ABSTRACT:-

Glassfibre Reinforced Concrete or GRC is one of the most versatile building materials
available to architects and engineers. Composed principally of cement, sand and special alkali
resistant (AR) glassfibres, GRC is a thin, high strength concrete with many applications in
construction.
he GRC!Glass "ibre Reinforced Concrete, which was first invented by #pilkington# in
$% and developed successfully by rest of the continent, is a product having uni&ue combination
of properties unchallenged by any other e'isting material in the construction industry.
Glass "ibre Concrete can be moulded into wide varieties of shapes and contours to
become an architectural element of any building. (n fact CRC is tailor made) it can take any
profile or shape as per consumer#s re&uirement. his fle'ibility is what gives the material its
tremendous demand in a wide ranging variety of applications.
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INTRODUCTION :-
WHAT'S GRC?
Glass Fibre Reinforced Concrete (sometimes called Glass Fibre Reinforced Cement) is a
mixture of Cement, fine aggregate, water, chemical admixtures and Alkali Resistant Glass
Fibres.
There are a number of different manufacturing rocesses, the most common are !and
"ra# and $remix.
Glass Fibre Reinforced Concrete (GRC) is a material which toda# is making a significant
contribution to the economics, to the technolog# and to the aesthetics of the construction industr#
worldwide.
The Alkali Resistant Glass fibre is generall# used at the % to &' le(el in !and "ra#
GRC $rocess and ) to %' in $remix GRC $rocess to manufacture of factor# finished
refabricated roducts.
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ROLE OF FIBRES*+
,hen the loads imosed on concrete aroach that for failure, cracks will roagate
sometimes raidl#, fibres in concrete ro(ide a means of assisting the growth. Reinforced "teel
bars in concrete ha(e the same beneficial effect because the# at as long continuous fibres. "hort
discontinuous Glass Fibre has the ad(antage, howe(er, being uniforml# mixed and disersed
throughout the concrete.
WHY "ALKALI RESISTANT" GLASS FIBRE MUST BE USED IN GRC?
,hen secif#ing the constituent materials of Glassfbire Reinforced Concrete it is an
essential art of the o(erall -ualit# and -uantit# Assurance in GRC roducts that a high .irconia
alkali Resistant Glass fibre is used to manufacture GRC roducts.
The reasons for this are clearl# illustrated. Figure+/ shows the loss in weight of Glass
Fibres held in a saturated cements solutions ($!0/).1) for )22 !ours at 32 degree Celsius
loated against the 4irconia content. As is seen, the higher the 4irconia cotent the lower the
weight loss.
Figure+) (isuall# illustrates the difference between high 4irnonia Alkali Resistant
Glassfibres and standard 5+glass, the t#e of glassfibre generall# used in ol#ester resins and
g#sum, 6uickl# deteriorates and loses strength, where as the high 4irconia Resistant Glassfibre
remains (irtuall# unaffected.
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The cost of the 4irconia makes Alkali Resistant Glassfbires considerabl# more exensi(e
than 5+glass but, as seen the rice for securit# is well work a#ing.
GRC romise of thinner and stronger elements, reduced weight (/7%rd of $recast
Concrete) and controlled cracking b# siml# adding a small amount of fibres an attracti(e feature
of Fibre Reinforced Concrete.
PROPERTIES OF GRC*+
A software code useful for the structural anal#sis of GRC elements, considering the
actual beha(ior of the material and time deendent effects was de(eloed. 8t consists of a general
rocedure for the material non+linear anal#sis of one+dimensional GRC elements, including time
deendent effects. The numerical model is based on a finite element dislacement formulation
couled with a time ste integral solution. 8t is also ossible to consider taered beam elements,
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(ar#ing the cross section along the whole element. 9ifferent boundar# conditions for simle
elements can be considered in the structural anal#sis. 8n order to reroduce the actual beha(ior of
the GRC matrix, a multilinear stress+strain relationshi for this material was adoted in the
structural anal#sis and in the software code.
Typic! P"#p$"%i$& #' GRC*+
PROPERTY HAND OR MACHINE
SPARY GRC
(IBRATION CAST
PREMI) GRC
Glassfibre (weight') % to &' ) to %'
:ending
;ltimate strength (<=R)
<a
/3 T= %2 /2 T= />
5lastic limit (?=$) <a @ T= // > T= 3
9r# 9ensit# t7m% /.1 to )./ /.3 to ).2
"ra#ed GRC is generall# stronger than $remix Aibration Cast GRC. The reasons for this
are firstl# that with "ra#ed GRC it is ossible to achie(e a fibre content %+&' easil# where as
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$remix GRC is limited to around )+%'. "econdl#, "ra#ed GRC has a lower water content than
$remix GRC.
HOW IS GRC MANUFACTURED?
Glassfibre Reinforced Concrete (GRC) is generall# manufactured b# either the B "ra#B
rocess or the B$remixB (ibration casting rocess. The method chosen is normall# dictated b#
factors such as strength re6uirements, si.e of mould, architects secification etc. As a general
rule, larger items, such as building cladding anels, are normall# B"ra#edB where as small items
are manufactured from B$remixB GRC $rocess.
8n B"ra#B GRC $rocess onl# thinner sectionCs roducts are referred where as in
B$remixB GRC $rocess thicker sectionCs roducts are referred.
SPRAYED GRC PROCESS*+
The water and admixture (and ol#mer if used) are laced in a Bhigh shear mixerB and the
sand7cement are slowl# added until a smooth cream# slurr# is achie(ed. The consistenc# of the
slurr# is achie(ed in /+) minutes of <ixing Time.
,hen read# the mix is transferred to a Bum7sra# unitB. The um con(e#s the slurr#
at a regular rate of flow to the "ra# Gun. At the "ra# gun fibre, in the form of a ro(ing, is
choed to a length of aroximatel# %) mm and added to the slurr#. The two materials are
roDected onto the mould surface using a comressed air (ressure E & to 3 kg7cm)) sul# from
Air Comressor.

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The GRC material is sra#ed and built u in the la#ers until the re6uired thickness is achie(ed
+normall# /2+/&mm. "imle hand rollers are used to comact the material between la#ers.
The roduct is left in the mould and co(ered with ol#thene to re(ent moisture loss until
the next da#. The roduct is then demoulded.
After demoulding the units are co(ered with ol#thene and allowed to cure for
aroximatel# ) to > da#s. Alternati(el#, if ol#mer curing comound is used in the mix the units
can be exosed to the atmoshere immediatel# although it is ad(isable to kee them rotected
from direct sunlight or se(ere external conditions for a da# or two. Reference should be made to
the $ol#mer "ulierCs instruction.
PRE MI) GRC*+
The sand and cement are mixed dr# and then the water7admixture and ol#mer (if used)
are added. Generall# a two+seed slurr#7fibre blender mixer is used. ,ith this t#e of mixer, the
fast seed is designed to create smooth cream# slurr#. This takes about one+two minutes. The
mixer is switched to slow seed and fibre in the form of choed strand (length aroximatel#
/%mm) is added slowl#. The fibre is blended into the mix for aroximatel# / minute.
=nce the mix is read#, it is oured into the moulds, which are (ibrating using a (ibrating table.
The roduct is left into the mould to set and is co(ered with ol#thene sheet to re(ent
moisture loss. The roduct is demoulded the next da#.
After demoulding the roducts are cured under ol#thene sheets to maintain moist
conditions for aroximatel# ) to > da#s. Alternati(el# a ol#mer curing comound can be used
as described for the sra#ed rocess.
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E)CLUSI(E FEATURES OF GRC*+
GRC anels are ideal for internal artitions and external cladding in high or low rise
building, restige, commercial and industrial de(eloments, hotels, schools and low cost
housing. Architectural features can be incororated during the roduction rocess. The other
exclusi(e features are F
Ti!#"-*+$
GRC is a tailor made roduct, which can take an# rofile or shae as er customerCs
re6uirement.
Wi+$ ",-$ #' c#!#."&
GRC can be made a(ailable in wide range of, Cbuilt in coloursC to suit architects demand.
C#&% &/i,-
Re6uire ainting for rest of its life Thus there is a cost sa(ing or maintenance, ainting
and reainting etc. Again the cost o GRC totall# deends uor number of reetition of design,
since the cost of rubber mould is (er# high, 8n general, ! reetition is more than )& times, then
the cost of GRC ranges from Rs. %&2@+ to &&7+ er s6.ft. 8t is alwa#s measured along girth of
erimeter of an# rofile.
Ti*$ &/i,-
Time re6uired to roduce GRC roduct as comared to stone is /7>
lh
. For examle, to
car(e one "FT of stone screen or free.es, will take atleast two da#s whereas )22 "FT of GRC
can be manufactured in one da#. =nce the master mould is reared, an# number of GRC articles
can be roduced in short time.
E&y %# Mi,%i,
A GRC article has a smooth washable surface. ,ell able to withstand the extreme of
climate conditions. 8t can be sra#ed to gi(e a rotecti(e coating of great strength.
I*p"#/$+ p0y&ic! p"#p$"%i$&
GRC combines lightness with high tensile7flexural strength and high imact resistance
and has a good thermal and acoustic insulation.
O%0$" $1c!.&i/$ '$%."$&
?ight weight due to thin section, 9esign flexibilit#, !igh bending strength, !igh imact
strength, !igh toughness and cracking resisti(it#, Gon+combustibilit#.
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WHAT IS GRC USED FOR?
GRC ro(ides the Architect with an end roduct range that no other material can match
in terms of shae, form, texture, lightweight, mouldabilit# and long term technical roerties.
This di(ersit# of roerties offers the Architect a material which has*
?ightweight, ease and seed of handling, with reduced erection and transortation costs.
?ow maintenance re6uirements.
?ow ermeabilit# i.e. good waterroof roert#.
5xcellent fire resistance roert#.
5n(ironmental accetabilit# i.e. excellent anti corrosi(e roert#.
Abilit# to reroduce fine surface details.
Reduce loading on building leading to substantial reductions in structural and foundation
cost, eseciall# useful for building reno(ation or restoration.
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CONCLUSION*+
5xerimental results and models demonstrated that it is ossible to achie(e a structural
beha(iour of light+weight GRC comonents using a sulementar# suorting grid.
;nfortunatel#, it has been noted that the erformance of final comonents can widel# change, b#
u to a factor 3, as a conse6uence of *+ the large disersion of strength (alues, b# u to a factor >,
due to a strong deendence from se(eral roduction arameters (i.e. water7cement ratio, fibre
segregation, anisotro# of the material, etc.) and to the difficulties to kee under strict control
these arametersF + the uncertaint# in the dimensions (e.g. thickness) due to the intrinsic limit of
current H manual or semi+automatic H roduction technologies (sra#ing and mould+casting), b#
u to a factor ).
At this moment, three different solutions ha(e been adoted to a(oid failures in final
comonents* + (er# low strength (alues ha(e been used to calculate the si.e of comonentsF +
sulementar# suorting grids (made of stainless steel, glass or carbon wires) were
incororatedF + large comonents were ost+stressed to minimise the maximum (alue of tensile
stress resent in the structure during working conditions. "uch solutions are not comletel#
satisfactor# because the# do not remo(e the main causes of the roblem but onl# mitigate the
effects. Therefore further RI9 acti(ities are necessar# to find a radical solution to the abo(e
roblems b# reducing the (ariation in the o(erall erformance of comonents.
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REFERENCES*+
/. Construction Dournal of 8ndia Aril )22/.
). G:CC <9C Dournal Jul# )22/. Aol H /&.
%. Reort of :. Kumar, (ice resident (Tech), J.K. ,hite Cement ,orks, Jodhur.
>. www.google.com

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