International Journal for Multidisciplinary Research (IJFMR)

E-ISSN: 2582-2160 ● Website: www.ijfmr.com ● Email: [email protected]

Glass Fibre Reinforced Concrete (GFRC)

Materials and Its Applications
Menaka T

Assistant Professor/ CIVIL, Unnamalai Institute of Technology, Suba Nagar, Kovilpatti, India

Abstract
In the 1940’s, potential of glass as a construction material was realized and improvement continued with the
addition of zirconium dioxide in 1960's for harsh alkali conditions. The development of new glass fibre
generations is focused on improving the process of material durability. In order to meet various needs, glass
fibre reinforced concrete, or GFRC, was thus introduced into production. Research and experiments
conducted on GFRC have demonstrated that the material quality and production precision have an impact on
the material's mechanical and physical characteristics. GFRC can be applied anywhere an impermeable,
weather-resistant, fire-resistant, light-weight, and robust material is required. With the development of
technology, it may be possible to construct sophisticated freeform structures and entire buildings at a
reasonable cost. Recently, research has been done on the impact of glass fibres in hybrid mixtures for high-
performance concrete (HPC), a newly developed technology that is gaining popularity in the building sector.

Keywords: Glass, Fibre, Reinforcement, Concrete, Properties, Application, Development

I. INTRODUCTION
For more than 40 years, glass fibre reinforced concrete (GFRC) has been a substantial advancement in the
technology, economy, and aesthetics of the global building sector. For architects and engineers, GFRC is one
of the most adaptable building materials available. Its unique structure causes it to have more complex
qualities than regular concrete. Numerous factors affect the qualities and behaviour of GFRC as well as the
precision of the production process. These factors include the water-cement ratio, porosity, composite
density, inter-filler content, fibre content, orientation and length, and type of cure. GFRC weighs
significantly less than conventional pre-cast concrete products since it can be made as thin as 6 mm. The
utilisation of premix, spray-up, and hybrid GFRC technologies, along with the advancement of 3D printing
technology, may create intricate architectural forms and entire buildings with exceptional dependability. The
GFRC has been impacted by the cost and popularity of self-cleaning, ecologically friendly panels for
industrial building. Recently, there has been an increase in the usage of glass fibre in the High Performance
Concrete (HPC) class, which is known for its exceptionally high mechanical performance, durability,
workability, and aesthetics. International standards, developed in Europe, America, Asia, and Australasia,
govern the design and production of GFRC products. More than 100 countries produce GFRC.

1.1 Methods
There are two primary methods for producing GFRC, spray-up and pre-mix being the most widely used. The
mortar is created independently of the fibres throughout the spray-up procedure, and the two are only
combined at the spray gun's jet. The glass fibre strands are chopped inside the spray cannon to the desired

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E-ISSN: 2582-2160 ● Website: www.ijfmr.com ● Email: [email protected]

size, which is typically between 25 and 40 mm and accounts for 4-5 percent of the weight of the mixture in
total. Spraying produces a thin coat that is as thin as feasible using a fiber-free matrix. To ensure integrity,
the following layers of matrix with fibres are placed swiftly. It receives the mixture to toughen after the
majority of the GFRC is layered on top of it. The typical thickness of the covering layer varies based on the
kind of surface treatment, between 3 and 5 mm. Approximately 4-6 mm of material is deposited with each
spray gun pass; however, corners and intricate designs require careful application of an appropriate layer
thickness. In order to remove any air that was retained in the mixture and to impregnate the fibres within the
mortar, the construction was finally compressed using a cylindrical roller or a float. Layer thickness is
measured using a depth gauge or template in order to ensure that GFRC is the minimum required. Pre-cut
glass fibres, ranging in weight from 2-4 percent (often 3.5% to 6%), are mixed with cement matrix in the
pre-mixture and casting process of producing glass fibre reinforced composites. Pre-cut fibres are typically 6
to 12 mm long; however, longer fibres limit the workability of the mixture. For maximum workability,
chopped fibre strands are introduced into the matrix through a low-speed mixing regime after the matrix is
created in a high-shear mixer. This makes it easier for them to disperse at the maximum volume content that
is practical while causing the least amount of fibre damage. Pre-mix GFRC production can include a number
of processes, including pressing, shotcreting, and injection and vibration.

Spray up process

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Pre–mixture and casting process

1.2 Curing
Curing stage of conventional concrete technique is essentially the same. Furthermore, the negative
consequences of incorrect water curing are far more noticeable in the GFRC product. Increased drying and a
decrease in strength may result from the GFRC's low thickness and larger surface area. Long-term moist
curing is frequently not necessary due to the polymer concentration. The fresh mixture retains its internal
moisture content due to the small concentrations of acrylic polymers that inhibit its evaporation. To
guarantee that the GFRC develops sufficient strength for the element to be securely removed from a mould,
sudden and rapid drying-out or significant temperature changes must be avoided. GFRC components are
usually stripped between 16 and 24 hours after casting, usually the next day. Although better concrete will
always result from longer cure times, most concrete tends to strip shortly after casting.

1.3 Properties
The composite's structure affects the characteristics of fiber-reinforced cementitious materials. Therefore, an
internal structure analysis of these composites is necessary in order to forecast their performance under
different loading circumstances. The following three factors need to be taken into account:
1. The structure of the bulk cementitious matrix,
2. The shape and distribution of the fibres,
3. The structure of the fibre–matrix interface.

1.4 Matrix
There are two forms of bulk cementitious matrix: paste/mortar (cement/sand–water mix) and concrete
(cement–sand–coarse aggregate–water mix), which are distinguished by the particle filler (aggregate) that
they include. The thin sheets that are primarily used for cladding are often coated with glass fibre reinforced
concrete pastes or mortars. The main reinforcing element in these applications is fibre, which typically
makes up 5–15% of the total volume. Such composites must be manufactured using specialised production
techniques.

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1.5 Fibers
Reinforcing arrays can be broadly classified into two categories: discrete short fibres, typically less than 20
mm long, that are incorporated into the matrix by means like spraying and mixing, and continuous
reinforcement in the form of long fibres that are incorporated into the matrix by means of filament winding
or the lay-up of layers of fibre mats. Depending on how the fibres are distributed within the matrix, the
reinforcing array can be further divided into random 2D and 3D categories.
Three-dimensional (3D) random reinforcement is the first type. This happens when concrete is combined
with fibres and then poured into shapes. Fewer fibres are genuinely able to withstand tensile loads that arise
in a particular direction due to the random and 3D orientation. This degree of fibre reinforcement requires
extremely high fibre loads and is highly inefficient. Only 15% of the fibres are usually orientated
appropriately.
The second level consists of two-dimensional (2D) random reinforcement. This is the content of spray-up
GFRC. Within a narrow plane, the fibres are arranged randomly. The fibres lay flat once they are sprayed
into the moulds, reinforcing their shape. In most cases, between 30 and 50% of the fibres are orientated
properly.

1.6 The Structure of the Fibre–Matrix Interface

In the area of the reinforcing inclusion, cementitious composites exhibit an interfacial transition zone where
the paste matrix's microstructure differs significantly from the bulk pastes, further away from the interface.
Depending on the fibre type and production method, this transition zone's characteristics might vary greatly
over time. A bundled filament should be created when taking into account how the microstructure is
developing in the transition zone. With bundled filaments, only the external filaments typically have direct
access to the matrix.

II. Mechanical Properties of GFRC

2.1 Compressive Strength
Fibres added to concrete mixtures have been shown to boost the compressive strength of the material;
however, additional fibre addition has been shown to gradually diminish certain characteristics of strength.

2.2 Modulus of Elasticity

The behaviour of the composite's elastic modulus is determined by the density and properties of the
transition zone in heterogeneous and multiphase materials like concrete. The elasticity modulus of concrete
remains unaffected by the addition of fibres, as demonstrated by the results of the laboratory tests.
According to reports, there is generally only a slight decrease in the concrete's modulus of elasticity when
the glass fibre percentage is minimal.

2.3 Stress–Strain Curve

Many factors, including the type of aggregate, loading rate, and fibre lengths, might influence stress-strain
behaviour. The climbing component of the stress-strain curve is significantly impacted by GFRC, as shown
in Figure, while the descending part of the stress-strain curve is crucial under compression loads.

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E-ISSN: 2582-2160 ● Website: www.ijfmr.com ● Email: [email protected]

2.4 Flexural Strength

The increase in flexural strength of concrete is influenced by glass fibres. When comparing plain concrete
specimens to those with increased fibre content, Figure 7 shows that the flexural strength of the concrete
increased, albeit not significantly. The fibres help to strengthen the concrete's load carrying capacity by
preventing cracks from spreading and reducing the likelihood of a sudden collapse of the building.

III. Physical Properties of GFRC

3.1 Drying shrinkage
Drying shrinkage significantly impacts the concrete's durability and structural performance. Although the
process of cementitious material shrinkage is complicated, the amount and kind of aggregate as well as the
water to cement ratio mostly determine overall shrinkage. These factors also affect drying and contribute to
the simultaneous spread of numerous microcracks. In addition to causing corrosion and freezing damage,
shrinkage in concrete structures can also significantly reduce the service life of concrete [32–33]. Alkali-
resistant glass fibres encourage multiple cracks and narrow crack widths while effectively reducing

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constrained shrinkage cracking in concrete.

3.2 Creep
Concrete has a low tensile strength and poor strain capacity, making it a fragile material that is easily
cracked. Because they let in hostile agents, these fissures can shorten a structure's lifespan. As a result, the
way that crack openings change over time affects how long concrete will last. The method of applying
GFRC must be considered in terms of creep and shrinkage. Glass fibre is added to mortar mixtures by
pneumatic spraying, and this results in a notable alteration to the compositions involved in binder
consumption during pouring. There may be a creep strain result from this.

3.3 Porosity, Chloride Penetration Resistance and Electrical Resistivity

Migrating ions allow the many micropores in concrete, a multi-phase material, to be transmitted. Thus,
measuring resistivity provides a conclusive method of examining the microstructure of concrete. The water-
to-cement ratio, the composition of the concrete, the admixtures, the curing conditions, and the humidity all
affect how resistive the concrete is. All of these effects could thereby raise the possibility of steel rebar
corrosion in concrete. Figures make this impact quite evident. Furthermore, electrical current and corrosion
risk can both rise when chloride is present in a concrete building. Alkali resistance less chloride seeps into
concrete according to GFRC, improving corrosion resistance. When compared to a plain concrete specimen,
Figure shows that a rise in fibre content significantly decreased the chloride permeability of the concrete. As
a result, one of the most crucial qualities of concrete—its durability—can be enhanced while concrete
constructions are in use.

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IV Applications and Latest Developments of GFRC

The unique structure of GFRC gives it more complex qualities than regular concrete. It has an appropriate
moulding and a sturdy, long-lasting construction because of its structural qualities. Furthermore, it is
inexpensive due to its quick installation time, ease of handling, and portability. It is eco-friendly and has the
ability to scatter or absorb sound.
One of the most important outcomes of these attributes has been the adaptability of GFRC. GFRC is
extensively and consistently utilised in engineering (i.e. permanent formwork, utilities, acoustics, bridges
and tunnels, highways, water and drainage), architecture (i.e. cladding, mouldings, landscaping), and
building (i.e. roofing, walls and windows, rehabilitation, foundations and floors).
For the first time ever, self-cleaning, ecologically friendly panels for an industrial structure were created in
Turkey using a special glass fibre reinforced concrete technology. Given that the building is located in the
centre of a refinery (Tüpraş), self-cleaning GFRC panels will be subjected to the toughest environmental
conditions, including emissions of NOx and SOx.

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GFRC Panels used for heat insulation

V FINAL COMMENTS
For engineers and architects, GFRC is one of the most adaptable building materials available. The building
business has benefited greatly from its substantial contributions to economy, technology, and aesthetics. To
better understand the mechanical and physical features of GFRC, a thorough review that examined popular
techniques of GFRC production and the compatibility of emerging technologies was conducted.
In general, adding glass fibre raises the compressive strength; however, adding too much fibre reduces the
strength because of decreased workability. The addition of modest volume fraction fibres to the concrete
does not significantly increase its modulus of elasticity. Due to a rise in the aspect ratio of the fibres, which
causes an increase in pull-out and energy absorption of the GFRC, glass fibres have a beneficial influence on
the stress-strain curve of GFRC and flexural strength.
In general, GFRC has a longer service life than conventional concrete because it reduces permeability,
corrosion (particularly AR-glass fibre corrosion), and the spread of microcracks. GFRC weighs between 50
and 70 percent less than conventional concrete. Self-mixing, however, is challenging (special substance
required). Because of the fibreglass, additives, and acrylic co-polymer, it is more expensive than regular
concrete; but, as technology advances, this disparity may be significantly altered.
In engineering, construction, and architecture applications, GFRC is often and consistently utilised. In
addition, digital technologies can be used to create intricate forms, ornamental materials, and entire
structures. An additional valuable resource is glass fibre reinforced composite (GFRC), which is used in
high-performance concrete applications, readily dyeable surfaces, and self-cleaning environmentally friendly
panels.
As such, there exists a large body of practice-based GFRC applications, but very little research to back them
up. Further research can be conducted to improve the properties of GFRC in order to meet the growing
requirements for its use in practical applications.

REFERENCES
1. “GRC for Architects and Engineers, GRC in Action UK”, GRCA International, 2003.
2. Masuelli, M. A., “Fiber Reinforced Polymers–The Technology Applied for Concrete Repair”, Open
Acess E–Book, 2013.
3. Faheem, A. G., “Comparison of Plain-Concrete and Glass–Fiber–Reinforced–Concrete Beams with
Different Flexural and Shear Reinforcement”, Department of Civil Engineering Capital University of
Science & Technology, Islamabad, Pakistan, Master Thesis, April 2017.
4. Afroughsabet, V., Biolzi L., Özbakkaloğlu, T., “High–Performance Fiber–Reinforced Concrete: A

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 International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: www.ijfmr.com ● Email: [email protected]

Review”, J. Mater. Sci., 2016, 51: 6517–6551.

5. https://www.grca.org.uk/about-grca.php (Access Date: 06.11.2017).
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9. Bartos, P. J. M., “Review on the Performance of Glass Fiber Reinforced Concrete”, IOP Conf.
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