ARCHITECTURAL GLASS REINFORCED CONCRETE

JULY 2011

THE WORLD OF GRC Glass Reinforced Concrete (GRC) was first introduced in the late 1960’s and since then has become the first choice for many architects and developers throughout the world when looking for a contemporary cladding solution. Products manufactured from GRC all share the same characteristics of high strength, light weight and a versatility of shapes and sizes that very few, if any, other cladding materials can match. As a result the material has been used on some of the most iconic and well known buildings of the last twenty five years. These include the Bernebeu Stadium in Madrid, Venetian Hotel in Macau, Emirates Palace Hotel in Abu Dhabi, Atlantis Hotel in Dubai, International Airport in Istanbul and the 2010 World Cup Stadium in Johannesburg. At last GRC is beginning to be recognised in the country of it’s origin with the two largest construction projects of recent times, the Olympic Village and Crossrail developments, featuring extensive use of this innovative and exciting composite.

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About us 5 Introduction, Design & Moulds, Manufacturing, Testing, Accreditation

Types of GRC 11 Premix & Spray

Applications 13 Architectural Dressings, Door Surrounds, Canopies, Copings, Cladding Panels, Interiors

Finishes & Textures 20 Sand Blasted, Textured, Photo Image, Bespoke Patterns

Technical Information 25 Material Selector, Characteristic Properties, Dead Load Comparisons, Standards & Specifications

Acknowledgements The company acknowledges the following organisations for the reproduction and use of photographs provided by them within this brochure: Berkeley Group, Jack Wills Ltd, Interserve Ltd Marilyn Munroe rubber mould liner manufactured by Reckli GbmH

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INTRODUCTION

GRCUK is one of the country’s leading manufacturers of GRC architectural components and cladding systems. We are totally committed and focused on providing our customers with the very best possible combination of high quality and customer service. Whilst we firmly believe in the principles and best practice of GRC manufacture evolved over the last forty years, we are equally innovative in our approach to providing building solutions in the most cost effective manner. As such research and development supported by a continuous process of testing and evaluation are an integral part of our business. Wherever possible all processes are carried out in house. This includes design, mould manufacture, steel fabrication and testing. We also pride ourselves on our close collaboration with associated trades and professions such as engineers, universities, other GRC manufacturers throughout the world as well as interfacing material suppliers and installers. As part of our total supply solution we offer a full package design, supply and fit service ensuring our main contractor clients can simply place one package and we will deal with everything. GRCUK—passionate about GRC

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ABOUT US

DESIGN & MOULD MAKING The design of GRC products is a very specialist activity which should only be undertaken by experienced engineers and technicians. We offer all our customers a complete design and detailing service to ensure that profiles are correctly manufactured to resist the various loads they will be subjected to. Equally important is to design support and restraint systems which are capable of providing the required range of movement due to reversible and irreversible shrinkage, thermal expansion and contraction and of course building deflection. During this design process we also work with other manufacturers and suppliers to ensure a successful interface with other materials used in the construction. Working with some of the world’s leading GRC engineers we routinely provide full design calculations based on the extensive data collected from our laboratory testing procedures. These would form part of any post completion documentation records required. All our design work is full backed by Professional Indemnity insurance and Design Warranties are available if required. Throughout the design process our skilled and time served pattern makers advise on the practicalities of creating the moulds required to translate drawings into high quality GRC components. In this way we can ensure that we offer not only the most practical but cost effective solutions.

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MANUFACTURING Our Sheffield facility is one of the largest dedicated GRC manufacturing plants in the UK. Completely self contained with pattern shop, steel fabrication works, casting area and internal storage we operate on the principle of all raw materials arriving at one end with cured products leaving at the other. We have the capability to manufacture GRC in any of the three recognised processes, cast premix, sprayed premix and simultaneous spray. Our factory is fully temperature controlled to ensure our products are manufactured and cured in optimum environmental conditions. All raw materials are stored internally to avoid any contamination. Essential to our philosophies the production cycle is fully traceable from start to finish using a highly developed software planning system which provides barcode labels for each and every component. These show not only the date and sequence of casting but useful site information such as item weight etc.

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ABOUT US

TESTING We are believe in a fully traceable production where representative tests are carried out on each days output. In this way we can ensure all material is standard compliant before despatch to site. As such we test well beyond the testing frequencies defined in BS EN 1169: 1999 or current GRCA requirements. Our on site laboratory is fully equipped to carry out all tests defined in BS EN 1170: Parts 1-6. This includes testing of 8 sample coupons per mixer each and every day for critical flexural and bending strength. In addition we also carry out aggregate sampling and regular pull off and pull out tests of flex anchors and embedded fixings.

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ACCREDITATION Our Sheffield facility is fully certified under the International Glassfibre Reinforced Concrete Association Approved Manufacturer Scheme for both premix and sprayed GRC . The scheme is a production based quality assurance scheme for specialist manufacturers of GRC throughout the world. All AMS members are assessed on their capability to manufacture in accordance with international best practice and relevant specifications and standards.

ABOUT US

TYPES OF GRC GRC is a composite material manufactured primarily, from hydraulic cement, silica sands, alkali resistant glass fibres, water and other additives. Where GRC differs from other precast concretes is the significantly enhanced tensile and bending strengths achieved by the addition of the glass fibre strands throughout the matrix. These characteristics allow components to be cast with profiles as thin as 10mm thus reducing the unit weight by up to 90%. Unlike other concretes which are classified by compressive strengths GRC is defined by its resistance to flexing or bending stresses. The International Glass Reinforced Concrete Association (GRCA) Specification recognises three grades of GRC, Grade 8, 10 and 18. These are obtained by the characteristic bending strength of the material, which is primarily a product of fibre content

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Premix GRC Premix is a process where the fibres are added to the concrete slurry during the mixing process. The material is then poured or pumped into a mould using very similar methods to precast concrete. Moulds are generally two part to create hollow core items. Because the mix is required to be relatively fluid, fibre content is at the low end of the scale. The lower strength of the material means it is generally only suitable for smaller architectural features. A relatively new development is sprayed premix. This uses the same mix formulations however the concrete is sprayed into an open mould thus removing the need for complex moulds.

Sprayed GRC Sprayed GRC is a process where the concrete slurry and fibres chopped from continuous rovings are simultaneously sprayed into open moulds. This method allows far higher fibre content along with longer strands and multi directional orientation. The resultant material offers significantly higher strength characteristics allowing large cladding panels up to 20m² to be manufactured.

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TYPES OF GRC

ARCHITECTURAL DRESSINGS Architectural dressings, usually in natural or cast stone, are part of the UK’s building heritage. Both private or commercial developments in either traditional or contemporary styles all benefit from designs featuring this type of product. However the use of these components can present builders with two major issues, weight and damage. Dressings manufactured from GRC can help alleviate or completely eliminate these problems. Because of the ability to cast with hollow cores, weight is reduced substantially and most components can easily be handled by one or two operatives without the need of expensive lifting equipment. The effect of blending fibres throughout the matrix and the increased cement content result in a material which is significantly more resistant to impact than traditional cast stone. Only a very severe impact will damage high quality GRC and in such situations the binding effect of the fibres ensure that any repairs required are minimal. GRC units can often be retro fitted which not only take the items away from the critical build path but also reduce the chances of any soiling scuffing etc. by secondary trades.

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DOOR SURROUNDS Our GRC door surrounds are an ideal alternative to the white plastic (GRP) type seen on many housing developments throughout the UK. Looking identical to a costly natural or cast stone surround, these components can be easily fitted to both new build and existing properties at minimal cost. All our door surrounds can be fitted to a suitable masonry substrate using supplied fixing kits in approximately 2-3 hours. We offer a range of standard surrounds, details of which can be obtained from our sales office, or of course, are happy to manufacture to any bespoke design as required. GRCUK door surrounds can transform the appearance of otherwise bland front entrances and of course add considerable “kerb appeal” in a difficult sales market.

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APPLICATIONS

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DOOR CANOPIES We offer a range of GRC door canopies in either traditional or contemporary design. Like our door surrounds these components are easily fitted to completed buildings and are comparable in price to similar products in plastic, acrylic etc. Please contact our sales office for further details PARAPET COPINGS Used primarily in traditional masonry cavity wall construction our copings are identical in appearance to those manufactured in natural or cast stone. The major advantage of these items in the reduction in weight offered. The installation of copings is normally considered a “repetitive” lifting operation. All our copings for cavity wall constructions up to 350mm wide weigh less than 20Kg. As such they can easily be installed by one operative without the need for risk assessments etc. Larger bespoke copings in either premix or simultaneous spray can easily be produced to client requirements. These units also offer significant weight savings over more traditional cast stone or precast

INTERIORS Few masonry materials are as versatile as GRC which is particularly suitable when creating stone or concrete features within buildings. As well as being able to be cast or sprayed in virtually any shape or size the lightweight nature of GRC products allows them to be easily transported and handled, a major advantage when working in a restricted environment. In refurbishment of existing buildings loads on floors etc is significantly reduced over more traditional materials. We offer a complete bespoke design, manufacture and installation service for all interior GRC applications in offices, hotels, retail outlets, shopping centres etc. Products include archways, columns, rock features, ceilings, stair treads and many more.

APPLICATIONS

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CLADDING PANELS GRC is an ideal facade cladding material and it’s principle use throughout the world is in this application. Unlike panel cladding systems our GRC can easily be moulded into virtually and shape or size allowing the ultimate in architectural expression. Returns, curves and multi dimensional faces are all possible in sizes ranging from 1-20m². As such we can offer not only walling panels but column claddings, balcony cladding panels, spandrel panels etc. In truth there’s not much we can’t clad. The major advantage of our GRC is to offer a relatively light weight cladding system when compared to either natural precast or cast stone products and yet when installed our products are virtually identical in both look and touch to natural stone. Due to the inherent characteristics of the material and the use of acrylic polymers within the mix designs both water absorption and carbonation and reduced thus allowing components to retain their supplied appearance longer. The lower weight of our GRC claddings not only makes installation easier and more cost effective but structures and support systems can be designed from the outset to carry less imposed loading again further reducing cost.

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Our standard and non pigmented colour is Portland stone which after a light grit blast is virtually identical to the quarried mineral. With the addition of colouring pigments and/or special aggregates such as granite, dolomite, crushed glass we can offer designers and developers a virtual unlimited pallet of colours and textures. In partnership with the University of Derby we can also offer our customers unique and innovate patterning option to many profiles. Using advanced digital modelling software developed by the university’s faculty of design and technology and our progressive mould manufacturing techniques virtually any form of motif or repeating pattern can be cast into the faces of our product. Provided the concept or design exists in digital format we effectively transform into concrete. This of course allows designers to embody buildings and structures with a distinctive and individual identities. All our cladding panels in excess of 1m² are generally cast using the “spray” process as defined in BS EN 15191. This is the strongest form of GRC offering significantly higher tensile, bending and impact strength than other classifications of GRC. All such cladding solutions are bespoke designed to individual projects and supported by full and comprehensive professional indemnity insurance.

APPLICATIONS

F01

F02

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The base colour of our GRC is virtually identical to that of naturally occurring Portland Stone. We can however utilise iron oxide pigments to achieve virtually any colour a customer may require. These include sandstone, bath stone and slate grey amongst many others. In addition most of our cladding panels are available in a range of standard patterns as shown.

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F00 F03

F11

F12

F14

F16

F15

F13

FINISHES & TEXTURES

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F05

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F07

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F10

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Bespoke Pattern Finish F19

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Photo Image Finish

FINISHES & TEXTURES

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TECHNICAL INFORMATION

GENERAL GUIDE TO MATERIAL SELECTION Components Premix Spray Cills Yes No Copings Yes No Heads, Band Courses (Retro Fit) Yes No Heads, Band Courses (Built in) Yes No Door Surrounds & Canopies Yes Yes Cornices < 1m² Area Yes Yes Cornices > 1m² Area No Yes Cladding Panels < 1m² Area Yes Yes Cladding Panels > 1m² Area No Yes Soffit Panels < 1m² Yes Yes Soffit Panels > 1m² No Yes Column Cladding < 1m² Yes Yes Column Cladding > 1m² No Yes

The above is given as general guidance only. All GRC should be engineer designed to suit individual applications. Please contact us to discuss specific project requirements

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CHARACTERISTC PROPERTIES Property Units Premix Spray Dry Density kg/m3 1800-2000 1800-2000 Water Absorption % 8-13 8-13 Apparent Porosity % 16-25 16-25 Compressive Strength MPa 40-50 50-60 Bend over Point (BOP) MPa 3-5 4-6 Ultimate Tensile Strength (UTS) MPa 3-6 8-12 Limit of Proportionality (LOP) or Elastic Limit MPa 6-10 7-12 Modulus of Rupture (MOR) or Ultimate Failure MPa 8-14 18-30 Interlaminar Shear MPa N/A 3-5 In-Plane Shear MPa 4-6 7-12 Impact Strength KJ/m² 7-12 15-20 Thermal Conductivity W/mK 0.5-1 0.5-1

DEAD LOAD COMPARISON CLADDING PANELS Area Precast GRC Saving 100m² 22 tonnes 6 tonnes 16 tonnes 200m² 44 tonnes 12 tonnes 32 tonnes 400m² 88 tonnes 24 tonnes 64 tonnes 800m² 176 tonnes 48 tonnes 128 tonnes 1600m² 352 tonnes 96 tonnes 256 tonnes 2200m² 704 tonnes 192 tonnes 512 tonnes 4400m² 1408 tonnes 384 tonnes 1024 tonnes Above data based on panel thickness of 100mm and average density at 3% moisture content of 2200 Kg/m³

TECHNICAL INFORMATION

STANDARDS AND SPECIFICATIONS All GRC products are manufactured, classified and tested in accordance with the following: BS EN 1169 General rules for factory production of glass fibre reinforced cement BS EN 15191* Classification of glassfibre reinforced concrete performance IGRCA International Specification for manufacture and testing of Glassfibre Reinforced Concrete BS EN 1170:1 Measuring consistency of the matrix BS EN 1170:2 Measuring the fibre content in fresh GRC BS EN 1170:3 Measuring the fibre content of sprayed GRC BS EN 1170:5 Measuring Bending Strength BS EN 1170-6 Determination of the absorption of water by immersion and the determination of the dry density. BS EN 1170-7 Measurement of extremes of dimensional variations due to moisture Content (on request) Please note at this time we, along with all UK manufacturers , are unable to test products in accordance BS EN 1170:8 due to unavailability of

testing facilities within the UK.

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Useful Information Available from www.grca.co.uk

International from www.bsi.org BS EN 1169 General rules for factory production of glass– fibre reinforced cement BS EN 1170 1:1998 Measuring the consistency of the matrix “Slump test” method BS EN 1170 2:1998 Measuring the fibre content in fresh GRC “Wash out test” BS EN 1170 3:1998 Measuring the fibre content of sprayed GRC BS EN 1170 4:1998 Measuring bending strength “simplified bending test” BS EN 1170 5: 1998 Measuring bending strength “complete bending test method” BS EN 1170 6:1998 Determination of the absorption of water by immersion and the determination of the dry density BS EN 1170 7:1998 Measurement of extremes of dimensional variations due to moisture content

BS 8297:2000 Design and installation of non-www.grconline.com

www.grctesting.com © Glass Reinforced Concrete UK Ltd 2011 Not to be reproduced in whole or part without the express permission of the author. Whilst every care has been taken in the preparation of the document to ensure that any advice, recommendations or information is accurate, no liability or responsibility of any kind is accepted in respect of Glass Reinforced Concrete UK Ltd

Glass Reinforced Concrete UK Ltd, 1-3 Redwood Court, Campbell Way, Dinnington, Sheffield. S25 3NQ T: +44 1909 566911 F: +44 1909 569399 info@grcuk.com

www.grcuk.com

© Glass Reinforced Concrete UK Ltd 2011 Not to be reproduced in whole or part without the express permission of the author. Whilst every care has been taken in the preparation of the document to ensure that any advice, recommendations or information is accurate, no liability or responsibility of any kind is accepted in respect of Glass Reinforced Concrete UK Ltd