GLASS FIBER REINFORCED CONCRETE {GFRC}

GENERAL DESCRIPTION

Fibre reinforced composite materials consist of high strength glass fibre embedded in a cementitious matrix. In this form, both fibres and matrix retain their physical and chemical identities, yet they produce a combination of properties that can not be achieved with either of the constituents acting alone. In general, fibres are the principal load- carrying members, while the surrounding matrix keeps them in the desired locations and orientation, acting as a load transfer medium between them, as well as protecting them from environmental damage. In fact, the fibres provide reinforcement for the matrix and other useful functions in fibre reinforced composite materials.

Glass fibres can be incorporated into a matrix either in continuous lengths or in discontinuous (chopped) lengths. The most common form in which fibre reinforced composites are used in structural application is called a laminate.
This is achieved by stacking a number of thin layers of fibres and matrix until reaching the desired thickness. The fibre orientation in each layer as well as the stacking sequence of various layers can be controlled to achieve a wide range of physical and mechanical properties for the composite laminate.

The design of glass fibre reinforced concrete panels proceeds from a knowledge of its basic properties under tensile, compressive, bending and shear forces, coupled with estimates of behavior under secondary loading effects such as creep, thermal and moisture movement.

HISTORIC DEVELOPMENT

The potential for using a glass fibre reinforced concrete system was recognized by the Russians in the 1940’s. The early work on glass fibre reinforced concrete went through major modifications over the next few decades.

In 1975 the late George Halliday, founder of RPC Ltd., introduced a modified version of glass fibre reinforced concrete (GFRC). This new GFRC material had several advantages and superior mechanical properties compared to other GFRC in the market.

In 1987, Dr. Ray Malekpour P. Eng. joined RPC Ltd. as Director of Research and Development. Following initial successful development, extensive research was carried out, with technical and financial assistance from the National Research Council of Canada. This intense research resulted in the development and subsequent introduction of a modified GFRC named SYNSTONE. This superior material has performed exceptionally well for over two decades in the harsh Canadian environment.

SYNSTONE is now manufactured by Concrete Cladding Systems Ltd. and Synstone West Ltd.  licensed manufacturers from Synstone International Ltd.

ARCHITECTURAL WALL AND CLADDING PANELS

Enclosure of buildings has always been a major concern for Architects and Engineers.

During the last few decades the demand for new buildings has been intense. Costs have been rising quickly and less time has been allocated for developing construction materials and methods. Also, buildings have become more complicated, largely as a result of increasing demand for greater control of interior conditions. Heating, venting and electrical systems have become more elaborate, mostly due to the design of the exterior walls

Because of this, in the past 15 – 20 years, there has been a growing knowledge of the physical phenomena that control the performance of buildings. This is sometimes referred to as “building science”.

In an endeavor to speed the process of  building and also to reduce costs, Concrete Cladding Systems Ltd. which is a leader in manufacturing of cementitious materials, by benefit of its knowledge of building science, has introduced materials and various methods for construction of exterior wall systems. The versatile “SYNSTONE” is the only material that can be utilized to construct wall systems in four different methods. The methods are as follows:

1. Concrete Cladding Systems “SYNSTONE” solid GFRC concrete panels attached to buildings by face fastening or back fastening to a wall system allowing the “Rain Screen Principle” to be used, as shown in our catalogue.
2. Light weight architectural GFRC precast concrete panels with steel studs and flex anchor as recommended by Prestressed Concrete Institute (PCI).
3. “THERMO-SHIELD” Cladding System – consisting of SYNSTONE GFRC fully bonded to rigid insulation of various thicknesses. This cladding panel can be attached directly by face fastening, to any substrate such as steel or wood studs, brick or block and/or cast-in place concrete wall.
4. Concrete Cladding Systems “SYNSTONE” solid GFRC precast concrete panels attached to buildings by hanging systems, as shown in our catalogue.

Glass fibre reinforced concrete architectural panels have the same general appearance as conventional concrete panels, but are different from them in several significant ways. For example, GFRC panels will, on the average, weigh substantially less than precast concrete panels due to there reduced thickness. The reduced weight of GFRC panels decrease the superimposed loads on the buildings structural components. The building frame thus becomes more economical. The reduced weight of GFRC panels can be less costly to transport and to erect.

In terms of creativity, GFRC panels can allow architects to exercise creative art in structures by utilizing various face mix decorative aggregates, form liners, and/or various form surface textures.