ref.
1.
Water. Water should be chemically analyzed when a pri
vate well or nonpotable water is used. Except for water
from a municipal supply, an analysis of the water should be
on file at the plant, be updated annually, and be clearly re
lated to the water in use.
Admixtures. Plant testing of admixtures is not required if
Certificates of Compliance with appropriate requirements
49
are supplied with each shipment. Instructions for admixture
use should be kept on file at the plant with the mill certifi
cates.
Curing Agent. Plant testing of curing agents is not re
quired if curing agents are certified to conform to specifi
cation requirements in Appendix L. Curing agents are sen
sitive to freezing and should be visually inspected for color
changes and/or coagulation upon delivery and prior to use.
Certificates of Compliance should be maintained on file.
Form Release Agents, Surface Retarders, and Sealers. In
structions for proper use and application should be ob
tained from suppliers and kept on file at the plant for all
such materials.
Structural Shapes, Cold-Formed Steel, Hardware, and
Inserts. Mill certificates for all of these items should be
obtained from the manufacturers and maintained at the
plant.
8.3 — Preproduction Testing
Face Mixes. All face mixes should be developed using the
brand and type of cement, the type and gradation of aggre
gates, and the type of admixtures proposed for use in pro
duction mixes. Face mixes should be tested to determine
volumetric changes due to moisture variation.
In addition, acceptance tests for face mixes should also in
clude compressive strength, absorption, unit weight, and air
content, as described in Ref. 1.
GFRC Backing. Prior to design and production, a mini
mum of twenty unaged flexural strength tests (of six speci
mens each) produced on twenty separate days should be
conducted.
Flex Anchor and Gravity Anchor Pull-off and Shear
Tests. Prior to design and production, a minimum of
twenty unaged strength tests of each type and size of an
chor should be conducted. The specimens and test proce
dures should accurately simulate the various service condi
tions that are expected to be encountered during the life of
the project.
8.4 — Production Testing of Aggregates
A sieve analysis (ASTM C 136) should be conducted in
the plant with test samples taken at any point between
stockpiling and batching. If material is stored in bulk, a
sieve analysis should be conducted at least monthly during
the period of time the material is being used or more fre
quently if necessary. Each shipment of aggregate should be
visually compared with the approved aggregate sample.
Moisture tests are not required for bagged aggregates
stored indoors. Surface moisture in bulk aggregates should
be evaluated and compensated for in all face mix and back
ing slurry proportioning. If moisture meters are not used to
continuously monitor moisture, the free moisture should be
determined any time a change in moisture content becom
obvious.
es The test board for a panel having a surface finish such as a
mist coat or exposed aggregate should be made without
that surface finish but should in all other respects duplicate
122883.
I
the production panel. Also see ASTM C
8.5 Production Testing Wet
Wash-out Tests. The wash-out test is used to determine
—
—

For details of test procedures, see Appendix F of Refer the glass fiber content of the backing.
ence 1. The average glass content determined by the wash-out test
Slurry Consistency Slump Test. Slurry consistency should be recorded and be within the control limits of —

slump tests for each mixer should be performed at the be 0.5, + 1.0% by weight of the mix. If either the spray gun
re
ginning of each shift. With the use of high range water calibration or spraying technique is modified, an additional
, slump test may not be approp ri
ducers in a mix design the wash-out test should be performed.
mixer should be equipp ed with an ss
ate. As an alternate, each The uniformity of glass distribution through the thickne
ammeter that indicates the relative resistance of the mixer (top to bottom) is important and can be checked by means
motor. This is an advisory test performed at the discretion of the wash-out test with split samples. This is an adviso
ry
of the manufacturer. test performed at the discret ion of the manuf acturer . If a
Slurry Unit Weight. The unit weight test (ASTM C dual head (rather than a concen tric) spray gun is used
138) should be performed once per day before starting (where the glass is sprayed into the slurry stream from
one
3
production. The unit weight should not vary more than side) this test should be perform ed weekly . Also see ASTM
) from the established unit weight for the par
pcf (48 kg/rn
3 C 122883 and C 122984.
ticular mix design in use. This is an advisory test per Thickness. The skin thickness specified is the minimum
formed at the discretion of the manufacturer. for all points on the skin. Thickness of both the face
mix
red
Slurry Temperature. Temperature should be measu and GFRC backing should be checke d with a suitabl e
nt in
and recorded when test specimens are made, at freque depth/thickness gage. This is best done using a simple pen
ons
tervals in hot or cold weather, and at start of operati etration gage.
F
each day. An armored thermometer accurate to ± 2 deg. A minimum of one thickness measurement should
be
sample until the reading
(± 1 deg. C) should remain in the made per 5 sq. ft. (0.5 m2) of panel surface with at least six
adviso ry test performed at the
becomes stable. This is an measurements per panel. Bonding pad size, thickness and
acturer . d.
discretion of the manuf compaction over anchors should be visually checke
Spray Rate. The slurry flow rate (bucket test) and the Bonding pad thickness over gravity anchors should be
fiber roving chopping rate (bag test) should be used to de checked with a penetration gage at 50% of the anchor loca
termine if the fiber content being delivered by the spray tions.
equipment is within limits. The ratio of the fiber roving Additional thickness measurements should be made at
chopping rate to the slurry flow rate gives an indication of sensitive areas of the panel such as at corners, reveals
the fiber content. These tests should be performed for each (false joints) and other breaks in plane surfaces, and attach
spray machine before starting production each day and af ment inserts. Inside corners require special attention to en
ter any extended shut-down. After final setting of the fiber sure that thin areas, voids, and non-reinforced areas are not
roving chopping rate, the length of any three fibers from incorporated into the panel. Thin areas should be built-u
p
the bag test should be measured and should be within 15% by spraying fresh material into the area concer ned and not
of the required length. mold
by transferring sprayed material from one part of the
Test Boards. Test boards should be sprayed alongside of to another.
and in exactly the same way as the panel (i.e., distance of Face Mix. Air content tests should be conducted daily
on
test
spray gun to surface, rolling, troweling, etc.). The mixes containing air-entraining admix tures.
board should be lightly trowelled and should be appropri
ately sized to provide two wash-out test specimens, six Production Testing After Curing
8.6 —

flexural test specimens, and anchor connection test speci

—

For details of test procedures, see Appendix F of Refer

mens as required. As a minimum, one test board should be
ence 1.
sprayed at least once per work shift per operator per spray
be Backing Strength Tests. Flexural tests of the GFRC back
machine per backing mix design. Each test board should
ication numbe r. The test ing should be performed at 28 ± 2 days. See ASTM
marked with a unique identif
so C96
8
.Te sts should be performed each day for each opera
47
boards should be fabricated at a different time each day lity
tion condit ions and tor, spray machine, and backing mix design. As variabi
they represent the full range of produc ses, as demon strated by plotted test
in these factors decrea
do not become part of a routine sequence of events. of testing may be reduce d to a mini
result data, frequency
Test boards manufactured with the panels should be cured
mum of one test per backing mix design per day. These re
and stored in a similar environment as the panels until they
duced frequency tests should be selected to check all oper
are removed for testing. The elapsed time between removal
be ators and machines on a rotating basis and the results of
of test board from this environment and testing should of
these tests should be plotted daily to verify consistency
kept as short as possible.
50
test results.
The strength level should be considered satisfactory if
both the following requirements are met:
1. The average of all sets of three consecutive yield
strength test values (average of six specimens each)
shall equal or exceed thef’ used in design. Also the
average of all sets of three consecutive ultimate
strength test values (average of six specimens each)
divided by 3 shall equal or exceed the f’ used in de
sign.
2. No individual yield strength test value (average of six
specimens each) shall be less than 90 percent of the
f’ used in design. Also no individual ultimate
strength test divided by 3 shall be less than 90 percent
of thef’ used in design.
If any strength test falls below these requirements, the
GFRC design engineer shall take steps to assure that the
GFRC panels represented by the test coupons are not jeop
ardized. The design engineer may request additional
coupon testing from the same test board, have the panel
load tested, have coupons cut and tested from suspect
GFRC panels or take other appropriate action.
Face Mix Strength Tests. Compressive strength tests of
the face mix should be conducted weekly in accordance
with ASTM C 3990
Bulk Density and Absorption. These measurements
should be used to establish the level of compaction of the
GFRC and should be performed weekly for each operator,
spray machine and backing mix design. A test sample (two
specimens) should be prepared from the test boards. Speci
mens may be taken from portions of actual flexural speci
mens. These tests should be conducted in accordance with
ASTM C948
.
97
51
Flex Anchor and Gravity Anchor Pull-off or Shear
Tests. Anchor connection tests should be conducted on 12
in. x 12 in. (30 cm x 30 cm) (minimum) specimens cut
from test boards. To confirm production values, two test
specimens of one type and size of anchor should be made
from the test boards produced during a week. During the
following weeks additional types and sizes of anchors
should be tested so that all types and size of anchors are
evaluated. Of the specimens produced during one week,
two test specimens of an anchor type and size should be
randomly selected and tested at an age of approximately 28
days after spray-up date. Manufacturers may develop alter
nate equivalent sampling procedures. Also see ASTM
.The anchor strength level should be considered
95
C1230
satisfactory if both of the following requirements are met:
1. The average of all sets of three consecutive anchor
strength tests equals or exceeds one and two thirds
times the P used in design.
2. No individual anchor strength test is less than one and
one half times the P used in design.
Bonding pad repair methods should be evaluated and doc
umented by test data.
Inspection
8.7 —
To ensure that proper methods for all phases of production
are being followed and that the finished product complies
with specified requirements, inspection personnel and a
regular program of inspecting all aspects of production
should be provided. Inspectors should be responsible for
the monitoring of quality and should not be responsible for
or to production.
 CHAPTER 9— LOADING AND DELIVERY
GFRC products are usually transported by tractors and
semi-trailers, but rail or barge transportation may be more
feasible over long distances. The normal highway restric
tions on weight and size will have to be observed. Because
of their thin wall construction, which reduces weight,
GFRC panels can offer a cost savings in delivery.
The manufacturer should ensure that panels are ready for
delivery before loading. This may necessitate a lead time
for final checking, possible cleaning and minor repairing
that may be required as a result of damage or accumulation
of dirt in storage. Panels should not be shipped to josites
until they have reached sufficient strength to withstand the
effects of the particular shipping and handling methods
used.
Factors such as the size, shape, type of finish, method of
transportation, type of vehicle, weather and road condi
tions, and distance of haul enter into determining the neces
sity of wrapping or protecting the GFRC panels during
shipment.
Panels should be loaded as necessary:
1. To permit their removal for erection from the load in
proper sequence to minimize handling.
2. With proper supports, blocking, cushioning, and tie-
downs to prevent or minimize in-transit damage.
3. With proper padding between GFRC and chains or
straps to preclude chipping of the GFRC.
4. To support the panels in a manner to minimize relative
movement between the panel frame and the skin.
The blocking points and orientation of the panels on the
shipping equipment should be determined by manufacturer.
GFRC panels should be loaded so the GFRC skin does not
support the weight of the unit. This is generally achieved
by blocking between the trailer bed and the panel frame. To
minimize cyclic loading of the skin anchors, it may be ad
visable to provide additional blocking to the skin, after the
panel weight is supported on the panel frame. Since the
trailer bed is flexible, two-point support is recommended.
Blocking, packing and other protective materials should
not cause damage, staining or other disfigurement of the
panels.
Suitable materials that will cushion and protect the panel
edges during shipment should be used. When tying down
the GFRC panels to the trailers, it is preferable to use nylon
straps rather than chains. Special care is required to protect
the panels at the binding points of the straps, and to protect
against the “slap’ of a long reach strap. Over tightening of
straps must be avoided as this may result in cracking and
permanent deformation of the panels. If panels are nested
or stacked, consideration should be given to transfer of ver
tical load to prevent progressive crushing or other damage.
This can be prevented by blocking the panels from panel
frame to panel frame. Special support frames may also be
used to prevent damage from occurring. Attention should
be given to adequately support any top or bottom returns at
52
Support Top Return
(remove after
installation)
Frame
Fig. 51. Recommended strapping (blocking) procedure.
the strapping points to avoid cracking of the GFRC skin
(see Fig. 51).
The erection supervisor should coordinate the arrival of
the panels at the jobsite for erection in a safe and proper
manner.
All GFRC panels should be clearly piece marked as indi
cated on the erection drawings. Any panels that require se
quential erection should be so marked. Weight of the units
should be communicated to transport and erection person
nel.
Corners and panels with returns of unusual length are of
ten shipped with edge-to-edge bracing, that should not be
removed until just prior to erection.
There are a variety of ways by which a panel may be
hoisted into position. The type of erecting equipment is de
termined by the weight of the product and reach distance to
set the panel. If possible, panels should be unloaded by
handling in a vertical position. All chains, binders, straps,
bracing, packing and edge protection of the panels should
be carefully removed prior to unloading.
Panels should be lifted slowly from the transport vehicle.
If any binding occurs during lifting, the panels should be
lowered and the obstruction removed. Panels should be
handled to prevent structural damage, cracking or chipping.
Groups of panels should not be removed with one lift un
less designed accordingly.
Adjacent panels remaining on the trailer should be tied or
blocked to prevent tipping.
Balance of the trailer should be maintained by unloading
alternate sides of the vehicle or by blocking the trailer. The
exterior panel should be unloaded first from a stack to min
imize chipping and scraping; panels should not be slid out
from the middle of a stack.
Site conditions should allow erection equipment and
transportation units to proceed under their own power to a
location where GFRC panels can be handled by the erec
tion equipment directly from the transportation units. Site
storage, other than on trailers, should be avoided, as it is
expensive and can result in damage to the product, If tem
porary job storage of panels is required, storage areas
should be relatively level and firm, well-drained, and lo
cated where there is little chance of damage due to other
construction activity. In addition, site conditions, season of
the year, and length of storage at the jobsite should be con
sidered in detennining the necessity of protection to pre
vent accumulation of dust, dirt or other staining material
from discoloring the panels. If a loaded trailer is stored at
the jobsite, the shipper should carefully block the trailer to
prevent damage to panels or accidental overturning. Block
ing of trailers is necessary on sites that are frozen, and sub
ject to thawing. The stored trailer should be parked on firm
level ground.
53
If required, rotation of panels should be done while sup
ported by the crane in the air and not by resting the panels
on the truck or ground unless the panels are specifically de
signed for such stresses.
Wall panels which are shipped flat should be picked up in
the same position and tilted to a vertical position by using
two crane lines, carefully avoiding tipping or twisting dur
ing this operation.
For unusually shaped panels, special erection rigs, such as
rotating sheaves, spreader beams or specially designed lift
ing brackets should be used to avoid damaging the panels
during hoisting and installation.
 CHAPTER 10—INSTALLATION
101 — Coordination
An efficient jobsite operation is the result of planning be
tween the manufacturer, trucker, erector, and the general
contractor. The following items should be reviewed prior to
installation:
1. Check jobsite access for all necessary equipment.
2. Check building frame tolerances and supporting sur
faces to minimize delays.
3. A sequence that will best utilize the available trucking
equipment.
4. A steady delivery of panels to the jobsite will ensure
efficiency and panel installation.

10.2 — 80
Erection
Erection supervision requires knowledge about handling
and positioning panels on the building. Advance planning
will ensure the presence of all necessary tools, equipment
and loose connection hardware. Jobsite conditions must
properly accommodate the erector’s equipment operating
under its own power.
A satisfactory installation results if the erector under
stands product manufacturing and erection tolerances cou
pled with permitted variations in building frame construc
tion. Panels that are to be installed in a special sequence
should be so noted on the erection drawings.
Prior to the start of erection and scheduling of delivery Fig. 52. Lightweight hydraulic crane used to erect
spandrel panels.
equipment, the jobsite should be inspected to determine ac
cessibility for the erection and delivery equipment. Sched that the connection system functions in the manner in
uling and coordination of erection with other trades is nec tended. Shims should be placed at panel frames not under
-

essary. The position and elevation of connections integral
with the building frame or foundation shall be verified be
fore the GFRC units are erected.
The GFRC erector shall establish joint locations prior to
actual panel installation. This will minimize the variation
in joint widths, as well as identify problems caused by the
building being out of dimensional or alignment tolerance.
In general, panels should move directly from truck to
building to minimize the hazards and costs of extra han
dling. Should jobsite storage be necessary, the erector
should observe proper yard storage practices. The erector
should confer with the manufacturer on proper storage
methods if they are not shown on the erection drawings.
The low weight of GFRC panels permits lighter and less
expensive handling equipment. A simple hoist, mounted on
the roof, or a small crane may be sufficient (Figs. 52 and
53). Care is required during lifting since the lightweight
GFRC panels are susceptible to movement due to wind.
The erector should understand the function and perform
ance of each connection detail to ensure that panels are in
stalled in keeping with the design concept. Field modifica
tions to the panel frame or connection system should be
made only with the approval of the engineer responsible
for the design. If connections require temporary support,
such as shims, they must be removed as soon as possible so
54
the GFRC skin.
The installation or prewelding of miscellaneous steel
hardware should be performed prior to the start of erection,
whenever possible, to minimize the cost of crew and equip
ment standby.
The supply of loose erection hardware needed for the con
nection of GFRC members is normally the responsibility of
the GFRC manufacturer.
The responsibility for supply of contractor’s hardware to
be placed on or in the structure to receive the GFRC units
varies with local practice and should be clearly defined in
the contract documents. Hardware should be incorporated
in the structure, within the specified tolerance, according to
a predetermined and agreed upon schedule.
Each GFRC unit should be securely fastened in place as
indicated on the erection drawings. Field checks should be
performed to ensure that panels have been installed in ac
cordance with the drawings.
During installation, priority is given to aligning the exte
rior face of the panels because of aesthetics. This may re
sult in the interior frame faces not being in a true plane.
Where necessary, the erector should correct misalignment
of the units resulting from minor deflection and/or rotation
of the supporting structure due to the weight of the GFRC
units.

Fig. 53. Truck crane used to erect window wall panel.
Units may be erected with a predetermined allowance for
such movements or, following field installation, adjust
ments may be made to connections which have been
specifically designed for such movements.
Window frames should be attached directly to the head
and sill tracks of the panel frame (or a separate framing
system). The window loads, both dead load and wind pres
sure, are to be supported by the panel frame and transferred
through the frame to the panel connections attached to the
structure. The window frame is shimmed by the glazier to
its proper location and then screw attached to the panel
frame (see Fig. 54).
The only contact between the window frame and the skin
is the joint sealant, allowing the skin to move and prevent
ing undue restraint of the skin. The skin can be expected to
expand and contract up to 1/8 in. per 10 ft. (3 mm per 3 m)
as a result of moisture and thermal effects. Restraint due to
improper installation of the window frame may result in
excessive restraint of the skin, thus creating a possible fu
ture cracking problem. The sealant joint between the win
dow frame and skin also keeps the wall system weather-
tight.
Insulation, fire safing, electrical and telephone conduits
may be placed in the wall cavity created by the panel frame
(Fig. 55). Insulation, safing and other trade items are in
stalled at the jobsite by other subcontractors.
Screws
Shim by Glazier
Sealant
Panel
Skin
Fig. 54. Attachment of window frame to panel frame.
55
Fig. 55. Conduit, and insulation, or fire sating placed in
wall cavity.
10.3 — Connections
All connections that serve similar functions should be
standardized as much as possible. As workers become fa
miliar with the procedures required to make the connec
tion, productivity is enhanced and the potential for errors is
reduced. Standardization of details facilitates selection and
shipment of connection items to the project with fewer de
lays and added economies.
Standardization also applies to the dimensioning of con
nection details. Little is gained by slight changes in dimen
sions, since the savings and materials maybe more than off
set by the extra labor involved in developing the modifica
tions. Furthermore, if different connections vary only
slightly in dimensions, there is a greater chance that an im
proper connection may be used at a given location.
It is desirable to have connections that are designed to en
able the erector to safely secure the member to the structure
in a minimum amount of time without totally completing
the connections. Often temporary connections are used
with final adjustment and alignment capability. The con
nection is then completed later without tying up the crane.
This allows the crane to begin placing the next unit while
connections on the first are being completed. Temporary
connections should not interfere with, or delay the place
ment of, subsequent members. Temporary connections may
have to be relieved or cut loose prior to completion of the
permanent connections.
Where welded connections are used, welding shall be per
formed by certified welders in accordance with the erection
drawings which shall clearly specify the type, size, length,
sequence if critical, and location of welds. Field welding
shall be inspected as per contract documents. Welding shall
be in accordance with AWS Dl. 1 and 1.3. The temperature
of the environment as well as materials to be welded shall
be taken into consideration prior to the start of welding.
Surfaces to be welded shall be clean and meet AWS re
quirements. Painted or galvanized components shall be
touched up after cutting or welding, if required, with a rust
inhibitive or zinc rich paint.
With welded connections, units may be temporarily
shimmed while initial tack welding is accomplished. Provi
sions shall be made to hold the unit safely in place while
adjacent units are placed and final adjustments are made.
Before shims are removed, the final welds shall be com
pleted
Bolting shall be in accordance with the erection drawings.
Following erection, a check of bolt size, position, and tight
ness shall be made. For sliding connections, the nut shall
be prevented from turning but not tightened so that it can
not move within the connection’s slot. Roughness at
sheared or flame cut edges of slots or holes may have to be
removed. When direct bolting through the panel skin is
used, over-sized washers, at least three times the bolt diam
eter should be used.
Bolting generally permits an initial connection to be made
with final alignment done later. Often, a bolted connection
is used for initial installation and alignment even if the fi
nal connection is to be welded.
Usually integral rib panels are fixed at one point while the
other connections have freedom to move. For integral rib
panels, it is preferable in connection design to have; (1) the
main support at the bottom of the panel so that the panel is
in compression under its own weight the connections are
-
only required to restrain the panel, (2) the fastening system
must allow movement between the panel and the structure
to avoid overstress.
If the panels are restrained, such as by over-tightening of
nuts or bolts, large or sharp changes in section thickness, or
by attachment of adjacent building components (e.g. win
dow frames), movement of the panel skin due to tempera
ture or moisture changes is restricted. As the panel skin
ages, any unrelieved strains could exceed the strain capac
ity of the aged GFRC, resulting in cracking. Low friction
washers (Teflon or nylon) may be desirable to ensure abil
ity for movement of bolts.
Connection details should provide sufficient three direc
tional allowance to accommodate creep, thermal and mois
ture induced panel movements, field tolerances, and di
mensional changes in the building frame. Slotted and/or
oversized holes in connections or special fasteners are the
usual means to achieve this.
Connections may have to be protected from corrosion de
pending on exposure conditions. Protection may be:
1. Painting with shop primer
2. Coating with the zinc rich paint
3. Epoxy paint
4. Hot dip galvanizing
5. Zinc or cadmium plating
10.4— Protection of Work
All GFRC units should be furnished to the jobsite in a
clean and acceptable condition.
The GFRC erector should protect the unit and adjacent
material such as glass and aluminum from damage by field
welding or cutting operations and provide noncombustible
shields, as necessary. To minimize staining, all loose slag
and debris should be removed immediately after welding is
complete. The general contractor should be responsible to
56
protect the erected panels from damage or staining by other
trades. Any cleaning or repair of the GFRC work subse
quent to installation and/or acceptance should be done by
the erector or manufacturer but under the responsibility of
the general contractor. Specifications should clearly state
this responsibility.
10.5 — Acceptance
One person should have final and undisputed authority for
acceptance of the work. Contract documents should iden
tify this person.
The manufacturer, if responsible for erection, should
make a thorough inspection of the installation after erection
and arrange for final repairs, and cleaning, if required, to
ensure readiness for other trades such as joint sealing, win
dow installation, etc., and final acceptance.
The erector/GFRC manufacturer should periodically re
quest approval and acceptance for all GFRC work com
pleted, as deemed necessary in order to adequately protect
the interests of everyone involved. In most cases the size
and nature of the project will dictate the proper intervals
for securing approval and acceptance. Periodic approval in
writing should be considered when it appears that such ac
tion will minimize possible problems, which could seri
ously affect the progress of the project.
Upon notification by the erector/GFRC manufacturer, the
contractor and architect and/or engineer should promptly
make arrangements for final inspection of the erected por
tion of the work to determine if it is plumb, level, aligned
within tolerances and that proper connections have been
made.
10.6 — Patching and Repair
GFRC panels may be superficially damaged (minor chip
ping or spalling) during transport or erection. A certain
amount of repair of product is to be expected as a routine
procedure. Production blemishes should have been cor
rected at the plant. Since patching and repair of GFRC is a
specialized activity, it is recommended that the manufac
turer’s personnel be used for repair work. They understand
the use of bonding agents and shading or texturing tech
niques. It may even be necessary to prepare a composite
patching mix reinforced with glass fibers. Damage that af
fects the structural integrity should be discussed with the
design engineer. In general, the extent of patching and re
pairing required should be minor. It is important that all re
pairs be performed in advance of final cleaning and joint
sealing. The repair work must be fully cured, clean, and dry
prior to sealing joints.
10.7 — Cleaning
Dirt and stains that occurred during yard storage, ship
ping, or erection shall be cleaned. Many panels will require
only spot cleaning and with soap and water while some
may require a general cleaning. Cleaning should be pre
formed no earlier than three days after any GFRC skin re
pairs have been completed and after all joints are sealed.
The manufacturer should be consulted regarding cleaning
procedures. Prior to preceding with general cleaning, a
small [at least one square yard (0.8 square meters)] incon
spicuous area should be cleaned and checked to be certain
that the procedures are not detrimental to the GFRC or ad
jacent materials. The effectiveness of the cleaning on the
sample area should be judged after the surface has been al
lowed to dry for it least one-week. Cleaning should be
done when the temperature and humidity allow rapid dry
ing. Slow drying increases the possibility of efflorescence
and discoloration.
A suggested order for testing procedures for removal of
dirt, stains, and efflorescence is:
l.Dry scrubbing with a stiff fiber brush.
2.Abrasive blasting with industrial baking soda.
3. Wetting the surface with water and vigorous scrubbing
with a stiff fiber brush followed by a thorough rinsing
with clean water. High-pressure water or steam clean
ing may also be thed.
4. Chemical cleaning compounds such as detergents,
muriatic acid, phosphoric acid, or other commercial
cleaners used in accordance with the manufacturer’s
recommendations.
5. Sand blasting may be considered if this method was
originally used in exposing the surface.
For information on removing specific stains from GFRC
reference should be made to “Removing Stains and Clean
ing Concrete Surfaces,” IS 214, published by the Portland
Cement Association, Skokie, IL.
For information on efflorescence that may occur to vari
ous degrees on panel surfaces, reference should be made to
“Efflorescence of Precast Concrete,” TN-3, published by
the Precast/Prestressed Concrete Institute, Chicago, IL.
10.8— Joint Sealing
One-stage joints are most commonly used in the United
States, normally in the form of an elastomeric sealant close
to the exterior surface. A minimum GFRC panel return of
1-1/2 in. (38 mm) at the joints is recommended with 2 in.
(51 mm) preferred. The following are general guidelines
for the use of joint sealants. For a comprehensive discus
sion of joint sealants used between wall panels, refer to
ASTM Cl 193° and consult with sealant manufacturers and
installers.
A joint will provide a degree of watertightness consistent
with its design and exposure. In addition the intended use
and size of the building will also determine design require
ments for the joint. Design criteria for joints include;
amount of movement to be accommodated, architectural
appearance, function of the building, exposure (orientation
and climatic conditions) and economics. The following de
cisions must be made in response to the design criteria:
width and depth, type, location, number, architectural treat
ment and materials selection.
Ideally, joint locations should be determined during the
57
design development phase. Items affected by joint design
are: panel size, weathering, tolerances, transition between
adjacent materials, and location of openings.
Characteristics that should be considered when making
the final selection of sealants from those with suitable
physical (durability) and mechanical (movement capabil
ity) properties are: adhesion to different surfaces, surface
preparation necessary to ensure satisfactory performance,
serviceable temperature range, curing characteristics (dirt
pickup, susceptibility to damage due to movement of joint
while sealant is curing), puncture, tear and abrasion resist
ance, color desired and color retention, ease of application
and compatibility with other sealants to be used on the job.
10.8.1 —Width of Joints
Sealant life and performance are greatly influenced by
joint width. Joints between GFRC panels must be wide
enough to accommodate anticipated wall movements. Joint
tolerances must be carefully evaluated and followed if the
joint sealant system is to perform within its design capabil
ities.
When joints are too narrow, bond or tensile failure of the
joint sealant will occur, and/or adjacent units may come in
contact and be subjected to unanticipated loading, distor
tion, cracking and local crushing (spalling).
Joint widths should not be chosen for reason of appear
ance alone, but must relate to panel size, anticipated move
ment, building tolerances, joint sealant materials and adja
cent surfaces. The required width of the joint is determined
by the temperature extremes anticipated, the movement ca
pability of the sealant to be used, the temperature at which
the sealant is initially applied, panel size and fabrication
tolerance of the GFRC units. The following factors take
precedence over appearance requirements:
1. Temperature Extremes: The temperature range used
must reflect the differential between seasonal extremes of
temperature and temperature at the time of sealant applica
tion. Although affected by ambient temperature, joint
movement must be determined from panel temperature
rather than ambient temperature. Consideration should be
given to the orientation of the wall surface in relation to the
sun. South walls will experience significantly higher tem
peratures, while north walls may experience lower.
2. Sealant Movement Capability: The minimum design
width of a panel joint must take into account the total antic
ipated movement of the joint (i.e., the GFRC panels) and
the movement capability of the sealant. All GFRC is sub
ject to volume changes from creep, shrinkage, and temper
ature variations.
3. Application Temperature: A practical range of instal
lation temperatures considering moisture condensation at
low temperatures and reduced working life at high temper
atures, is from 40 to 90 deg. F (5 to 35 deg. C). This tem
perature range should be assumed in determining the antic
ipated amount of joint movement.
Many factors may be involved in actual joint movement.
These include, but are not limited to: mass of material,
 lion, building settlement, method of fastening
color, insul of fasteners, differential heating due to van- Tooled Exterior Face
and locatio’ , thermal conductivity, differential thermal Surface
able shadirg), building sway, and seismic effects. Larger
stress (bowje wider joints in order to accommodate realis
panels reqU in straightness of panel edge, edge taper, and
tic toleranc Material and construction tolerances that can
panel W1dtt1ler joints than anticipated are of particular im
produce Smch tolerances should be considered in the de
portance. S jjons and considerations. Skin
sign calcu1’ also accommodate variations in building and
Backer Rod
Joints musions so a liberal tolerance should be allowed
panel dime’s widths. For example a 3/4 in. (19 mm) joint
Fig. 56. Joint with field-molded sealant.
for the Ofl/_jfie(J with a ± 1/4 in. (± 6 mm) tolerance.
may be spe’ calculation of panel joint size can be made as on the ideal proportion, however, generally accepted guide
A practic lines are:
1. For joints from 1/2 in. to 1 in. (13 to 25 mm) wide: The
followLc + B + C
sealant depth should be 1/2 the width.
2. For joints in excess of 1 in. (25 mm) wide: Sealant
where: um joint width, in. depth should be 1/2 in. (13 mm) maximum.
J = mini movement capability of the sealant in percent.
The depth of the sealant should be controlled by using a
X = stattd movement of panel from thermal changes
suitable backup material. To obtain the full benefit of a
A = calcjcjent of thermal expansion) (change in tern-
well designed shape factor, the backup materials must have
e) (panel length)
= (coe3-
1 a bondbreaker surface or be flexible enough that it doesn’t
perat .jal construction tolerances.
limit shape change of the sealant, Fig. 56. (Note sealant
B = matj or other considerations as appropriate.
shape: wide edges for bond, narrow center for flexibility.)
C = seis ,4ng example will illustrate the use of the equa
The follo” of 15 ft. (4.57 m) length, expecting a maxi 10.8.2 — Sealant Installation
tiOn. PaneJramre change in the concrete of 60 deg. F (33 The sealants used for specific purposes are often installed
mum temp by different subcontractors. For example, the window sub
sealant installation temperature, with a mate
deg. C) 0 contractor normally installs sealants around windows,
tj-uction tolerance of 0.25 in. (6 mm), are to be whereas a second subcontractor typically installs sealants
rial or con a sealant having ± 25% movement capability
sealed W1tl’jned by ASTM C7 1 9)B1 If the coefficient of between panels. The designer must select and coordinate
(as deteril
1 nsion of the GFRC is assumed to be 12 x l0 all of the sealants used on a project for chemical compati
thermal e?(
j2, the calculated movement of the panel from
9 bility and adhesion to each other. In general, contact be
iniinideg’ ge is as follows: tween different sealant types should be minimized.
thermal cl1 iinJdeg. F) (60 deg. F) (180 in.) = 0.130 in. The recommendations of the sealant manufacturer should
(l2xl06 always be followed regarding mixing, surface preparation,
X = 25’on tolerance =0.25 in. (6 mm) priming, application life, and application procedure. Good
Construct considerations workmanship by qualified sealant applicators is the most
c important factor required for satisfactory performance.
No seisn3ted minimum joint width is as follows:
The0.13j) +0.25 in.=0.77 in. The edges of the GFRC units and the adjacent materials
must be sound, smooth, clean, and dry. They must also be
.th determined is too wide, another sealant hay- free of frost, dust, loose mortar or other contaminants that
If joint movement capability should be selected. For may affect adhesion such as form release agents, retarders,
rug a gre movement capability is ± 50%, the joint width or sealers. Sometimes, smooth GFRC has a ‘skin” on the
example, ple becomes 0.51 in. (13 mm). surface, which may peel off leaving a gap between it, and
in the exaió optimum quality for the installation and per- the GFRC after the joint sealant has been applied. It may
To provi 0 field-molded sealants, the architect should be more economical and effective to prepare joint surfaces
formancet widths not less than 3/4 in. (19 mm). Corner prior to erection, if required. It may be desirable to conduct
specify j0 j be 1 in. (25 mm) wide to accommodate the
1 adhesion or peel tests to determine the compatibility of the
joints shOnent and bowing often experienced at this loca sealant with the contact surfaces.
extra moV v joints are a high risk for any joint sealant in Backup materials help to shape sealants. When selecting a
tion. Naii
0 backup material andlor bond breaker, the recommendations
stallation ed sealant depth is dependent on the sealant of the sealant manufacturer should be followed to insure
The req1) time of application. The optimum sealant compatibility. The backup should not stain the sealant, as
width at this may bleed through and cause discoloration of the joint.
th relationships are best determined by the
width/d@Vjjfacturer Since all manufacturers do not agree Backup materials, should be of suitable size and shape so
sealant nV
58
that, after installation, they are compressed 30 to 50 per
cent. Principal functions of backup materials are: control
ling the depth and shape of the sealant in the joint (provide
proper sealant dimensions and shape), serving as a bond
breaker, assisting in tooling of the joint and protecting the
back side of the sealant from attack by moisture vapors try
ing to escape from the building.
Primers may be recommended by the sealant manufac
turer. Special care should be exercised to avoid staining the
outside face of the GFRC unit since some primers will
leave an amber colored stain if brushed along the surface.
This stain will have to be mechanically removed which
will be expensive. The primer should be allowed to cure
before application of the sealant. The sealant and primer
should always be supplied by the same manufacturer.
10.9 — Sealers Clear Surface Coatings
-
Due to its density, even with the minimum practical thick
ness, GFRC does not require sealing for waterproofing.
Sealers or clear surface coatings may be considered for the
possible improvement of weathering characteristics or to
59
reduce water absorption and dirt accumulation.
Sealers or clear surface coatings should be tested on rea
sonably sized samples of varying ages, and their perform
ance verified over a suitable period of exposure, or use
based on prior experience under similar conditions. Sealers
should be applied in accordance with the manufacturers
written recommendations. Some sealers may stain, soil,
darken, or discolor the finish. Also, some sealers may af
fect the bond of joint sealants or cause the joint sealants to
stain the panel. The manufacturer of both the sealer and the
joint sealant should be consulted or the specified materials
should be pre-tested before application.
Jobsite applied coatings should not be applied until all re
pairs and cleaning have been completed. In cases where the
panels have been coated at the manufacturing plant, and
additional cleaning is required; it may be necessary to re
coat those particular panels.
Low-pressure, airless spray equipment is commonly used
to apply sealers. This results in a uniform application while
avoiding excessive rundown. Care must be taken to keep
sealers off of glass or metal surfaces unless testing shows
no detrimental effect.
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81. “Test Method for Adhesion and Cohesion of Elastomeric
Joint Sealants Under Cyclic Movement (Hockman
Cycle) “ASTM C7 19, ASTM, West Conshohocken, PA.
82. “Method of Test for Strength Retention of Glassfibre in Ce
ments and Mortars” The Glassfibre Reinforced Cement
Association, Wigan, United Kingdom, GRCA S0104/0184,
January 1984,20 pp.
83. Standard Practice for Preparing Coupons for Flexural and
Washout Tests on Glass Fiber Reinforced Concrete, ASTM
C1228, ASTM, West Conshohocken, PA.
84. Test Method for Determination of Glass Fiber Content in
Glass Fiber Reinforced Concrete (GFRC) (Washout Test),
ASTM C 1229, ASTM, West Conshohocken, PA.
85. Test Method for Performing Tension Tests on Glass-Fiber
Reinforced Concrete (GFRC) Bonding Pads, ASTM
C1230, ASTM, West Conshohocken, PA.
86. Test Method for Flexural Properties of Thin-Section Glass-
Fiber-Reinforced Concrete (Using Simple Beam With
Third-Point Loading, ASTM C947, ASTM, West Con
shohocken, PA.
87. National Building Code, Building Officials Code Adminis
trators International, Country Club Hills, IL
88. Standard Building Code, Southern Building Code Congress
International, Birmingham, AL
89. Horsley, F. Wm., “The Durability And Degree Of Aging Of
GFRC Wall Panels After Ten Years of Service on a Beach-
front near Boston Massachusetts in the USA,” Proceedings
10th Biennial Congress of the GRCA, Strasbourg, The
Glassfibre Reinforced Cement Association, Wigan, United
Kingdom, 1995.
90. Test Method for Compressive Strength of Cylindrical Con
crete Specimens, ASTM C39, ASTM, West Conshohocken,
PA
91. Test Method for Sieve Analysis of Fine and Coarse Aggre
gates, ASTM C136, ASTM, West Conshohocken, PA
92. Test Method for Unit Weight, Yield, and Air Content
(Gravimetric) of Concrete, ASTM C138, ASTM, West
Conshohocken, PA
93. Ball, Hiram P. Jr. and Wackers, Math “Long Term Durabil
ity of GFRC Composites Containing Polymer”, Proceed-
62
ings 10th Biennial Congress of the GRCA, Strasbourg, The
Glassfibre Reinforced Cement Association, Wigan, United
Kingdom, 1995.
94. Ball, Hiram P. Jr. “Polymer modified glass fiber reinforced
concrete composites- a 20 year review”, Proceedings 11th
Biennial Congress of the GRCA, Cambridge, The Glassfi
bre Reinforced Cement Association, Wigan, United King
dom, 1998.
95. Firestop Systems Inc., 1412 Derwent Way, Delta, B. C.,
Canada V3M 6H9.
96. International Building Code, International Code Council,
Inc., Falls Church, VA., 2000.
97. Test Method for Dry and Wet Bulk Density, Water Absorp
tion and Apparent Porosity of Thin Sections of Glass Fiber
Reinforced Concrete ASTM C948, ASTM, West Con
shohocken, PA
Supplementary References
5-1. “International Congress on Glass Fibre Reinforced Ce
ment,” Proceedings, The Glassfibre Reinforced Cement
Association, Wigan, United Kingdom, October 1977, 343
pp.
S-2. Hannant, D. J., “Fiber Cements and Fiber Contents,” John
Wiley & Sons, 1978,213 pp.
S-3. “The Developing Success of GFRC,” Proceedings Interna
tional Congress on Glassfibre Reinforced Cement, London,
The Glassfibre Reinforced Cement Association, Wigan,
United Kingdom, October 1979, 122 pp.
S-4. “GRC in the 80’s” Proceedings of the International Con
gress on Glass Fibre Reinforced Cement, The Glassfibre
Reinforced Cement Association, Wigan, United Kingdom,
November 10-12, 1981,412 pp.
S-5. Fordyce, M. W., and Wodehouse, R. G., “GRC and Build
ings,” Butterworth Publishers, Stoneham, MA, 1983, 226
pp.
S-6. “Proceedings of International Congress on Glass Fibre Re
inforced Cement,” October 5-7, 1983, The Glassfibre Rein
forced Cement Association, Wigan, United Kingdom, 1983,
254 pp.
S-7. “Proceedings 5th Bicentennial Congress of the
GRCA,”October 16-18, 1985, Darmstadt, West Germany,
The Glassfibre Reinforced Cement Association, Wigan,
United Kingdom, 1985, 352 pp.
S-8. “Fiber Reinforced Concrete and it’s Applications,” SP-105,
American Concrete Institute, Detroit, MI, 1987, 600 pp.
S-9. “Proceedings 6th Bicentennial Congress of the
GRCA, “October 20-23, 1987, Edinburgh, Scotland, The
Glassfibre Reinforced Cement Association, Wigan, United
Kingdom, 1987,282 pp.
S-b. “Proceedings 7th Bicentennial Congress of the
GRCA, “September 26-28, 1989, Maastricht, The Nether
lands, The Glassfibre Reinforced Cement Association,
Wigan, United Kingdom, 1989, 323 pp.
S-il. “Thin-Section Fiber Reinforced Concrete and Ferroce
ment,” SP- 124, American Concrete Institute, Detroit, MI,
1990,448 pp.
S-12. “Fiber Reinforced Concrete,” SP 39T, Portland Cement
Association, Skokie, IL. 1990, 54 pp.
S-13. “Proceedings 8th Bicentennial Congress of the
GRCA, “October 21-24, 1991, Maastricht, The Netherlands,
The Glassfibre Reinforced Cement Association, Wigan,
United Kingdom, 1991,402 pp.
5-14. Majumdar, A. J., and Laws, V., “Glass Fibre Reinforced
Cement,” Blackwell Scientific Publications, Inc., Cam
bridge, MA, l99l,pp. 197.
S-15. Balaguru, R N., and Shah, S. P., “Fiber-Reinforced Cement
Composites,” McGraw-Hill Inc., New York, NY, 1992, 530
pp.
S-16. “Proceedings 9th Biennial Congress of the GRCA”, June
13-17, 1993, Copenhagen, Denmark, The Glassfibre Rein
forced Cement Association, Wigan, United Kingdom, 1993.
S-17. “Proceedings of the 9th Biennial Congress of the GRCA”,
Copenhagen, Denmark. The Glassfibre Reinforced Cement
Association, Wigan, United Kingdom, June 13-17, 1993,
219 pp.
63
S-18. “Proceedings 10th Biennial Congress of the GRCA”, Stras
bourg, The Glassfibre Reinforced Cement Association,
Wigan, United Kingdom, October 9-16, 1995,256 pp.
S-19. “Proceedings 11th Biennial Congress of the GRCA”, Cam
bridge, The Glassfibre Reinforced Cement Association,
Wigan, United Kingdom, April 14-16, 1998, 192 pp.
S-20. Glassfibre Reinforced Concrete-Practical Design and
Structural Analysis, Peter Curiger (Editor) Fachvereinigung
Faserbeton e.V., Dusseldorf, Germany, Beton-Verlag GmbH
[Also: Glassfibre Reinforced Cement Association, Wigan,
United Kingdom], 1995, 8Spp.
 APPENDIX A
In order to maintain the required reliability it is important
that an adequate number of tests be made under production
conditions by each manufacturer on the specific mix to be
used for a job. Each flexure test is the average of three
specimens loaded with the mold side in tension and three
with it in compression to account for thickness, and surface
variations. A minimum of twenty tests (120 flexure speci
mens or twenty anchor specimens of a type) are recom
- STUDENTS t
mended, more are better. Students t values listed below
with the procedures in Section 5.4.1 and 5.7.2.3 account
for the actual number of tests. A wide range of Students
values are presented so that equivalent reliability can be
obtained while taking advantage of a greater number of
tests or if circumstances dictate, proceeding with a smaller
number of tests.

um value.
Table Al. Students t for the required 99% of tests to be above the assumed minim
Number Degrees Students Number Degrees Students
Number Degrees Students
of of t of of t
of of t
Tests Freedom Tests Freedom
Tests Freedom
14 13 2.650 26 25 2.485
2 1 31.821
15 14 2.624 27 26 2.479
3 2 6.965
16 15 2.602 28 27 2.473
4 3 4.541
17 16 2.583 29 28 2.467
5 4 3.747
18 17 2.567 30 29 2.462
6 5 3.365
19 18 2.552 31 30 2.457
7 6 3.143
20 19 5.539 41 40 2.423
8 7 2.998
21 20 2.528 61 60 2.390
9 8 2.896
22 21 2.518 121 120 2.358
10 9 2.821
23 22 2.508 00 00 2.326
11 10 2.764
12 11 2.718 24 23 2.500
13 12 2.681 25 24 2.492

The variation of test values is as important as high average both the number of tests and their coefficient of variation
values. Small variation indicates more uniformity and a on the ratio of assumed ultimate strength for design to the
higher reliability. Fig. Al shows the effect of variation in average test value.

(1)

E
D
0
E
D
C’)

0 0.10 0.20 0.30

Coefficient of Variation

Fig. Al. vs coefficient of variation and number of tests.

64
 Appendix B — Limiting Stress Determination

Table Bi. Data from 20 consecutive 28-day andf’ = 1/3 fur (1t V) (540)
unaged production flexural tests (stresses in psi). = 1/3 {2703 [1-(2.539)(0.090)J}

= 694 psi
Yield Ultimate controllingf’ is smallest of: [f’] 876, V’taIl 694, and
842 1210 2269 2665 [f’maxl 1200 (5-9,5-10,&5 11)
1282 1322 2961 2792 = 694 psi

1199 1114 2764 2400

1137 1177 2767 3148 For single skin in flexure:
1234 1187 2864 2886 f = sf’ = (0.75) 1 (694) = 521 psi (5-8)
1126 1298 2533 2698
1100 992 2576 2107 For box section flexure: f = sf’ = (0.75) (0.5) (694)
1271 1330 2876 2686 = 260 psi (5-8)
1256 1103 2861 2552
1112 1264 2796 2860 For tension:f = 0.4 bf’
= (0.4) (0.75) (694) = 208 psi
Average yield strength,f= 1178 psi
Standard Deviation, o, = 119 psi Quality control notes:
Coefficient of Variation, V., = o, /f = 119/1178 = 0.101 The average of all sets of three consecutive yield strength
tests must be not less than thef’u used in design [694 psi].
f’uy fyr(1-i’ V) (5-9) Also the average of all sets of three consecutive ultimate
= 1178 [1-(2.539)(0.101)] strength tests must not be less than three timesf’ used in
= 876 psi design [694 x 3 or 2082 psi].
No individual yield strength test shall be less than 90% of
Average ultimate strength,fr, = 2703 psi thef’ used in design [694 x 0.9 or 625 psi]. Also no indi
Standard deviation, o, = 243 psi vidual ultimate strength test (6 coupons) shall be less than
3 times 90% of thef’ used in design [3 x 0.9 x 694 or
Coefficient of Variation, =u ‘fur = 243 / 2703
1874 psi].
= 0.090

65
 Appendix C — Integral Rib Wall Panel Wind Stress Analysis
-

Design Criteria
Assume a single skin GFRC panel (see Figs. Cl to C5)
Since self loads are essentially in the plane of the panel
and, even when the panel is in the horizontal attitude, are
less than wind loads they can be ignored except for con
nections.

Fig. C3. Vertical cross section of panel(in as-sprayed

1-6” Typical Insert position).
Location on Inside
Seismic
Even allowing for overage in thickness, this panel weighs
Typical Rib less than 10 psf. Though conditions often result in a heav
Location on Inside
ier panel, even with UBC Zone 4 factors, the perpendicular
seismic forces are seldom greater than wind loads.

Lf)
Connections
Connection design is typical, taking dead load on bottom
pair, wind on all four, and in-plane seismic on either the
bottom pair or a side pair.
Connections and joints must allow for a GFRC length
change between them of not less than 1/8 in. per 10 ft. This
usually results in fixing one corner and using slotted or
oversized holes in the others.

Design Considerations
This example is only for purpose of investigating stresses
8-2”
due to wind. It does not consider effects of thermal or
moisture movements or restraints. These are often additive
Fig. Cl. Elevation of panel.
to wind stresses and may control design.

Rib Skin Design

For the design of the skin between stiffeners it is often ad
Insert
Boss vantageous to consider plate action with two-way spans,
giving consideration to edge conditions and aspect ratio.
However, when the skin panels get long and narrow, as in
Exterior this case, this refinement is of minimum value.
(mold) Side
This skin can be considered as a four-span continuous
vertical strip with the three interior supports provided by
All GFRC 1/2” Thick the box ribs and the top and bottom support provided by
Except Boss
the hZ panel returns. Similarly, the Z” returns at the sides
of the panel pick up the load from the box rib ends and
carry them as a vertical beam to the connectors.
Fig. C2. Typical perimeter section. The upper and lower panels are assumed pinned at the ‘Z”
support but fixed at the box ribs due to the balancing action
of the adjacent span. The two interior spans can be consid
Wind ered fixed at both ends.
Assume a 20 psf wind load in or out =W In calculating section properties of both the box rib and
Load factor per Section 5.3.2 the “Z’ beam, an effective flange width of 24 times the
w = 1.3 (20) = 26 psf skin thickness is considered (12 in. for typical 1/2 in. skin).
The sides of the box rib are at a 45-deg. slope for ease in
66
roller compacting against the interior polystyrene foam Service Load Stresses
form. Skin
It is convenient to design the skin in terms of span/depth Assume skin is pinned at “Z” panel return (top and bot
( / t) ratios, which vary only with the load, stress, and end tom), fixed at interior box ribs and free at sides.
conditions. For example with fixed ends: The section properties of the 1/2 in. skin are as follows:
M M —
w((6) 2
w/ —
— —

3
bd = 3
12C/2)
W
J s (12)(12)(12t
)
2 2
288t — =0.125 in.
/ft of width
4

/288f I 0.125
S=—= /ftofwidth
3
=0.5Oin.
t
__yI
w C /4

in whichf is in psi, w is in psf, and £ and tare in inches. End spans:

Then, if f = 600 and w, = 26, and both ends are fixed, the
span/depth ratio can be expressed as:
28” ‘

82
= 20(28)2
M = =131 in.-lb.
ore =41 in. fora 1/2 in. skin. 10 10(12)
2
M 131
When one end is fixed and the other end is pinned or f =—-- =•öj =262 psi
when both ends are pinned:
£ /192f Interior spans:
T/WU -
66

or £ = 33 in. for a 1/2 in. skin whenf = 600 and w = 26. 33”

When the member is cantilevered: w £2 20(33)2

MS =—---= =l5lin.-lb.
12 12(12)
=33
t Iwu
2
M 151
=302 psi
or £ = 16.5 in. for a 1/2 in. skin when f = 600 and w =
26.

Deflection expressions for the above cases become:

continued
Both ends fixed:
23
z=w /(4608t
4
£
E )

One end fixed, the other end pinned:

/=w £/(2220t
E)
3

Both ends pinned:

2 £/(921 .6t
zl=w E)
3

Cantilevered member:
23
z=w /(96t
4
£
E )

Note that in the deflection equations W is the service

load (unfactored).

It is desirable to have the end and interior spans in ap

proximately the same ratios as the preceding LI t) ratios
(i.e., end span = 0.8 interior span). A little trial and error
design (omitted here for brevity) will produce the rib spac
ing shown in Fig. C3.

67
 1/2” Skin
1/2’TYP.-
$f!
[4I
I 12” (24t) 3/4 5 39.5” I
i—
Fig. C4. Rib section.
Assumed Effective
L__L== 12” (24t) 9”
Assumed Effective
Horizontal Rib
Fig. C5. Edge beams.
Maximum tributary width on box rib:

33+ 14=47in.=3.92ft.
Deflections at Service Load
The section properties are: Skin interior span:
4
wçe — 20(33)
1= 96.6 • 5 = 19.5 in. 92.9 in.
3
,
T
4 SB =
E
3
384(12)t — 4608(0.5)31.5(106)
= 3.92(20X6.5)
(
3 12)
M = ± 5045 = 0.027 in. or Li 1200

Cross rib:
In this case the minimum section modulus controls since
4
L
5
5w 5(3.92)(20)(6.5)(l2)
wind load is stipulated as being equal in both directions. If
the outward load is greater (putting the outside skin in ten 384 El — 384(1.5)(106)(96.6)
sion) advantage could be taken of the greater outside sec =0.O2in.orL/3590
tion modulus (SB) since the 0.5 shape factor for boxes is set
in order to limit tensile stresses. The compressive stress Vertical member:
could go up to that allowed for single skin (shape factor =
4
L
5
5w 5(4.1)(20)( 1 2.33)( 12)
1.0).
—

384El — 384(1 .5)(l06)(760)

M 5045
f= = ± 259 psi =0.O4in.ore/3955
mm

The maximum total deflection at the center of an interior

Vertical Member panel could be:
The panel shape is conducive to the skin itself carrying
the loads vertically between connections. The same shaped 0.027 + 0.02 + 0.04 = 0.087 in.
beam also acts as the upper and lower horizontal beam
This deflection is quite small compared to the span be
picking up the load from the top and bottom 2 ft of panel.
tween supports (vertical L/1700) but should be recognized
By inspection this is a less critical condition than the side
in detailing adjacent materials. Note that the modulus of
beams. Assume each vertical edge beam carries the wind of
elasticity used is also very conservative.
half the panel width as a uniform load.
2 4.1(20)(12.33)2(12)
= w/
M ± 18,700 in.-lb.

The section properties are:

1=760 m
ST= 103 in.
4 ,
Sb = 93 in.
3
M 18700
fw=_M =±200 psi
mm =

In the above it is assumed, for simplicity, that the load to

verticals is uniform, which gives a maximum moment very
close to that due to rib loads.

68
 Appendix D — Frame Panel I Skin Wind Stress Analysis
-

Analyze GFRC skin as a two-way slab system using direct Maximum moment @ face of bonding pad
design method (ACT 318-99 Section 13.6) with bonding
pads acting as “support.’ If bonding pad is round, assume a = 0.65(0.75) w
L
2
(1/122)
square with the same area (square with a side of 0.89(diam-
eter).
Resisted by GFRC 2 /2 wide with a section modulus of:
2
(L2(t

where
t= thickness, in.

M o.65(0.75)we
L, (11122)/(
2 —

f)
S 8 j)
w
4
1 2 2
(
2
use

e.g. using 5 in. square pads (= 5.6 in. round with apprecia
ble thickness) at 2 ft on center each way (i.e., £ = 24 5
-

= 19 in.), 1/2 in. thick skin and 20 psf service wind load
Moments will be greatest in longest span direction so only 20 u192
the moments in this direction need to be examined, i.e., L fu=) =l44psi
and £,. Moment curve shape and sign are for any strip cut
anywhere along £2. Column and middle strips are both 1/2 Midspan moment and related stresses are 43% of negative
bay wide. moment.
=W
Lfl
L
2
Total moment/bay = Mo

where:

w = service load per unit area, psf.

£2 length of span transverse to L, measured center-to

center of supports, in.

= length of clear span in direction that moments are

being determined, measured face-to-face of supports,
in.

= length of span in direction that moments are being

determined, measured center-to-center of supports,
in.; L L
.
2

Total moment per bay, M

0 is distributed as follows:
Negative moment is 65%, of which 75% is taken in the
column strip and 25% in the mid strip.

Positive moment is 35%, of which 60% is taken in the

column strip and 40% in the mid strip.

69
 Appendix E In-Plane Anchor Restraint
— -

Skin Stress Analysis

In-plane anchor restraint stress is the stress in panel skins If the unit volume change strain of the skin is, e, and the
anchored to panel frames that is due to the anchors acting distance from the panel center (or other neutral’ point
as springs which resist the volume changes of the skin. which is assumed to be stationary) is, X, the movement at
The changes are due to initial drying shrinkage, reversible an anchor is, s, and equal to the anchor deflection, D. So
shrinkage and thennal expansion or contraction. Often, the distance from the panel ‘neutral’ point, at which the an
initial drying shrinkage in GFRC is high enough that it is chor yields,
6
y—
never overcome by subsequent changes, so the skin re
mains in tension. = Z£
therefore: for anchors of diameter, d:
For two material skins the stress due to in-plane vQlume 6E1e
change should be assumed to be resisted entirely by the
backing. z=f andI=
To be conservative, the anchor is assumed fixed at one
end by welding it to a (assumed rigid) stud and at the other l6f 2
therefore: (E-l)
end (parallel to the foot) with the bonding pad: = 9 n- E dE

and at this location and beyond: F)‘ = (E-2)

Assumed Point 3e
ofContraflexure
Anchors less than from the panel center (or other ‘neu
tral’ point) would have less force, proportional to their dis
T F tance from the ‘neutral’ point, to be resisted by the backing
of the skin. The force in the skin would be the sum of the
= 2 F (.5 )3 anchor forces from the ‘neutral’ point to the edge of the
Deflection: skin.
3 El
where: For simplicity all anchors in rows of spacing, s, may be
assumed to reach yield, and the skin backing of thickness,
E = Modulus of elasticity of anchor t, and width, s, resists the force of the, n, anchors from the
I = Moment of Inertia of anchor ‘neutral’ point to the panel edge, or:
andForce,F nf d
Axial skin tension = fa (E-3)
3 St
Moment, M, is limited by the anchor yield stress, so, For movement perpendicular to the anchor foot replace, £,
after rearranging the above equations; and if, Z, is the above with, 2, if the heel of the anchors are not restricted
plastic section modulus then: from rotation by the bonding pad.
fZ Note that skin stress is a function the yield stress of the
Force atyieldis:F fZ anchors. Anchors provided are often well above specified
o.5e
=——-

2 (O.5) yield so conservatively high values should be used in de

o5
and the Deflection at yield is: \ = sign and procedures should assure that it is not exceeded.
3E1
2
simplifying: Z) = fZ
6E1
(continued

70
 5 Flex Anchors
Each Stcle n = 5

: _ravAnc+s
: : : :
For horizontal volume change: so only the two anchors farthest from the center yield at an

=
With 5 flex anchors, 3/8 in. diameter x 2-12 in. effective
length, with 48,000 psi yield, s 24 in. and a 1/2 in. skin
)‘
— f
d
3
3
—

—
48000(0.375)
3(2.5)
—

—
338 lb
(E-2)

(E-3) and the other

fa= = 3 5(48000)(0.375)
nfd
3(2.5)(24)(0.5)
=141 psi
based on taking
three anchors exert a smaller force, proportional to their
distance form the panel center.

all anchors at yield.

Actually if = 0.0002:
338) =521b;338()= 156 ib; and 338 (= 260 lb

16f/
=
so the five anchors together exert a total of:
—

- 9tEd 52 + 156 + 260 + 338 + 338 1144 lb

1144
(E- 1)

= 16(48000) (2.5)2
9t(29x 106)(0 .375)(0,0002)
= 78 in
SOfa= P5105
(
24
9
)

For vertical volume change from gravity anchors,

£ =2 and n =4

fa 4 (48000)(0.375)
3(2)(2.5)(24)(0.5)
=56 p51 (E-3)

71
 Appendix F — Facing I Backing Interaction Stress Analysis
The effect of differential volume change between the face
mix and backing layers of a panel skin is very complex. A
brief discussion of the phenomenon is in Section 5.10. The
procedures in this and the next appendix can be used to es
timate the stresses due to differences in characteristics be
tween the two layers and to thermal and moisture changes.
Two procedures are given, one in each appendix, both with
sample calculations. They differ substantially in complex
ity, but under the same conditions, the same stresses are
computed.
These procedures do not consider a thermal gradient
across the individual layers of the skin, so the stress in each
layer is axial, but varies in a straight line across the layer
and also along the span between anchors due to the fixity
of the assumed beam supportlcontinuity conditions. Theo
retically the fixity can vary from zero to one and one half.
The first procedure shows the wide range of stress that oc
curs through the thickness of the skin, both at the anchors
and midway between them. The second procedure gives
only the maximum stress in each layer, without showing
where it occurs.
The greatest benefit will be achieved if a short computer
program is written using the procedure in this appendix. A
sample spread sheet program follows to facilitate this.
Once written, this procedure becomes easy to use, gives
more information, greater accuracy, and allows the investi
gation of a greater number of variables.
This procedure allows the simultaneous consideration in
each layer of any: thickness, modulus of elasticity, creep,
Poisson’s ratio, shrinkage (or moisture induced expansion),
coefficient of thermal expansion, and increase or decrease
in temperature. Fixity can be varied from zero to one and
one half. The latter is an extreme and unlikely to occur in a
typical panel. A typical maximum design value of one and
one quarter has been suggested.
The values in the curves for the Ratio Coefficient proce
dure in Appendix G are determined with this procedure by
using appropriate values of face to back thickness ratio and
fixity. Namely both moduli of elasticity of one, both creep
coefficients of zero, both Poisson’s ratios of two tenths,
both temperature changes and thermal coefficients of zero,
facing shrinkage of zero, backing shrinkage of one, and
fixity of one and one and a half. A sample of the derivation
Reference:
Garlich, John D. and Tulin, Leonard G., “Modeling of GFRC/Tile Laminate Behavior,” University of Colorado, Boulder,
Colorado, Structural Research Series 8905,June, 1989, 76pp.
72
-
of the coefficients (for the sample calculation in Appendix
G) is in the last column, ‘F’, in the sample calculations at
the end of this appendix.
At the end of this appendix is a sample use of the spread
sheet procedure which has 6 investigations. Column F is
described above. Column A is for the long hand calcula
tion earlier in this appendix. Its answers are slightly differ
ent because the computer works with more significant fig
ures than are practical in a long hand calculation. The ex
amples herein are purely for illusfrative purposes. They
are not intended to be representative of actual practice.
The user must use values appropriate to their individual
circumstances.
Columns B through E are a sample of the kind of investi
gation that can be rapidly made to see the effect of different
variables for a given panel skin with an architectural facing
on a GFRC backing. Columns B and C both have the same
facing shrinkage and the same, but higher, backing shrink
age. In column B both layers have a zero creep coefficient,
while column C has creep coefficients of two for each
layer. Note that the resulting stresses are proportional to
‘one plus the coefficient’, so the stresses in column C are
one third of those in column B. This applies as long as the
creep coefficients are the same for both layers.
Columns D and E have the no shrinkage. Column D has a
temperature increase, while column E has a temperature
decrease. It is best to analyze shrinkage and temperature
changes separately, and add the resulting stresses, to allow
the use of different creep factors for temperature than for
shrinkage. For seasonal temperature changes the creep
might be less than it is for shrinkage, but for daily changes
there would probably be no creep effect.
Column D has a creep coefficient of one and a tempera
ture increase of 40 deg. F in both layers. As long as the
creep and temperature change are the same in both layers
the stresses are proportional to: 1+ creep, and to the tem
perature change. If there were a temperature decrease the
stresses would be the same magnitude but opposite sign.
Column E has a temperature decrease of 40 deg. F in the
facing and 30 deg. F in the backing. This column also has
a creep coefficient of one and a half for both layers.
GFRC FACING AND BACKING STRESS: Equations
FACING & BACKING PROPS. & VOL. CHANGES Facing Backing
Thickness in. tb =
Modulus of elasticity psi =

Creep coefficient 0 = none Cf= C,, =

Poisson’s ratio b
4
1
Shrinkage in. / in. f ——
b ——

Temperature Change Increase is pos., decrease is negative deg. F Df = — Db = —

Thermal coefficient of expansion in. / in. / deg. F af =— ab = —

Effective modulus of facing and backing

E Eb=
-i;
—

i+Cb

Section properties of composite =

EAf EAb =
i-/lb

1:’ ••3
-
3
Ebtb
Elf Elb=
— l2(l-u.) 12 (-i’,,)

Neutral Axis to face — 1 (0.5 tf)] + [EAb(tf + 0.5 tb)J

[EA
Yf EAf+EA,,
-

Neutral Axis to back and interface Yb = Yf(tf+tb) 1 =

c Yftf

Neutral Axis to center of facing and backing f

Cf=Yf-O.
t
5 Cf=yf[(O.Stb)+tf]

Composite bending stiffness El = El+ EAf Cf 2 El,, + EAb 2

Cb

Membrane force each layer t [D a -D a +(6 .-s)]

F= ff b b b f
(l-Uf) tf(l/lb)
Ef ÷ tbEb

Fixed end moment and Rotation FM = 0.5 F (tf+ tb) 0 = -FM/El

Corrected moment in face and back Mf=OElf Mb=OEIb

Axial force each layer M+M

f b
0.5 (tf+ tb)

FIXITY = 0 & N Note: Zero is automatically included in equations, a value (N) up to 1.5 must be input for the other limit

Stress face of face

- Fx =0 and N psi = 6M - P - 0 N YfEf
=
f
t tf Uf

Stress interface of face Fx =0 and N

- psi -6M P Nc E
40= —i-_— fgINf
tf tf -,Uf

Stress interface of back Fx = 0 and N psi 6M P ONcE

-
b b
0 =
fb fIbN=fibO-
tb i-/lb

Stress back of back Fx =0 and N psi -6M P ONy E

-
b b b
fbbO = +_ fbz,N=fbbO-
t tb

73
GFRC FACING AND BACKING STRESS: Sample long hand calculation

FACING and BACKING PROPS. & VOL. CHANGES Facing Backing

Thickness in. tf =0.2 tb =0.6

Modulus of elasticity psi Yf = 3 x 10 = 3 x 10
Creep coefficient 0 = none Cf= 1 Cb = 1
Poissons ratio if =0.22 ILb =0.18
Shrinkage in./in. =800x 106 Eb 6
=1000x10
Temperature Change Increase is pos., decrease is negative deg.F Df =20 Db= 15
Thermal coefficient of expansion in./in./deg.F af = 5 x 106 ab = 10 x 106
3 x 10 — 3x 106
Ef= 6
=1.5x10 Eb— 6
=1.5x10
11 1 +1

EAf= 6
1.5x10
x 0.2_ 0.385x 106 EAb= 6
1.5x10
x 0.6 = 1.lx 106
1-0.22 1-0.18

EIf= 1.5x10
1280
x
6 0.2’_ EIb= 6
1.5x10
x 0.6’.. 32900
12(1- 0.22) 12(1- 0.18)
(0.385 x 106 x 0.5 x 0.2 )+{1.1 x 106 [0.2 +(0.5 x 0.6)]} = 0.396
Yf=
(0.385 x 106) + (1.1 x 106)

Yb = 0.396 -(0.2 + 0.6) = - 0.404 c, = 0.396 —0.2 = 0.196

Cf = 0.396 - (0.5 x 0.2) = 0.296 Cb = 0.396 -[(0.5 x 0.6) + 0.2] = - 0.104
El = 1280 + (0.385 x 106 x 0.2962)+ 32900 + (1.1 x 106 x 0.1042) = 79800
F= 0.2[(20 x 5 x 106) - (15 x 10 x 106)+(1000 x l0 - 800 x 10.6)1 — 40
(1-0.22) 0.2(1-0.18) —
6
1.5x10 + 6
0.6x1.1x10
FM = 0.5 x 40 (0.2 + 0.6) = 16 4’ = -16 /79800 =—0.0002
-0.0002 x 1280 =-0.26 Mb= - 0.0002 x32900=-6.6
-0.26-6.6 =-18
0.5 (0.2 + 0.6)
FIXITY=N=0 & 1.25 Assume Flex anchor spacing 24” x 24”
=
6x(-0.26) - -18 fN= 50- -0.0002 6
xl.25x0.396x1.5x10
=S0psi = 250 psi
0.22 0.2 1 - 0.22
-6 x (- 0.26) - - 18 130-
-0.0002 x 1.25 x 0.196 x 1.5 x 106
= 130 psi =23Opsi
0.2 0.2 1 - 0.22
= 6x (- 6.6) + = -0.0002x 1.25 xO.196x 1.5x 106
0
fib - 140 psi 50 psi
0.62 0.6 1 - 0.18
- 6 x (- 6.6) + - 18 - 0.0002 x 1.25 x -.404 x 1.5 x 106
fbbO = = 80 psi fbbN= 80- =- lOOpsi
0.62 0.6 1 - 0.18

The facing stresses at the indicated locations are:
50, 130, 230 and 250 psi compression.
The backing stresses at the indicated locations are:
80 psi compression, and 50, 100, and 140 tension.
74
Note that this example has combined shrinkage and ther
mal expansion for illustrative purposes. This is inadvis
able in practice as they may have different creep and load
factors. The values used here are chosen purely for il
lustration, and are not necessarily realistic.
GFRC FACING & BACKING STRESS: Spread Sheet Format

FACING PROPERTIES & VOLUME CHANGES Cell

Thickness tf in. D5
Modulus of elasticity Yf psi D6
Creep coefficient 0 none
= Cf D7
Poissons ratio Lf D8
Shrinkage Lf in/in D9
Temp Change Incr. is +, Decr. is Df deg.F
- Dl0
Thermal coefficient of expansion ce inlin!deg. F Dli

BACKING PROPERTIES & VOLUME CHANGES

Thickness tb in. D14
Modulus of elasticity psi D 15
Creep coefficient 0 none
=
Cb D16
Poisson’s ratio D17
Shrinkage Lb in/in D18
Temp Change Incr. is +, Decr. is Db deg. F
- D19
Thermal coefficient of expansion in/in/deg. F D20

PLATE SIZE (anchor spacing)

Plate Height H in. 1D23 =

Plate Width W in. 1:D24 =__

Effective modulus of facing Ef D26 = D6/(l-i-D7)

Effective modulus of backing Eb D27 = D15 / (l+Dl6)
Section properties of composite EAf D28 = D26*D5 / (l-D8)
EAb D29 = D27*Dl4/(lD17)
El D30 = D26*(D5A3) / [l2*(lD8)]
Elb D3l = D27*(D14A3) / [12*(1Dl7)J
Neutral Axis to face Yf D32 = ([D28*(05*D5)]+{D29*[D5+(Oi*D14)J}) / (D28+D29)
NA to back Yb D33 = D32-(D5+D14)
NA to interface c D34 = D32-D5
NA to center of facing Cf D35 = D32(0.5*D5)
NA to center of backing Cb D36 = D32[(0.5*Dl4)+D5J
Composite bending stiffness El D37 = D30+[D28*(D35A2)]+D31÷[D29*(D36A2)]
Membrane force each layer F D38 = D5*{[(Dl0*Dll)(Dl9*D20)+(Dl8D9)]} Divisor is on next line
/ {[(l-D8) / D26j÷[D5*(lDi7) / (D14*D27)]}
Fixed end moment FM D39 = 0.5*D38*(D5+D14)
Rotation D40 =-D39/D37
Corrected moment in face Mf D41 D40*D30
Corrected moment in back Mb D42 D40*D3l
Axial force each layer P D43 = (D41+D42) / [0.5*(D5+D14)1

FIXITY = o &N N D45 = Note: Zero is programmed, select appropriate N 1.5

Deflection at center Fixity =0 ins tD46 D40* [(D23A2)+(D24A2)j / 8
Lo =

Deflection at center Fixity N =

IXN ins tD47 = (lD45)*D40*[(D23A2)+(D24A2)] / 8
Stress @ face of face Fixity =0 ffJO psi D48 = [6*D41 / (D5A2)j-(D43 / D5)
@ face of face Fixity N = ffV psi D49 = D48[D45*D40*D32*D26 / (l-D8)]
@ interface of face Fixity 0 = 0
1
f psi D50 = [6*D4l / (D5A2)1-(D43 / D5)
@ interface of face Fixity N = psi D51 = D50[D45*D40*D34*D26 / (l-D8)]
@ interface of back Fixity 0 =
fibO psi D52 = [6*D42 / (D14A2)J+(D43 / D14)
@ interface of back Fixity= N fibN psi D53 = D52[D45*D40*D34*D27 / (l-D17)]
@ back of back Fixity =0 fbbO psi D54 = [6*D42 / (D14A2)J+(D43 / D14)
“@back of back Fixity N =
fbbN psi D55 = D54[D45*D40*D33*D27 / (l-D17)]

Note lines (cells) 23,24,46 and 47 can be omitted as they relate only to deflection, not stress
75
 SPREAD SHEET Sample Calculations

A B C D E F
Sample Shr Shr+Crp Hot+Cip Cold+Crp App G
FACING PROPERTIES & VOLUME CHANGES
Thickness fl. tf 0.2 0.25 0.25 0.25 0.25 0.4
Modulus of elasticity psi Y1 3x10
6 3x10
6 3x10
6 3x10
6 3xl0
6 1
Creep coefficient 0=none 1 0 2 1 1.5 0
Poisson’s ratio 0.22 0.22 0.22 0.22 0.22 0.2
Shrinkage iniin. 800x10 800x10 6
400x10 0
Temp Change Incr. is +, Decr. is — deg. F Df 20 80 -60 0
Thermal coefficient of expansion inJinfdeg. F af 6
5x10 5x10
6 5x10 0

BACKING PROPERTIES & VOLUME CHANGES

Thickness in. tb 0.6 0.5 0.5 0.5 0.5 1
Modulus of elasticity psi Y 3x10
6 3x10
6 3x10
6 3x10
6 3x10
6 1
Creep coefficient 0=none Gb 1 0 1 1 1.5 0
Poisson’s ratio l-b 0.18 0.18 0.18 0.18 0.18 0.2
Shrinkage inlin b 6
l000xlO 6
900x10 6
SOOxlO 1
Temp Change +1- deg. F Db 15 70 -50 0
Thermal coefficient of expansion iniinfdeg. F Ub 6
l0xl0 7x10
6 7x10 0

PLATE SIZE
Plate Height in. H 24 24 24 24 24
Plate Width in. W 24 24 24 24 24

Effective modulus of facing Ef 1500000 3000000 1000000 1500000 1200000 1

Effective modulus of backing Eb 1500000 3000000 1500000 1500000 1200000 1
Section properties of composite EAf 384615 961538 320513 480769 384615
EAb 1097561 1829268 914634 914634 731707 1
Elf 1282 5008 1669 2504 2003 0
El,, 32927 38110 19055 19055 15244 0
Neutral Axis to face Yf 0.3962 0.3708 0.4027 0.3708 0.3708 0.7000
NA to back Yb -0 .4038 -0.3792 -0 .3473 -0 .3792 -0 .3792 -0 .7000
NAtointerface c 0.1962 0.1208 0.1527 0.1208 0.1208 0.3000
NAtocenteroffacing Cf 0.2962 0.2458 0.2777 0.2458 0.2458 0.5000
NAto center of backing Cb -0.1038 -0.1292 -0.0973 -0.1292 -0.1292 -0.2000
Composite bending stiffness El 79779 131747 54100 65873 52699 0
Membrane force ea layer F 43 63 24 -28 13 0
Fixed end moment FM 17 24 9 -11 5 0
Rotation (p -0.0002 ‘ -0.0002 -0.0002 0.0002 -0.0001 -0.8746
Corrected moment in face Mf -0.27 -0.90 -0.27 0.40 -0.18 -0.01
Corrected moment in back Mb -7.05 -6.84 -3.13 3.08 -1.37 -0.09
Axial force each layer P -18.32 -20.63 -9.09 9.28 -4.13 -0.14

FIXITY = 0 & N N= 1.25 1.25 1.25 1.25 1.25 1.5

Deflection at center Fixity = 0 in. A -0.0308 -0.0258 -0.0237 0.0232 -0.0129 0.0000
Deflection at center Fixity = N in. AN 0.0077 0.0065 0.0059 -0 .0058 0.0032 0.0000
Stress@faceofface Fixity=0 psi fO 50 -4 10 2 -1 0.128
Stress @ face of face Fixity = N psi N
1
f 1 254 316 116 -142 63 1.276
Stress @ interface of face Fixity =0 psi 133 169 63 -76 34 0.565
0
f
Stress @ interface of face Fixity = N psi füdV 234 273 103 -123 55 1.057
Stress @ interface of back Fixity = 0 psi fj,,O -148 -205 -93 92 -41 -0.685
Stress @ interface of back Fixity = N psi -52 -106 -36 48 -21 -0.193
Stress @ back of back Fixity = 0 psi fO 87 123 57 -55 25 0.408
Stress @ back of back Fixity = N psi fbl,N -111 -188 -74 85 -38 -0.740

Shrinkage and temperature increases are both input as positive numbers.

Moisture induced expansion and temperature decreases are both input as negative numbers.
Compressive stresses are positive. Tensile stresses are negative.
76
 Appendix G Facing I Backing Interaction Stress
—

Analysis Ratio Coefficients

- -

The Ratio Coefficient procedure makes several simplify
mg assumptions and has some limitations. It assumes all
the properties, except volume change, are the same for both
the facing and the backing; namely the modulus of elastic
ity, creep, and Poisson’s ratio. Poisson’s ratio is assumed to
be 0.2 for both layers. Creep could be considered (with
both layers the same) by dividing the stresses by [1+C],
where C is the creep coefficient (creep strain / initial strain)
from Chapter 4 for the GFRC and other sources for the
face mix.
This procedure uses the unit volume change of the back
ing with respect to the facing, with backing shrinkage
- With a facing thickness of 0.2 inches and a GFRC backing
taken as positive. If the backing expands (relative to the
facing), it would be taken as negative, so the resulting
stresses would reverse in sign. For a given ratio of facing
to backing thickness of the skin, the curves give two coeffi
cients, which are the maximums determined with the other
procedure. These are to be multiplied by the modulus of
elasticity and the differential volume change strain between
the facing and backing to find the maximum stress in the
skin, with positive results indicating compression and neg
ative indicating tension. Proper attention must be given to
the signs of the volume change, the coefficient and the re
sultant stress. For the plotted conditions, backing shrink
age produces backing tension.
The curves for the Ratio Coefficients can be determined
with the procedure in the preceding appendix by using ap
propriate values of face to back thickness ratio and fixities;
both moduli of elasticity of one, both creep coefficients of
zero, both Poisson’s ratios of two tenths, both temperature
changes and thermal coefficients of zero, facing shrinkage
of zero, backing shrinkage of one. The coefficients plotted
are based on fixities of zero and an extreme of 1.5. A
smaller maximum value could be input in the previous ap
pendix equations to develop other similar coefficient
curves. The example below is shown in column F of Ap
pendix F.
thickness of 0.5 inches the facing to backing ratio is 0.4.
Reading from the curve the multipliers are +1.28 and -0.74.
If the moduli of elasticity (of both facing and backing) are
2 x 106 and the backing shrinks by 200 x 10.6 (with respect
to or more than the facing) stresses would be:
+1.28 (2) (106) (200) (10.6) = + 512 psi
and 0.74 (2) (106) (200) (106)
- = -296 psi
Backing tension of 296 psi and facing compression of 512
psi. If the facing shortened more than the backing by the
same amount the stresses would be reversed, 512 psi facing
tension and 296 psi backing compression.

1.5 I

joacin
*CoIumn F
0.5 - Appendix F
m
0

:
:•

-1.5 -

0 0.2 0.4 0.6 0.8 1.0

Ratio of Facing to Backing Thickness
Note: These curves are valid only for facing and backing mixes which have the same material properties.

77
 Appendix H — Combining Load Factors and Limiting Stresses

Strength design procedures require that the sum of the If this skin was subject to the following stresses due to
factored loads be less than the factored member strength. service loads:
With GFRC, load effects and member strength are both
measured in terms of flexural and axial stress. Equations Single skin flexural stress
5-1 through 5-7 require consideration of different load fac
Dead Live Wind Erthq Moist Temp
tors for various load combinations. Sections 5.4.1 and
10 0 100 0 0 0
5.4.2 give different limiting stresses for various conditions.
Though the critical combination of these variations can be Box section flexural stress
determined in several ways; the easiest is to compute the 0 0 0 15 0 0
stresses due to service loads, multiply them by the appro
Tensile stress
priate load factors, and divide that product by the appropri
12 0 0 0 150 80
ate limiting stress. These ratios can then be added, using
traditional interaction methods for combining flexural and
For illustration the following example assumes only equa
axial stresses. i.e.:
tions 5-1 through 5-5 apply.
By inspection Equation 5-5 is more critical than 5-1
Single skin factored flexural stress
+ through 5-4, i.e.:
Single skin limiting flexural stress
0.75 [1.4D+1.7(greaterof L,Worl.1E)+
Box section factored flexural stress 1.6 (greater of M or T)j
+
Box section limiting flexural stress
Also by inspection, for all conditions: Live is less than
Factored tensile stress 1.0 Wind, and Temperature is less than Moisture so the L and T
Limiting tensile stress
terms drop out. 1 .1E is also less than W even considering
its lower limiting stress so it is not critical.
Stresses due to skin anchor restraint and to the interaction
between facing and backing with differential material prop
Equation 5-5 for this case simplifies to:
erties are tensile.
0.75 [1.4D+1.7W +1.6 M]
Particular caution must be exercised in determining the
but since stresses must be separated, to flexural + tensile,
appropriate limiting stress. The shape factor, s, is not the
equation becomes:
same for all sections as defined in Section 5.4.1 and the
tensile limit is different than the flexural limit.
0.75 [1.4 D + 1.7W] flexural + .75 [1.6 M] tensile
For example if a member had anf’ of 900 psi, the:
Single skin limiting flexural stress would be:
therefore:

0 sf’= 0.75 (1) (900) = 675 psi 0.75 [1.4(10) + 1.7 (100)1 0.75 [1.6(150)]
675 + 270
Box section limiting flexural stress would be:

øsf’= 0.75 (0.5) (900) = 338 psi +--=0.19+0.67=0.86 <1.00K

675 270

And the limiting tensile stress would be:

0.4 øf’ = 0.4 (0.75) (900) = 271 psi

78

.—-.:....
.
 Appendix I — Alternate Cementitious Systems
for GFRC Panels
Three cementitious systems introduced into the United
States since 1993 appear to minimize the loss in ductility
of the GFRC. The approaches are different.
One system uses a calcium suiphoaluminate rapid-harden
ing cement and an additive which is at least 5 percent of
cement weight (see Refs. I-i to 1-4). This system obtains
80 percent of the 28 day strength in 24 hours with the 28
day strengths comparable to conventional GFRC. Panels
must be kept wet during initial set and while heat is being
liberated during the initial cement hydration (exotherm),
(typically lasting 15 to 30 minutes). No further curing
need be provided. Polymer curing admixtures must not be
used because they can interfere with the curing of the ce
ment.
The other system consists of modifying the cement matrix
by the addition of a synthetic pozzolanic material rich in
metakaolinite 2 .A1 produced by the thermal acti
(2Si0
)
3
0 6th Biennial Congress of the GRCA, 20-23 October,
vation of kaolin in air at 1290 to 1650 deg. F (700 to 900
deg. C) (see Refs. I-S to 1-9). Generally, an attempt is
made to consume with the addition of 20 to 25 percent
metakaolinite by weight of portland cement as much as
possible of the calcium hydroxide generated during the hy
dration process. This prevents growth of the calcium hy
droxide crystals from filling the spaces between the fiber
bundles. This system may be designed to use or not use
polymer curing admixture. Unlike most other pozzolans,
which develop strength slowly, the high reactivity of the
metakaolin results in high early strength enabling normal
stripping time.
A third system was introduced in 1999 which is based on
a matrix of ordinary Portland cement, granulated blast fur
nace slag, and a super low shrinkage admixture (NSR).
NSR is an admixture consisting of calcium sulfate and cal
cium fluoroaluminate. In addition to providing stable long
term properties, it also confers very low shrinkage proper
ties on the composite. (see Refs. 1-10 and I-li). The system
can be used with or without polymer curing admixture.
References
I-i. Tallentire, A. C., “New Developments in Rapid Hard
ening and High Strength Cement Technology of Rele
vance to the GRC Industry,” Proceedings 6th Biennial
Congress of the GRCA, 20-23 October, 1987, Edin
burgh, Scotland, p.53-58, The Glassfibre Reinforced
Cement Association, Northway, Wigan, United King
dom.
1-2. Gartshore, G. C., Kempster, B., and Tallentire, A. G.,
“A New High Durability Cement for GRC Products,”
Proceedings 8th Biennial Congress of the GRCA, 21-
24 October, 1991, Maastricht, Netherlands, p. 3-11,
The Glassfibre Reinforced Cement Association,
Northway, Wigan, United Kingdom.
79
1-3. Molloy, H. J., Jones, J., and Harmon, T., “Glass Fiber
Reinforced Concrete with Improved Ductility and
Long Term Properties,” Proceedings 9th Biennial
Congress of the GRCA, 13-17 June, 1993, Copen
hagen, Denmark, 9 pp.. The Glassfibre Reinforced
Cement Association, Northway, Wigan, United King
dom.
1-4. Molloy, H. J., and Jones, J., “Application and Produc
tion Using Rapid Hardening Hydraulic Cement Com
posites,” Proceedings 9th Biennial Congress of the
GRCA, 13-17, June, 1993, Copenhagen, Denmark, 7
pp., The Glassfibre Reinforced Cement Association,
Northway, Wigan, United Kingdom.
I-S. Ambroise, I., Dejean, J., Foumbi, J., and Pera, J.,
“Metakaoline Blended Cements: An Efficient Way to
Improve GRC Durability and Ductility,” Proceedings
1987, Edinburgh, Scotland, p. 19-24, The Glassfibre
Reinforced Cement Association, Northway, Wigan,
United Kingdom.
1-6. Soukatchoff, P., and Ridd, P. J., “High Durability
Glass-Fibre Reinforced Cement Using a Modified Ce
mentitious Matrix,” Proceedings 8th Biennial Con
gress of the GRCA., 21-24, October. 1991, Maas
tricht, Netherlands, p.45-60, The Glassfibre Rein
forced Cement Association, Northway, Wigan, United
Kingdom.
1-7. Thiery, I., and Genis, A., “High Durability Glass Ce
ment Composites: New Vetrotex System,” Proceed
ings 7th, Biennial Congress of the GRCA, 26-28 Sep
tember, 1989, Maastricht, Netherlands pp. 10, The
Glassfibre Reinforced Cement Association, Northway,
Wigan, United Kingdom.
1-8. van der Plas, C., Yue, B., and Bijen, J., “Effect of Poz
zolans on the Durability of Polymer Modified Glass
Fibre Reinforced Cement,” Fly Ash. Silica Fume,
Slag and Natural Pozzolans in Concrete--Proceedings,
Fourth International Conference, Istanbul, Turkey,
American Concrete Institute, Detroit, Michigan. 1992,
pp. 175-188.
1-9. Marikunte, Aldea, and Shah “Durability of Glass
Fiber reinforced Cement Composites Effect of Silica
Fume and Metakaolin” Advanced Cement Based Ma
terials, 1997 5,100-108, Elsevier Science Ltd., NY.
I-10.K. Imai, M. Hayashi, T. Tamaki, and H. Tanaka,
“Glass Fiber Reinforced Concrete using Super Low
Contractile Admixture,” Proceedings ACT 549 Com
mittee Symposium on “High Performance Fiber Rein
forced Thin Products”, ACT Convention, Chicago, IL
March 14-19, 1999
I-11.US Patent # 3,856,540, December 24, 1974.
 Appendix J
CHAPTER Ji - INTRODUCTION
J1.1- Scope
1
This Appendix is intended to provide information con
cerning premix glass fiber reinforced concrete and indicate
where it differs from spray-up GFRC which is the primary
material discussed in the Recommended Practice. This Ap
pendix covers only those sections presented within the
body of the Recommended Practice that require revision to
address the difference between premix glass fiber rein
forced concrete and spray-up GFRC. For sections not cov
ered, it is intended that the main body of the Recom
mended Practice be referred to unless indicated otherwise
in this Appendix.
Ji .2- General Description
Premix glass fiber reinforced concrete is the term applied
to a cement/sand slurry and chopped strands of alkali-re
sistant glass fiber mixed together before transport to the
mold. The slurry is cast usually with vibration into a mold,
similar to precast concrete products, or may be sprayed.
Typically, premix products contain less than 4 percent AR
glass fiber by weight of the total mix.
Ji .5- Applications and Advantages
Premix is used in products where strength is not the prime
requirement. Premix is not recommended for the type of
thin wall architectural panels covered by the main body of
the Recommended Practice. It is used for smaller, highly
sculptured architectural units and mass produced standard
products.
Premix provides an efficient means of producing items
with good dimensional control, particularly thickness, and
complex detail. Premix manufacturing processes usually
have low material losses and provide accurate and repro
ducible control of product weight.
CHAPTER J3 MATERIALS-
Materials for use in the manufacture of premix products
should conform to the requirements set forth in Chapter 3
of the Recommended Practice with the exception of the
following section.
J3.2 Glass Fibers
-
The range of pre-chopped fiber lengths is between 1/4 in.
to 1-1/2 in. (37mm), although special processes may use
longer lengths. Fibers normally used for spray-up produc
tion are not normally suitable, being too soft and prone to
tangling.
In general 1 in. to 1-1/2 in. (25mm to 37mm) chopped
strands are suitable for simple flat or thick section products
and 1/4 in.(6mm) to 1/2 in. (12mm) strands are more suit
Section numbers in Appendix I parallel those in the Rec
1 tively, proprietary mixers designed specifically for pre
ommended Practice.
— Premix GFRC
able for complex shaped, narrow section products.
CHAPTER J4 PHYSICAL PROPERTIES
-
The physical properties of premix composites depend
heavily on the fiber content, fiber length and quality of
mixture. They are also greatly influenced by the type of
manufacturing process.
J4.1 Factors Affecting Properties
-
As with spray-up GFRC, strength properties, such as flex
ural, tensile and impact strengths increase with increased
fiber content and length. Fiber contents below 3 percent
even at longer lengths of 1 in. and 1-1/2 in. (25 mm and 37
mm) can show a dramatic fall off in early strength.
In theory the longer fiber length should produce a stronger
product. In practice there is often little difference, and the
1/2 in. (12mm) strand length is preferable because it is eas
ier to incorporate and the premix has better workability.
As a general rule, premix with the same fiber content and
fiber length wifi have lower strengths than spray-up GFRC.
Reasons for this are:
a. Premixing may entrap more air, thereby reducing
the density of the composite. Strengths of premix-
are density sensitive.
b. The mixing action may cause filamentizing and
reduce tensile strength of strand.
c. The spray-up process lays the fibers down with
almost perfect random planar orientation or two
dimensional orientation, whereas premix will have
a more three dimensional orientation. This
reduces the effective fiber content in the plane of
the composite, thereby reducing the inherent
strength of those planar related strengths such as
flexural and tensile strength.
J4.17 Property Summary
-
Different manufacturers achieve different ranges of values
of physical properties of premix. Specific values of prop
erties should be supplied by the manufacturer to the de
signers. For general information, Table 1.1 gives typical
ranges of 28 day property levels using cement) sand ratios
of between 3:2 to 1:1.
CHAPTER J7 MANUFACTURE
-
J7.2 Plant Facilities
-
These are the same as discussed in the Recommended
Practice except for the following:
1. Equipment for mixing the cement/sand slurry at high
speed and the ability to blend the chopped strands on a
slower speed setting to avoid fiber damage. Alterna
mix can be used.
80
 Table J. 1. Typical Range of Premix Properties

Property 28-day, (E)

Density (dry) 110 to 1 30(pcf)
Compressive strength (edgewise) 6000 to 9000 (psi)
Flexural: Yield (FY) 700 to 1200 (psi)
Ultimate strength (FU) 1450 to 2000 (psi)
Modulus of elasticity 6 to 2.9x10
1.0x10 6 (psi)
Direct tension: Yield (TY) 600 to 900 (psi)
Ultimate strength (TU) 600 to 1000 (psi)
Strain to failure 0.1 to 0.2 (percent)
Shear In-plane 600 to 1000 (psi)
Coefficient of thermal expansion (77 to 115 deg. F) in./inideg. F)
Approx. 12x lO
6
Thermal conductivity /deg. F)
3.5 to7 .0(Btu/in.Ihr/ft
2

These are typical values and are not to be used for design or control purposes. Each
manufacturer must test production composites to establish physical properties for de
sign. The values achieved in practice will be dependent on mix design, quality con
trol of materials, fabrication process and curing.

2. Means of vibrating the cast item at frequencies from
3000 to 9000 vpm with a high amplitude or correct
equipment to spray the fibrous premix into a mold.
J7.3 Molds
-
Molds for premix manufacture are essentially the same as
for spray-up GFRC manufacture. The principal difference
being that premix allows the use not only of open molds
but also back formed (inner core) molds, similar to precast
concrete molds, which cannot be used in spray-up.
J7.4 Proportioning and Mixing
- the range 0.3-0.35. Workability adjustments should be
Each product has its own particular requirements and
records should be kept enabling correlation between prop
erties of cured product to the specified requirements.
The majority of premix architectural products are based
on 3 to 3-1/2 percent by weight of AR glass fiber on the to
tal weight of the mix and 1/2 in. (12 mm) to 1 in. (25 mm)
fiber length. These parameters can be varied to produce
many different combinations of materials giving different
end properties. The fiber content of premix is usually lim
ited by the mixer and/or workability considerations. The
fiber length may also affect the fiber content limit.
Increasing fiber content over four percent reduces the
workability of the mix and most conventional mixers can
not incorporate fiber contents much higher than four per
cent. Longer fibers will have a tendency to reduce the
workability of the mix and make mixing difficult.
Higher fiber contents than four percent can be achieved
with special mixers. One such mixer has a flexible base,
which is undulated by the action of an eccentric shaft pro
jecting into the center of the mixing vessel. This undulating
action causes the material to be turned over on itself
thereby mixing the fibers into the slurry. This mixing ac
tion enables the mixer to be capable of mixing higher fiber
81
contents than conventional mixers .A typical premix formu
lation is:
Cement 100 lbs.
Sand 75 lbs.
Water 29 lbs. (approx.)
Superplasticizer l6ozs.
Polymer curing admixture 10.6 to 12.6 lbs.
Chopped 1/2 in. AR glass fiber 6.5 to 9 lbs.
Good premix properties require a water/cement ratio in
made with the use of water reducers or superplasticizers.
The mixing process should create a thoroughly mixed
slurry, while at the same time causing minimal strand
breakdown, fiber damage, or entangling of the strands
(fiber balling). This requires that the mixing process must
be capable of incorporating the fibers speedily and uni
formly.
The mixing processes use either the special mixer de
scribed above or a two stage process in which the slurry is
prepared in a high shear mixer followed by a slow blending
phase in which the fibers are incorporated.
The fiber should be added last over a period not exceeding
2 minutes and the mixer should only be allowed to run for
a sufficient time to fully incorporate the fiber, normally
only a few seconds.
J7.7- Placing
Placing or casting of the premix must be done in such a
way that the glass fiber strands are not orientated in any
particular direction, particularly with strand lengths over 1
in. (25mm).
When casting, the molds should be filled in a way that
avoids two or more material charges. Flow lines can be cre
 ated where flows meet and the fibers may not bridge the
flow lines. This will create a weak point in the product,
which may result in a crack.
The mold must be filled in a manner that avoids pockets
of air being trapped between the premix and the mold sur
face. Whenever possible, the mold should be filled from
one point only.
If the premix is pumped from the mixer to the mold using
a peristaltic action pump the mix must be designed to avoid
separation of the mix components. A thixotropic or pump
ing aid can help avoid separation.
Because it is not usually possible to build up cast premix
in layers, as is done in spray-up, (the total thickness being
placed in one casting), rolling out is usually not ‘effective
with premix. However, the mixing process inevitably in
corporates some air into the mix and as the composite
properties are density dependent, premix castings should
involve vibration of the mix at some point, in order to ex
pel as much as possible of this entrapped air. The vibration
can be applied either during the transfer of the premix to
the mold and or when the material is filling the mold. Ex
cessive vibration must be avoided as it can cause separa
tion of the mix components.
J7.11 Stripping
-
In the case of a mold with a back form, it is useful to re
move the core as soon as possible after casting. This pre
vents the premix from shrinking onto the core and making
demolding difficult.
If a product is overstressed on demolding it may crack at a
later date.
CHAPTER J8 QUALITY CONTROL
-
With the exception of those procedures designed to check
spray-gun settings, such as bag and bucket tests, all quality
82
control procedures recommended for spray-up GFRC are
applicable to premix. Premix properties are highly depend
ent on density and glass content and these should be
checked.
General References
J-l. Hills, D. L., “Premix glass fiber reinforced cement,”
Precast Concrete, May 1975, p.251.
J-2. True, C., “GRC Production and Uses,” Palladian
Publications, London, 1986, 104 pp.
J-3. Smith, I. W., “A Review of GRC Production
Processes,” Glass Fibre Reinforced Cement Associa
tion, Northway, Wigan, United Kingdom, 1986, 16 pp.
J-4. Majumdar, A. J., and Laws, V., “Glass Fibre Rein
forced Cement,” BSP Professional Books, Blackwell
Scientific Publications, Inc., Oxford, United King
dom, 1991, 197 pp.
J-5. “A Guide to Vibration Cast Premix GRC,” Cem-FIL
International Limited, Merseyside, England, 1984.
J-6. Ferry, R., Lowe, D., and Pickavance, A., “Premix
Methods of GRC Manufacture,” Proceedings 4th Bi
ennial Congress of GRCA, 5-4 October 1983, Strat
ford-Upon-Avon, England, p.66-76, The Glassfibre
Reinforced Cement Association, Northway, Wigan,
United Kingdom.
J-7. White, I. C., “The Economic Argument for the Use of
Appropriate Machinery in GRC Production,” Pro
ceedings 6th Biennial Congress of the GRCA, 20-23
October, 1987, Edinburgh, Scotland. p 133-138, The
Glassfibre Reinforced Cement Association, Northway,
Wigan, United Kingdom.
 Appendix K — Specification for AR Glass Fiber
This document specifies requirements for glass fibers
made from alkali resistant glass compositions and in
tended for use as reinforcement in portland cement con
crete. Tests shall be carried out by the fiber supplier who
shall certify compliance.
1. Condition and Properties
1.1 The product shall be packed in containers in such a
manner as to give adequate protection in transport and
storage. A roving package shall be free from obvious
damage and should not be deformed.
1.2 The container shall be clearly labeled alkali resistant
glass and indicate manufacturer, product code, filament
diameter and roving tex. The end count for roving prod
ucts shall also be given.
1.3 The roving shall be free from oil, grease, and other
visible contaminants.
1.4 The nominal filament diameter shall be as agreed be
tween purchaser and manufacturer, or as specified.
1.5 The properties of roving shall comply with the re
quirements given in Table K.1 below.

Table K.1. Test Requirements.

Property Specified Value Method of Test Frequency of Testing

Zirconia Content, Zr0
2 16 % Mm. X-ray Fluorescence Every 6 Months
Loss on ignition ±0.3% of ISO 1887 or JIS R 3420 Daily
Manufacturer’s nominal
Moisture content 0.5% Maximum ISO 33444 or JIS R 3420 Daily

Linear Density ± 10 % of Manufacturer’s ISO 1889 or JIS R 3420 Daily

(Roving tex) nominal
Chopped Strand ± 20 % of Manufacturer’s Process Calibration or Continuous or Monthly
Filament Diameter nominal ISO 18882 or JIS R 3420
Chopped Strand Length ± 2mm of Manufacturer’s Caliper Average of 20
- Monthly
nominal measurements

References
K-i Textile glass Determination of combustible-matter content, ISO 1887, International Organization for Standardization,
-

Geneva, Switzerland
K-2 Textile glass Staple fibres orfilaments Determination of average Diameter, ISO 1888, International Organization for
- -

Standardization, Geneva, Switzerland

K-3 Reinforcement yarns Determination of linear density, ISO 1889, International Organization for Standardization,
-

Geneva, Switzerland
K-4 Reinforcement Products Determination of moisture content, ISO 3344, International Organization for Standardization,
-

Geneva, Switzerland
K-5 Testing Methods of Textile Glass Products, JIS R 3420, Japanese Industrial Standard, Japanese Standards Association,
Akasaka, Minato-ku, Japan

83
 APPENDIX L — Specification for Polymer Curing Admixture
1. Property Requirements 2. Performance Requirements
1.1 Type compound To ensure GFRC product quality, curing compounds shall
aqueous thermoplastic copolymer dispersion be tested by an independent laboratory to demonstrate
that...
12 Type polymer
acrylic based .the recommended quantity of polymer curing admixture
in GFRC mix with no moist curing equals flexural proper
ties of GFRC cured 7 days moist when both are tested at 28
1.3 % Solids days.
45 to 55% by weight
...the long term durability of the dry cured polymer admix
1.4 Free monomer content ture modified composite, verified by aging tests, is equal to
maximum 0.2% by weight in dispersion or greater than the durability of GFRC cured 7 days moist.

1.5 Appearance .unit weight of mix design incorporating polymer curing

milky white, creamy, free from lumps ).
admixture is greater than 120 pcf (1930 g!m
3

1.6 Odor ..the polymer exhibits durability, ultraviolet stability and

must meet OSHA and EPA requirements oxidation resistance and stability in a high alkaline envi
ronment.
1.7 pH
8 to 10

1.8 Minimum film forming temperature

45 to 54°F (7 to 12°C)

1.9 Average polymer particle size

150-200 mm (Malvern autosizer)

1.10 Molecular weight

400,000-500,000

1.11 Ultraviolet resistance

good (weatherometer 500 brs.)

1.12 Alkali resistance

good
Example: Test saponification of polymer film-
4 weeks in 1 mole NaOH/KOH
hydrolysis (less than 5% at 50°C)

1.13 Viscosity
100-300 cps
[Brookfield, spindle 2, 100 RPM, 70°F (21°C)

1.14 Freeze-thaw stability

No gelation in a minimum of 5 cycles

84
 GUIDE SPECIFICATION FOR
GLASS FIBER REINFORCED
CONCRETE PANELS
THIS DOCUMENT
This document provides a basis for specifying in-plant
fabrication of glass fiber reinforced concrete (GFRC) pan
els by the spray-up process, including product design not
shown on contract documents, and field erection of glass
fiber reinforced concrete panels with a variety of textures
and finishes. It does not include architectural prec4st con
crete panels, precast structural concrete, nor does it include
coatings applied to the panels, or sealing the joints between
panels.
DRAWINGS AND SPECIFICATIONS
Drawings:
The Architect’s or Engineer’s drawings should show panel
locations and necessary sections and dimensions to define
the size and shape of the GFRC panels, indicate location of
joints, (both functional and aesthetic), and illustrate details
between units. When more than one type of panel material
or finish is used, indicate the location of each type on the
drawings. Plans should clearly differentiate between this
work and architectural precast concrete if both are on the
same job. Illustrate the details of corners of the structure
and interfacing with other materials. Details and locations
of typical and special connection items and inserts may or
may not be shown depending on local practices. If connec
tions are not detailed, identify the requirements for design
and indicate load support points and space allowed for con
nections.
Specifications:
Describe the type and quality of the materials incorpo
rated into the units, the design criteria of the GFRC, the
finishes, and the tolerances for fabrication and erection. It
is important in the event of a performance specification
that an appropriate test method be agreed upon as provid
ing the basis of assessment.
A performance approach to specifying GFRC building
components is appropriate. Specifiers should permit differ
ences in production, structural design, materials, connec
tion, and erection techniques due to preferences of different
85
manufacturers. Specifying the results desired without
specifically defining manufacturing procedures will ensure
the best competitive bidding. This may be done by stating
structural and aesthetic results to be achieved and by re
quiring complete details in shop drawings. Required sub
mittals should also include range-bracketing samples for
color and texture,
The panel specification section should include connection
components embedded in the GFRC, related loose connec
tion hardware, any special devices for lifting or erection, if
required, as responsibilities of the panel manufacturer.
Items to be specified in other sections include any building
frame support provisions required to support panels, in
cluding portions of connectors attached to the structure,
joint sealing and final cleaning and protection.
Coordination:
The responsibility for supply of GFRC support items to be
placed on or in the structure in order to receive the GFRC
units depends on the type of structure and varies with local
practice. Clearly specify responsibility for supply and in
stallation of hardware. Assurance that type and quantity of
hardware items, required to be attached to GFRC units for
other trades, are specified is important. Specialty items,
however, should be supplied by the trade requiring them.
Verify that materials specified in the section on flashing are
galvanically compatible with reglets or counterfiashing re
ceivers. Check that GFRC coatings, adhesives, and
sealants specified in other sections are compatible with
each other and with the form release agents or surfaces to
which they are applied.
Guide Specification Development:
These Guide Specifications have been developed jointly
by PCI and ARCOM and are intended to be the same as
MASTERSPEC® Section 03491. MASTERSPEC is a
product of the American Institute of Architects (AlA), pub
lished by ARCOM.
 Guide Specification
This Guide Specification is intended to be used as a basis for the development of an office master specification or in the
preparation of specifications for a particular project. In either case this Guide Specification must be edited to fit the condi
tions of use. Particular attention should be given to the deletion of inapplicable provisions or inclusion of appropriate re
quirements.
MASTERSPEC® Section 03491 Glass Fiber Reinforced Concrete (© 2001 The American Institute of Architects) is a prod
-

uct of the American Institute of Architects (AlA) and is used by permission of ARCOM, publishers of MASTERSPEC®.

Shaded portions are Notes to the Specification Writer.

SECTION 03491
GLASS FIBER REINFORCED CONCRETE
This Section uses the term “Architect. Change this term to match that used to identify the design professional as defined
in the General and Supplementary Conditions.
Verify that Section titles referenced in this Section are correct for this Project’s Specifications; Section titles may have
changed.

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1
Specification Sections, apply to this Section.

1.2 SUMMARY
A. This Section includes glass fiber reinforced concrete (GFRC) panels, consisting of GFRC, panel frames, anchors,
and connection hardware.
Retain subparagraph below if listing GFRC panel applications.
1. GFRC panels include [wall units] [window wall units] [mullions] [column covers] [fascia units] [cornices]
[soffits] <Insert applications>.
B. Related Sections include the following:
List below only products and construction that the reader might expect to find in this Section but are specified elsewhere.
1. Division 3 Section “Cast-in-Place Concrete” for placing connection anchors in concrete.
2. Division 3 Section “Plant-Precast Architectural Concrete.”
3. Division 5 Section “Structural Steel” for connection attachment to structural-steel framing.
4. Division 7 Section “Joint Sealants” for elastomeric joint sealants and sealant backings.
5. Division 8 Section “Aluminum Windows” for windows set into GFRC panels.

1.3 DEFIMTIONS
Retain paragraph below if a design reference sample has been preapproved.
A. Design Reference Sample: Sample of approved GFRC color, finish and texture, preapproved by Architect.

1.4 PERFORMANCE REQUIREMENTS

A. Structural Performance: Provide GFRC panels, including panel frames, anchors, and connections, capable of with
standing the following design loads, as well as the effects of thermal- and moisture-induced volume changes,
according to load factors and combinations established in PCI MNL 128, “Recommended Practice for Glass Fiber
Reinforced Concrete Panel.”
Retain subparagraph below if loads are indicated on Drawings and delete four subparagraphs that follow.
1. Design Loads: <As indicated.>
Retain four subparagraphs below if indicating loads here and delete subparagraph above.
2. Dead Loads: <Insert loads.>
3. Live Loads: <Insert loads.>

86
 4. Wind Loads: <Insert loads or wind-loading criteria, positive and negative for various parts of the building.>
5. Earthquake Loads: <Insert applicable earthquake design data including seismic coefficient and importance
factor.>
Revise deflection limit in subparagraph below to suit Project.
6. Deflection: Design panel frames to withstand design loads without lateral deflections greater than 1/240 of wall
span.
Differential values in first subparagraph below are suitable for most of the U.S. Revise to suit local conditions.
7. Thennal Movements: Provide for thermal movements resulting from annual ambient temperature changes of
100 degF (56 degC) <Insert temperature>.
8. Design panel frames and connections to accommodate deflections and other building movements.
Retain below if window loads will be transmitted to structure through panel frames. Insert other performance and design
criteria here to suit Project or add to Drawings.
9. Design panel frames to transfer window loads to building structure.

1.5 SUBM1TTALS
A. Product Data: For each type of product indicated. Include GFRC design mixes.
B. Shop Drawings: Show fabrication and installation details for GFRC panels, including the following:
1. Structural analysis data signed and sealed by the qualified professional engineer responsible for their
preparation.
2. Panel elevations, sections, and dimensions.
3. Thickness of facing mix, GFRC backing, and bonding pads for typical panels.
4. Finishes.
5. Joint and connection details.
6. Erection details.
7. Panel frame details for typical panels, including sizes, spacings, thicknesses, and yield strengths of various members.
8. Locations and details of connection hardware attached to structure.
9. Sizes, locations, and details of flex, gravity, and seismic anchors for typical panels.
10. Other items sprayed into panels.
11. Erection sequence for special conditions.
12. Relationship to adjacent materials.
13. Descriptions of loose, cast-in, and field hardware.
C. Samples: Representative of finished exposed face of GFRC showing the full range of colors and textures expected,
16 by 16 inches (400 by 400 mm) and of actual thickness.
Retain paragraph below if procedures for welder certification are retained in “Quality Assurance” Article.
D. Welding certificates.
Retain paragraph below if steel sheet certification is retained in “Quality Assurance” Article.
E. Steel Sheet Certification. For steel sheet used in cold-formed steel panel framing.
Retain paragraph below if mill certificates are retained in “Quality Assurance” Article.
F. Mill Certificates: For structural-steel shapes and hollow structural sections used in panel framing.
Coordinate first paragraph below with qualification requirements in Division 1 Section “Quality Requirements” and as
supplemented in “Quality Assurance” Article.
G. Qualification Data: For GFRC manufacturer, including proof of current PCI Plant Certification.
H. Source Quality-Control Program: For GFRC manufacturer.
I. Source Quality-Control Test Reports: For GFRC, inserts, and anchors.
Insert specific model code organization below or revise if report must be from another source. PCI’s ICBO Evaluation Re- -

port #4359 for GFRC is an example.

I. Research/Evaluation Reports: For GFRC.

1.6 QUALITY ASSURANCE

A. Manufacturer Qualifications: A qualified manufacturer who participates in PCI’s Plant Certification Program and is
designated a PCI-Certified Plant for Group G, Glass Fiber Reinforced Concrete.

87
Retain option in first subparagraph below if requiring manufacturer to install GFRC.
1. Manufacturer’s responsibility includes fabricating [and installing] GFRC panels and providing professional
engineering services needed to assume engineering responsibility for GFRC panels.
2. Engineering responsibility includes preparation of Shop Drawings and comprehensive engineering analysis,
based on GFRC production test values, by a qualified professional engineer experienced in GFRC design.
Retain paragraph below if requiring mill certificates or test reports for cold-formed steel framing used in panel frames.
B. Steel Sheet Certifications: Obtain mill certificates, signed by manufacturers of steel sheet or test reports from a
qualified testing agency indicating that steel sheet used in cold-formed metal panel framing complies with require
ments, including uncoated steel thickness, yield strength, tensile strength, total elongation, chemical requirements,
and galvanized-coating thickness.
Retain first paragraph below if requiring mill certificates for structural-steel shapes and hollow structural sections used in
panel frames.
C. Mill Certificates: Obtain certified mill test report from manufacturer of structural-steel shapes and hollow structural
sections used in panel framing indicating compliance of these products with requirements.
D. Source Limitations: Obtain GFRC panels from a single manufacturer.
Retain “Welding certificates” Paragraph in “Submittals” Article with paragraph below.
E. Welding: Qualify procedures and personnel according to AWS Dl .1, “Structural Welding Code--Steel,” and AWS
Dl .3, “Structural Welding Code--Sheet Steel
F. PCI Manuals: Comply with requirements and recommendations in the following PCI manuals, unless more strin
gent requirements are indicated:
1. PCI MNL 128, “Recommended Practice for Glass Fiber Reinforced Concrete Panels.”
2. PCI MNL 130, “Manual for Quality Control for Plants and Production of Glass Fiber Reinforced Concrete
Products.”
Retain paragraph below if using cold-formed metal framing for panel frames.
G. AISI Specifications: Comply with AISI’s “Specification for the Design of Cold-Formed Steel Structural Members.”
Retain subparagraph below if using structural-steel shapes or hollow structural sections for panel frames. Retain one of
first two options if requiring ASD or LRFD calculations with submittals.
H. AISC Specifications: Comply with AISC’s [“Specification for Structural Steel Buildings--Allowable Stress
Design and Plastic Design”] [“Load and Resistance Factor Design Specification for Structural Steel Buildings ‘9
[and] [“Specification for the Design of Steel Hollow Structural Sections”].
Retain paragraph and subparagraphs below if required for GFRC. If retaining, indicate location, size, and other details of
mockups on Drawings or by inserts. Revise wording if only one mockup is required.
I. Mockups: Build mockups to demonstrate aesthetic effects and set quality standards for fabrication and installation.
1. Build mockup of typical wall area as shown on Drawings [as part of] [separately from] building.
2. In addition to GFRC panels, mockups include [architectural precast concrete] [unit masonry] [aluminum
windows] [joint sealants] [metal flashings] [and] [copings] <Insert construction>.
Retain subparagraph below if mockups are erected as part of building rather than separately and the intention is to make an
exception to the default requirement in Division 1 Section “Quality Requirements” for demolishing and removing mock
ups.
3. Approved mockups may become part of the completed Work if undamaged at time of Substantial Completion.
Delete below if Work of this Section is not extensive or complex enough to justify a preinstallation conference. If retain
ing, coordinate with Division 1.
J Preinstallation Conference Conduct conference at Project site to comply with requirements in Division 1 Section
‘Project Management and Coordination”

17 DELIVERY, STORAGE, AND HANDLING

A Handle and transport GFRC panels to avoid damage
1 Place nonstaining resilient spacers between panels
2 Support panels dunng shipment on nonstaining material
3 Protect panels from dirt and damage during handling and transport
B Store GFRC panels to protect from contact with soil staining and physical damage
1 Store panels with nonstaining resilient supports in same positions as when transported

88
 2. Store panels on firm, level, and smooth surfaces.
3. Place stored panels so identification marks are clearly visible.

PART 2-PRODUCTS
2.1 MANUFACTURERS
Delete this Article unless naming GFRC manufacturers. See PCI’s magazine “Ascent” or its Web site www.pci.org for cur
rent PCI-certified plant listings.
See Editing Instruction No. 1 in the Evaluations for cautions about naming manufacturers and products.
A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be
incorporated into the Work include, but are not limited to, the following:
Retain above for nonproprietary or below for semiproprietary specification. Refer to Division 1 Section “Product Require
ments.”
B. Manufacturers: Subject to compliance with requirements, provide products by one of the following:
1. <Insert, in separate subparagraphs, manufacturer’s name>

2.2 MOLD MATERIALS

A. Molds: Rigid, dimensionally stable, nonabsorptive material, warp and buckle free, that will provide continuous and
true GFRC surfaces; nonreactive with GFRC and capable of producing required finish surfaces.
1. Mold-Release Agent: Commercially produced liquid-release agent that will not bond with, stain, or adversely
affect GFRC surfaces and will not impair subsequent surface or joint treatments of GFRC.
Delete paragraph below if not using form liners against molds. Revise to add description if particular form liner is se
lected.
B. Form Liners: Units of face design, texture, arrangement, and configuration [indicated] [to match GFRC design
reference sample]. Provide solid backing and form supports to ensure that form liners remain in place during
GFRC application. Use with manufacturer’s recommended liquid-release agent that will not bond with, stain, or
adversely affect GFRC surfaces and will not impair subsequent surface or joint treatments of GFRC.
Delete below if not using retarder to help obtain exposed-aggregate finish on face mix.
C. Surface Retarder: Chemical liquid set retarder capable of temporarily delaying hardening of newly placed GFRC
face mix to depth of reveal specified.

2.3 GFRC MATERIALS

A. Portland Cement: ASTM C 150, Type 1,11, or III.
Select portland cement color from options in subparagraph below.
1. For surfaces exposed to view in finished structure, use [gray] [white] [buffl of same type, brand, and source
throughout GFRC production.
Retain metakaolin as supplementary cementing material if its use by GFRC manufacturer has been proven in service to
maintain GFRC ductility.
2. Metakaolin: ASTM C618, Class N.
B. Glass Fibers: Alkali resistant, with a minimum zirconia content of 16 percent, 1 to 2 inches (25 to 50 mm) long,
specifically produced for use in GFRC, and complying with PCI MNL 130.
C. Sand: Washed and dried silica, complying with composition requirements of ASTM C144; passing No. 20 (0.85-
mm) sieve with a maximum of 2 percent passing No. 100 (0.15-mm) sieve.
Delete paragraph and subparagraph below if no face mix is required.
D. Facing Aggregate: ASTM C33, except for gradation, and PCI MNL 130, 1/4-inch (6-mm) maximum size.
Revise subparagraph below and add descriptions of selected face aggregate colors, sources, sizes, shapes, and gradations if
known.
1. Aggregates: Selected, hard, and durable; free of material that reacts with cement or causes staining; to match
sample.
Delete first paragraph below if coloring admixture is not required. Add color selection if known.
E. Coloring Admixture: ASTM C979, synthetic mineral-oxide pigments or colored water-reducing admixtures,
temperature stable, nonfading, and alkali resistant.
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 F. Water: Potable; free from deleterious material that may affect color stability, setting, or strength of GFRC and
complying with chemical limits of PCI MNL 130.
Usually retain paragraph below as manufacturer’s option with moist curing in “GFRC Fabrication” Article. PCI MNL 130
sets product requirements and mandates published independent laboratory test data verifying curing agent eliminates need
for moist curing. Polymer curing admixture is used by most GFRC manufacturers.
G.Polymer Curing Admixture: Acrylic thermoplastic copolymer dispersion complying with PCI MNL 130.
Retain paragraph below if in-service exposure involves freeze-thaw conditions and face mix does not include polymer cur
ing admixture. Air-entraining and polymer curing admixtures are incompatible.
H. Air-Entraining Admixture: ASTM C260, containing not more than 0.1 percent chloride ions.
Add types of chemical admixtures, if known, or limit types if required. Water-reducing admixtures, Types A, E, and D, or
a high-range water reducer, Type F, predominate.
I. Chemical Admixtures: ASTM C494/C494M, containing not more than 0.1 percent chloride ions.

2.4 ANCHORS, CONNECTORS, AND MISCELLANEOUS MATERIALS

Edit this Article to suit Project. Add other materials as required.
A. Carbon-Steel Shapes and Plates: ASTM A36/A36M. Finish steel shapes and plates less than 3/16 inch (4.76 mm)
thick as follows:
Retain one of two subparagraphs below. Hot-dip galvanized finish provides maximum corrosion resistance. Electrode-
posited zinc coatings provide some corrosion protection. MPI 79 in second paragraph provides some corrosion protection
while SSPC-Paint 25, without topcoating, provides minimal corrosion protection.
1. Finish: Zinc coated by [hot-dip process according to ASTM A123/A123M, after fabrication, or ASTM
A1531A153M, as applicable] [electrodeposition according to ASTM B633, SC3].
2. Finish: Shop primed with [MPI 79] [SSPC-Paint 25] on surfaces prepared to comply with SSCP-SP2, “Hand
Tool Cleaning,” or better.
Carbon-steel rods in paragraph below are used as flex, gravity, and seismic anchors.
B. Carbon-Steel Bars: ASTMA1O8,AISI Grade 1018. Finish steel bars less than 3/16 inch (4.76mm) thick as
follows:
Retain one of two subparagraphs below. Hot-dip galvanized finish provides maximum corrosion resistance. Electrode-
posited zinc coatings provide some corrosion protection. MPI 79 in second paragraph provides some corrosion protection
while SSPC-Paint 25, without topcoating, provides minimal corrosion protection.
1. Finish: Zinc coated by [hot-dip process according to ASTM A1231A123M, after fabrication, or ASTM
A153/A153M, as applicable] [electrodeposition according to ASTM B633, SC3J.
2. Finish: Shop primed with [MPI 79] [SSPC-Paint 25] on surfaces prepared to comply with SSCP-SP2, “Hand
Tool Cleaning,” or better.
C. Malleable-Iron Castings: ASTM A47/A47M, Grade 32510 (Grade 22010).
D. Carbon-Steel Castings: ASTM A27/A27M, Grade 60-30 (Grade 415-205).
E. Bolts: ASTM A307 orASTM A325 (ASTM F568M or ASTMA325M).
Delete subparagraph below unless service conditions warrant this added protection. Hot-dip galvanized finish provides
maximum corrosion resistance. Electrodeposited zinc coatings provide some corrosion protection.
1. Finish: Zinc coated by [hot-dip process according to ASTM A123/A123M, after fabrication, and ASTM
A153/A153M, as applicable] [electrodeposition according to ASTM B633, SC3].
Select PVC reglet or add another material to suit Project. Coordinate with counterfiashing materials and details.
F. Reglets: PVC extrusions.

2.5 PANEL FRAME MATERIALS

A. Cold-Formed Steel Framing: Manufacturer’s standard C-shaped steel studs, complying with AISIs “Specification
for the Design of Cold-Formed Steel Structural Members,” minimum uncoated steel thickness of 0.0538 inch (1.37
mm)[of web depth indicated], with stiffened flanges, U-shaped steel track, and of the following steel sheet:
Select required steel sheet and finish from two subparagraphs below. Select weight of zinc coating from options in first
subparagraph for galvanized steel framing.
1. Metallic-Coated Steel Sheet: ASTM A 653/A653M, structural-steel sheet, [G60 (Z180)] [G90 (Z275)} zinc
coating, of grade required by structural performance of framing.
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 iect subparagraph below if using painted steel framing.
2. Painted, Nonmetallic-Coated Steel Sheet: ASTMA1O11/A1O11M hot rolled orASTM A1008/A1008M cold
rolled; nonmetallic coated according to ASTM A1003/A1003M; of grade required by structural performance of
framing.
B. Hollow Structural Sections: Steel tubing, ASTM A500, Grade B, or ASTM A5 13. Finish hollow structural sections
with wall thickness less than 3/16 inch (4.76 mm) as follows:
Select finish options from two subparagraphs below. Zinc-rich primer offers some corrosion resistance; primer, minimal
corrosion resistance.
1. Organic Zinc-Rich Primer: SSPC-Paint 20 on surfaces prepared to comply with SSPC-SP6/NACE No. 3,
“Commercial Blast Cleaning.”
2. Primer: [MPI 79] [SSPC-Paint 25] on surfaces prepared to comply with SSCP-SP 2, Hand Tool Cleaning,” or
better.
C. Steel Channels and Angles: ASTM A36/A36M, finished as follows:
(Select finish options from two subparagraphs below. Finishes are placed in descending order of corrosion resistance.
1. Organic Zinc-Rich Primer: SSPC-Paint 20 on surfaces prepared to comply with SSPC-SP6INACE No. 3,
“Commercial Blast Cleaning.”
2. Primer: [MPI 79] [SSPC-Paint 25] on surfaces prepared to comply with SSCP-SP 2, “Hand Tool Cleaning,” or
better.

2.6 GFRC MIXES

Backing and face or mist-coat mix proportions should be determined by GFRC fabricator.
A. Backing Mix: Proportion backing mix of portland cement, glass fibers, sand, and admixtures to comply with design
requirements. Provide nominal glass-fiber content of not less than 5 percent by weight of total mix.
B. Face Mix: Proportion face mix of portland cement, sand, facing aggregates, and admixtures to comply with
design requirements.
Usually retain mist-coat mix in first paragraph below with backing mix above where there is no face mix. Delete below if
retaining face mix or where GFRC is faced with dimension stone or another veneer.
C. Mist Coat Mix: Portland cement, sand slurry, and admixtures, of same proportions as backing mix without glass
fibers.
D. Polymer Curing Admixture: 6 to 7 percent by weight of polymer curing admixture solids to dry portland cement.
Retain first paragraph below if GFRC panels are exposed to freeze-thaw conditions and GFRC manufacturer does not use
polymer curing admixture. Air content range below is based on PCI MNL 130 recommendations for freeze-thaw condi
tions.
E. Air Content: 8 to 10 percent; ASTM C 185.
F. Coloring Admixture: Not to exceed 10 percent of cement weight.

2.7 PANEL FRAME FABRICATION

A. Fabricate panel frames and accessories plumb, square, true to line, and with components securely fastened, according
to Shop Drawings and requirements in this Section.
1. Fabricate panel frames using jigs or templates.
2. Cut cold-formed metal framing members by sawing or shearing; do not torch cut.
3. Fasten cold-formed metal framing members by welding. Comply with AWS Dl .3 requirements and procedures
for welding, appearance and quality of welds, and methods used in correcting welding work.
4. Fasten framing members of hollow structural sections, steel channels, or steel angles by welding. Comply with
AWS Dl .1 requirements and procedures for welding, appearance and quality of welds, and methods used in
correcting welding work.
5. Weld flex, gravity, and seismic anchors to panel frames.
B. Reinforce, stiffen, and brace framing assemblies, if necessary, to withstand handling, delivery, and erection stresses.
Lift fabricated assemblies in a manner that prevents damage or significant distortion.
C. Galvanizing Repair: Touch up accessible damaged galvanized surfaces according to ASTM A780.
Select paragraph above for galvanized surfaces or below for prime-painted surfaces.
D. Painting Repair: Touch up accessible damaged painted surfaces using same primer.
I
2.8 MOLD FABRICATION

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 - -

A. Construct molds that will result in finished GFRC complying with profiles, dimensions, and tolerances indicated,
without damaging GFRC during stripping. Construct molds to prevent water leakage and loss of cement paste.
1. Coat contact surfaces of molds with form-release agent.
Usually retain subparagraph above. Delete subparagraph below unless exposed-aggregate surfaces require surface retarder
to achieve desired finish.
2. Coat contact surfaces of molds with surface retarder.
Delete paragraph below if form liners are not used.
B. Place form liners accurately to provide finished surface texture indicated. Provide solid backing and supports to
maintain stability of liners during GFRC application. Coat form liner with form-release agent.
Delete below if flashing reglets are not used.
C. Locate, place and secure flashing reglets accurately.

2.9 GFRC FABRICATION

A. Proportioning and Mixing: For backing mix, meter sand/cement slurry and glass fibers to spray head at rates to
achieve design mix proportions and glass-fiber content according to PCI MNL 130 procedures.
B. Spray Application: Comply with general procedures as follows:
1. Spray mist coat over molds to a nominal thickness of 1/8 inch (3 mm) on planar surfaces.
Retain subparagraph above or first subparagraph below, unless neither is required.
2. Spray or place face mix in thickness indicated on Shop Drawings.
3. Proceed with spraying backing mix before [mist coat] [face mix] has set, using procedures that produce a
uniform thickness and even distribution of glass fibers and matrix.
4. Consolidate backing mix by rolling or other technique to achieve complete encapsulation of glass fibers and
compaction.
5. Measure thickness with a pin gage or other acceptable method at least once for each 5 sq. ft. (0.5 sq. m) of
panel surface. Take not less than six measurements per panel.
C. Hand form and consolidate intricate details, incorporate formers or infill materials, and over spray before material
reaches initial set to ensure complete bonding.
D. Attach panel frame to GFRC before initial set of GFRC backing, maintaining a minimum clearance of 1/2 inch (13
mm) from GFRC backing, and without anchors protruding into GFRC backing.
E. Build up homogeneous GFRC bonding pads over anchor feet, maintaining a minimum thickness of 1/2 inch (13
mm) over top of anchor feet, before initial set of GFRC backing.
F. Inserts and Embedments: Build up homogeneous GFRC bosses or bonding pads over inserts and embedments to
provide sufficient anchorage and embedment to comply with design requirements.
G. Curing: Employ initial curing method that will ensure sufficient strength for removing units from mold.
1. After initial curing, remove panel from mold and place in a controlled curing environment.
2. Keep GFRC panels continuously moist for a minimum of seven days, unless polymer curing admixture was
used. Maintain temperature between 60 and 120 degF (16 and 49 degC) during this period.
Coordinate below with Shop Drawings.
H. Panel Identification: Mark each GFRC panel to correspond with identification mark on Shop Drawings. Mark
each panel with its casting date.

2.10 FABRICATION TOLERANCES

A. Manufacturing Tolerances: Manufacture GFRC panels so each finished unit complies with PCI MNL 130 for
dimension, position, and tolerances.
Retain paragraph above if incorporating tolerances by reference; retain first paragraph and subparagraphs below if detailed
listing is required in this Section.
B. Manufacturing Tolerances: Manufacture GFRC panels so each finished unit complies with the following
dimensional tolerances. For dimensional tolerances not listed below, comply with PCI MNL 130.
Tolerances below are PCI recommendations. Manufacturers may be able to comply with closer tolerances if required.
Closer tolerances normally increase costs.
1. Overall Height and Width of Units, Measured at the Face Adjacent to Mold: As follows:
a. 10 feet (3 m) or less, plus or minus 1/8 inch (3 mm).
b. More than 10 feet (3 m), plus or minus 1/8 inch per 10 feet (3 mm per 3 m); 1/4 inch (6 mm) maximum.

92
 2. Edge Return Thickness: Plus 1/2 inch (13 mm), minus 0 inch (0 mm).
3. Architectural Facing Thickness: Plus 1/8 inch (3 mm), minus 0 inch (0 mm).
4. Backing Thickness: Plus 1/4 inch (6 mm), minus 0 inch (0 nun).
5. Panel Depth from Face of Skin to Back of Panel Frame or Integral Rib: Plus 3/8 inch (10 mm), minus 1/4 inch
(6 mm).
6. Angular Variation of Plane of Side Mold: Plus or minus 1/32 inch per 3 inches (0.8 nmi per 75 mm) of depth or
plus or minus 1/16 inch (1.5 mm) total, whichever is greater.
7. Variation from Square or Designated Skew (Difference in Length of Two Diagonal Measurements): Plus or
minus 1/8 inch per 72 inches (3 mm per 1800 mm) or plus or minus 1/4 inch (6 mm) total, whichever is greater.
8. Local Smoothness: 1/4 inch per 10 feet (6 mm per 3 m).
9. Bowing: Not to exceed L/240 unless unit meets erection tolerances using connection adjustments.
10. Length and Width of Block Outs and Openings within One Unit: Plus or minus 1/4 inch (6 mm).
11. Location of Window Opening within Panel: Plus or minus 1/4 inch (6 mm).
12. Maximum Permissible Warpage of One Corner out of the Plane of the Other Three: 1/16 inch per 12 inches (1.5
mm per 300 mm) of distance from nearest adjacent corner.
C. Position Tolerances: Measured from datum line locations, as indicated on Shop Drawings.
1. Panel Frame and Track: Plus or minus 1/4 inch (6 mm).
2. Flashing Reglets at Edge of Panel: Plus or minus 1/4 inch (6 mm).
3. Inserts: Plus or minus 1/2 inch (13 mm).
4. Special Handling Devices: Plus or minus 3 inches (75 mm).
5. Location of Bearing Devices: Plus or minus 1/4 inch (6 mm).
6. Blockouts: Plus or minus 3/8 inch (10 mm).
D. Panel Frame Tolerances: As follows:
1. Vertical and Horizontal Alignment: 1/4 inch per 10 feet (6 mm per 3 m).
2. Spacing of Framing Member: Plus or minus 3/8 inch (10mm).
3. Squareness of Frame: Difference in length of diagonals of 3/8 inch (10 mm).
4. Overall Size of Frame: Plus or minus 3/8 inch (10 mm).

2.11 FiNISHES
This Article presumes Architect has preapproved one or more design reference samples. Include complete description of
design reference sample here. If preapproving manufacturers, coordinate with “Manufacturers” Article. Revise paragraph
below to add requirements if GFRC finish is to match another product such as architectural precast concrete.
A. Finish exposed-face surfaces of GFRC as follows to match approved [design reference sample] [and] [mockups].
Panel faces shall be free of joint marks, grain, or other obvious defects.
Delete subparagraph below if Architect’s design reference sample is not used. Revise if multiple samples are approved.
1. Design Reference Sample: <Insert description and identify manufacturer and code number of sample.>
Retain type of finish from subparagraphs below. If more than one frnish is required, add locations to fmish descriptions or
indicate on Drawings. Add more detailed descriptions of finishes outlined below when greater definition is required.
2. Smooth-Surface Finish: Provide free of sand streaks, honeycombs, and excessive air voids, with uniform color
and texture.
3. Textured-Surface Finish: Impart by form liners to provide surfaces free of sand streaks, honeycombs, and
excessive air voids, with uniform color and texture.
4. Retarded Finish: Use chemical-retarding agents applied to concrete forms and washing and brushing proce
dures to expose aggregate and surrounding matrix surfaces after form removal.
5. Sand- or Abrasive-Blast Finish: Use abrasive grit, equipment, application techniques, and cleaning procedures
to expose aggregate and surrounding matrix surfaces.
6. Acid-Etched Finish: Use acid and hot-water solution equipment, application techniques, and cleaning
procedures to expose aggregate and surrounding matrix surfaces.

2.12 SOURCE QUALITY CONTROL

PCI MNL 130 mandates source testing requirements. PCI certification also ensures periodic auditing of plants for compli
ance with requirements in PCI MNL 130.
A. Quality-Control Testing: Establish and maintain a quality-control program for manufacturing GFRC panels according
to PCI MNL 130.
1. Test materials and inspect production techniques.
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 2. Quality-control program shall monitor glass fiber content, spray rate, unit weight, product physical properties,
anchor pull-off and shear strength, and curing period and conditions.
3. Prepare test specimens and test according to ASTM C 1228, PCI MNL 128, and PCI MNL 130 procedures.
4. Test GFRC inserts and anchors according to ASTM C1230 to validate design values.
Revise frequency of testing in first subparagraph below to suit Project.
5. Produce test boards at a rate not less than one per work shift per operator for each spray machine and for each
mix design.
a, For each test board, determine glass fiber content according to ASTM C 1229, and flexural yield and
ultimate strength according to ASTM C947.

PART 3- EXECUTION
3.1 EXAMINATION
A. Examine structure and conditions for compliance with requirements for installation tolerances, true and level
bearing surfaces, and other conditions affecting performance.
1. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 ERECTION
A. Install clips, hangers, and other accessories required for connecting GFRC panels to supporting members and
backup materials.
B. Lift GFRC panels and install without damage.
C. Install GFRC panels level, plumb, square, and in alignment. Provide temporary supports and bracing as required to
maintain position, stability, and alignment of panels until permanent connections are completed.
1. Maintain horizontal and vertical joint alignment and uniform joint width.
2. Remove projecting hoisting devices.
D. Connect GFRC panels in position by bolting or welding, or both, as indicated on Shop Drawings. Remove temporary
shims, wedges, and spacers as soon as possible after connecting is completed.
E. Welding: Comply with applicable AWS Dl .1 and AWS Dl .3 requirements for welding, appearance, quality of
welds, and methods used in correcting welding work.
1. Protect GFRC panels from damage by field welding or cutting operations, and provide noncombustible shields
as required.
F. At bolted connections, use lock washers or other acceptable means to prevent loosening of nuts.

3.3 ERECTION TOLERANCES

I Tolerances below are PCI MNL 130 recommendations.
A. Erect GFRC panels to comply with the following noncumulative tolerances:
1. Plan Location from Building Grid Datum: Plus or minus 1/2 inch (13 mm).
2. Top Elevation from Nominal Top Elevation: As follows:
a. Exposed Individual Panel: Plus or minus 1/4 inch (6 mm).
b. Nonexposed Individual Panel: Plus or minus 1/2 inch (13 mm).
c. Exposed Panel relative to Adjacent Panel: 1/4 inch (6 mm).
d. Nonexposed Panel relative to Adjacent Panel: 1/2 inch (13 mm).
3. Support Elevation from Nominal Elevation: As follows:
a. Maximum Low: 1/2 inch (13 mm).
b. Maximum High: 1/4 inch (6 mm).
4. Maximum Plumb Variation over the Lesser of Height of Structure or 100 Feet (30 m): 1 inch (25 mm).
5. Plumb in Any 10 Feet (3 m) of Element Height: 1/4 inch (6 mm).
6. Maximum Jog in Alignment of Matching Edges: 1/4 inch (6 mm).
7. Maximum Jog in Alignment of Matching Faces: 1/4 inch (6 mm).
8. Face Width of Joint: As follows (governs over joint taper):
a. Panel Dimension 20 Feet (6 m) or Less: Plus or minus 1/4 inch (6 mm).
b. Panel Dimension More Than 20 Feet (6 m): Plus or minus 5/16 inch (8 mm).
9. Maximum Joint Taper: 3/8 inch (10 mm).
10. Joint Taper in 10 Feet (3 m): 1/4 inch (6 mm).
11. Differential Bowing, as Erected, between Adjacent Members of Same Design: 1/4 inch (6 mm).

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3.4 REPAIRS
Production blemishes should have been corrected at manufacturer’s plant. Blemishes occurring after delivery are normally
repaired before final joint cleaning and sealing.
A. Repairs will be permitted provided structural adequacy of GFRC panel and appearance are not impaired, as
approved by Architect.
B. Mix patching materials and repair GFRC so cured patches blend with color, texture, and uniformity of adjacent
exposed surfaces.
C. Prepare and repair accessible damaged galvanized coatings with galvanizing repair paint according to ASTM A780.
Retain paragraph above if using galvanized framing, anchors, connections, and other items; retain first paragraph below if
items are prime painted.
D. Wire brush, clean, and paint accessible weld areas on prime-painted components with same type of shop primer.
E. Remove and replace damaged GFRC panels when repairs do not comply with requirements.

3.5 CLEAMNG AND PROTECTION

A. Perform cleaning procedures, if necessary, according to GFRC manufacturer’s written instructions. Clean soiled
GFRC surfaces with detergent and water, using soft fiber brushes and sponges, and rinse with clean water. Prevent
damage to GFRC surfaces and staining of adjacent materials.

END OF SECTION 03491

Table of Metric Equivalents

1 in. = 25.4 mm
1 ft = 0.3048 m
1 sq.ft= 2
O.0929m
1 cu.ft= 3
0.0283m
1 lb. = 4.448 N
1 psi = 0.006895 MPa
°F = (F-32) 5/9 °C
section modulus (in.
) =
3 16,387 mm
3
moment of inertia (in.
) =
4 416,231 mm
4
Coefficient of heat transfer
IhI°F) =
2
(BtuIft 5.678 W/(m
2 °C)
Thermal expansion (in./in.°F = 1.800 mm/(mm°C)

95