Prequalification - storage.googleapis.com...manufacturing GRC. Glass fiber Reinforced Concrete (GRC) is a material which today is making a significant contribution to the economics,

UNITED CODE CONTRACTING Prequalification

2015

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2015

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We Supply and Install a various Architectural materials like GRC panels , Landscaping Precast Elements.

All our Execution work under Engineering supervision , with guarantee and high quality.

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WHAT IS GRC?

Glass fiber Reinforced Concrete (sometimes called Glass fiber Reinforced Cement) is a mixture of cement, fine aggregate, water, chemical admixtures and alkali resistant glass fiber. There are a number of different manufacturing processes; the most common are Hand-Spray and Premix, see manufacturing GRC. Glass fiber Reinforced Concrete (GRC) is a material which today is making a significant contribution to the economics, to the technology and to the aesthetics of the construction industry worldwide. This environmentally friendly composite, with its low consumption of energy and natural raw materials, is being formed into a great variety of products and has won firm friends amongst designers, architects, engineers and end users for its flexible ability to meet performance, appearance and cost parameters. Since its introduction in 1969, GRC has matured and today›s designer has available to him, depending upon his performance requirements, a range of matrix modifiers such as acrylic polymers, rapid set cements and additives to improve the long term stability of the material. Extensive independent test and performance data are available on all aspects of matrix formulation.WHAT IS GRC?

Glass fiber Reinforced Concrete (sometimes called Glass fiber Reinforced Cement) is a mixture of cement, fine aggregate, water, chemical admixtures and alkali resistant glass fiber.

typical formulations material spray(kg) casting(kg) cement 50 50 fine aggregate 50 50 plasticizer 0.5 0.5 polymer 5 5 Water 13.5 14.5 AR glass fiber 4.5-5% 2-3.5%

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There are a number of different manufacturing processes; the most common are Hand-Spray and Premix, see manufacturing GRC. Glass fiber Reinforced Concrete (GRC) is a material which today is making a significant contribution to the economics, to the technology and to the aesthetics of the construction industry worldwide. This environmentally friendly composite, with its low consumption of energy and natural raw materials, is being formed into a great variety of products and has won firm friends amongst designers, architects, engineers and end users for its flexible ability to meet performance, appearance and cost parameters. Since its introduction in 1969, GRC has matured and today's designer has available to him, depending upon his performance requirements, a range of matrix modifiers such as acrylic polymers, rapid set cements and additives to improve the long term stability of the material. Extensive independent test and performance data are available on all aspects of matrix formulation.

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GRC Equipment :

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Properties of GRC

The final properties of a particular type of GRC material will depend on the mix design and the method of manufacture. Typical properties for GRC materials made using the spray up and Premix processes are presented in the table below.

GRC and the Environment

The main constituents of GRC are based on the naturally occurring earth oxides that are used in the manufacture of cement and glass fibers. These are not generally regarded as pollutants. Wash water from the manufacturing process contains cement and this is alkaline. It is normal for factories to have settlement tanks so that solids are not put into the drainage system.

Properties of GRC The final properties of a particular type of GRC material will depend on the mix design and the method of manufacture. Typical properties for GRC materials made using the spray up and Premix processes are presented in the table below.

typical properties at 28 days property hand / machine spray vibration cast Glass fiber weight % 5 bending ultimate strength (MOR) MPa 20-30 10-14 elastic limit (LOR) MPa 7-11 5-8 shear interlinear strength MPa 3-5 NA in-planar strength MPa 8-11 4-7 compressive strength MPa 50-80 40-60 impact strength Kj/m2 10-25 10-15 elastic modulus GPa 10-20 10-10 strain to failure % 0.6-1.2 0.1-0.2 dry density t/m3 1.9-2.1 1.8-2.0

GRC and the Environment

The main constituents of GRC are based on the naturally occurring earth oxides that are used in the manufacture of cement and glass fibers. These are not generally regarded as pollutants. Wash water from the manufacturing process contains cement and this is alkaline. It is normal for factories to have settlement tanks so that solids are not put into the drainage system.

The reduced weight of GRC compared to steel reinforced concrete products does provide environmental benefits. An assessment carried out as part of a DETR/ Concrete Industry Alliance PIT Project compared two concrete and GRC products that fulfil the same function. The results show that GRC has a lower environmental impact. The summary results are shown in the graphs on this page The main reasons are an overall reduced cement usage per product and reduced transport costs.

USES OF GRC - INTRODUCTION GRC presents architects and engineers with a material from which the most ambitious designs can be created. It can be moulded to form modern futuristic designs or to replicate traditional historic features. GRC can be painted, faced with fine aggregates, coloured or simply left with a natural white or grey, smooth or textured finish.

Key features GRC is environmentally friendly GRC products reduce loadings on buildings leading to significant savings in

superstructure and foundations GRC is excellent for reproduction and renovation

GRC provides the designer with a complete technology that few other materials can match for versatility.

CLADDING GRC is one of the most popular materials used for creative prefabricated architectural cladding. GRC’s ability to be moulded into thin, lightweight panels with a wide variety of shapes, forms and surface finishes has been appreciated by a growing audience of architects and engineers worldwide.

Keyfeatures GRC is easily moulded to reproduce shapes, details and textures GRC is high strength allows design of thin, lightweight cladding elements GRC can be coloured with pigments, paints and natural stone facings GRC cladding can replace non-structural precast concrete where weight and/or shape

may be problematic

GRC cladding panels are generally manufactured by the ‘Hand Spray’ technique. As the name implies, the material is sprayed into a mould using special machinery. The method can produce high-performance materials from which panels with extremely thin, lightweight sections are achievable.

FEATURES & MOULDINGS GRC products are formed by a variety of manufacturing techniques. One of the most versatile is to cast the composite in

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CLADDING..GRC is one of the most popular materials used for creative prefabricated architectural cladding. GRC’s ability to be moulded into thin, lightweight panels with a wide variety of shapes, forms and surface finishes has been appreciated by a growing audience of architects and engineers worldwide.


FEATURES & MOULDINGSGRC products are formed by a variety of manufacturing techniques. One of the most versatile is to cast the composite in moulds manufactured from rubber, timber or Glassfiber Reinforced Plastic (GRP/FRP). This is known as Premix GRC. As the high-performance alkali resistant glass fibers are evenly distributed in the mix, the material is reinforced throughout, enabling products with the finest of details to be created.

GRC is used to produce beautiful architectural moldings and features. Whilst often cast with thicknesses in excess of 25 mm these products remain easy to handle and erect, and permit the architect or engineer an unrivalled freedom for creative design. GRC does not suffer from corrosion of the reinforcement. Unlike traditional concrete, GRC does not require a minimum of concrete cover to the reinforcement.


Key features GRC is environmentally friendly GRC products reduce loadings on buildings leading to significant savings in

superstructure and foundations GRC is excellent for reproduction and renovation


CLADDING GRC is one of the most popular materials used for creative prefabricated architectural cladding. GRC’s ability to be moulded into thin, lightweight panels with a wide variety of shapes, forms and surface finishes has been appreciated by a growing audience of architects and engineers worldwide.

Keyfeatures GRC is easily moulded to reproduce shapes, details and textures GRC is high strength allows design of thin, lightweight cladding elements GRC can be coloured with pigments, paints and natural stone facings GRC cladding can replace non-structural precast concrete where weight and/or shape

may be problematic


FEATURES & MOULDINGS GRC products are formed by a variety of manufacturing techniques. One of the most versatile is to cast the composite in moulds manufactured from rubber, timber or Glassfiber Reinforced Plastic (GRP/FRP). This is known as Premix GRC. As the high-performance alkali resistant glass fibers are evenly distributed in the mix, the material is reinforced throughout, enabling products with the finest of details to be created.

Key features GRC can be cast into fine details GRC offers designers unrivalled flexibility GRC moldings and features are easy to handle and erect GRC does not suffer from corrosion


LANDSCAPING In building projects, leisure facilities, urban renewals and municipal schemes ever-increasing attention is being focused on the built environment. GRC is playing a major role.

Key features GRC is environmentally friendly GRC is durable against extreme weather conditions GRC products are lightweight and easy to handle GRC offers a wide variety of shapes and surface finishes

Seating, planters, receptacles, kiosks, bollards, signs, statues and fountains, to name but a few, all benefit from being made in GRC with its ability to tailor shape, form and surface finish and to be aesthetically compatible with the chosen environment. GRC also provides theme park and zoological architects with a medium through which they can turn dreams into reality. Many of the world’s largest theme parks and zoos use GRC to create rockscapes, replica buildings, simulated environments for animals, and much more.

Projects Glass fiber reinforced concrete (GRC) is a versatile material which has been used worldwide since the early 1970’s on some of world’s largest and most prestigious building projects. The use of GRC continues to grow every year and new applications continue to be found where GRC’s unique blend of light weight, mouldability, durable surface and eco-friendly properties provide economic solutions to many problems. Over the last few years GRC has gained in popularity with architects, contractors and house builders and there has been a growing recognition of the material as a durable light weight alternative to traditional construction products.

Row Material :

moulds manufactured from rubber, timber or Glassfiber Reinforced Plastic (GRP/FRP). This is known as Premix GRC. As the high-performance alkali resistant glass fibers are evenly distributed in the mix, the material is reinforced throughout, enabling products with the finest of details to be created.







Row Material :

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LANDSCAPINGIn building projects, leisure facilities, urban renewals and municipal schemes ever-increasing attention is being focused on the built environment. GRC is playing a major role.


ProjectsGlass fiber reinforced concrete (GRC) is a versatile material which has been used worldwide since the early 1970’s on some of world’s largest and most prestigious building projects.

The use of GRC continues to grow every year and new applications continue to be found where GRC’s unique blend of light weight, mouldability, durable surface and eco-friendly properties provide economic solutions to many problems.

Over the last few years GRC has gained in popularity with architects, contractors and house builders and there has been a growing recognition of the material as a durable light weight alternative to traditional construction products.

moulds manufactured from rubber, timber or Glassfiber Reinforced Plastic (GRP/FRP). This is known as Premix GRC. As the high-performance alkali resistant glass fibers are evenly distributed in the mix, the material is reinforced throughout, enabling products with the finest of details to be created.







Row Material :

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Row Material : Silica Sand

Chemical and Thermo-Physical Properties Silica Sand is used predominantly due to its chemical purity and advantageous thermal properties. It is resistant to molten Steel and Iron it has high hardness and is compatible with all types of Foundry Binder systems. Silica has a high fusion point above 1690 degrees Celsius. This is dramatically lowered however by Fluxing agents such as Calcium, Sodium, Potassium, and Iron. These elements can drastically lower the sintering point of Silica the alkaline nature of the elements and their oxides listed above can drop a 99.8% Silica Sand from 1700C to less than 1200C! |Deleterious agents such as lime for example not only raise the pH of the sand but will render some binder systems useless. Acid Catalysed Furan will not harden whilst the phenolic urethane systems will react and harden instantaneously!

Silica does exhibit a rapid thermal expansion as it undergoes a phase change from Alpha Quartz to Beta Quartz and at a temperature of approximately 570 Celsius. This expansion can lead casting defects such as “Veining or Rat Tails” however this can be compensated for by the use of complex binder systems and additives to the sand mix dispensed via a controlled dosing system.

The expansion of Silica Sand is compared below against the popular “Special Refractory Sands” such as Chromite and Zi

IMPURITIES CONTAMINATES AND TESTING PROCEDURES The Acid Demand Value test: The acid demand value is important because it displays the amount of alkaline materials that should not be present in washed and classified foundry silica sand. Minerals such as limestone and shell, (CaCO3), dolomite Ca/Mg CO3, Lime CaO. The importance of the Acid Demand in testing should not be overlooked as it reveals various carbonates and salts that may be missed with a standard pH test. A high ADV will significantly shorten bench life in the cold box system and lead to pinhole defects in castings due to the production of CO2 gas evolution. Typical Values for Queensland silica Sands are: FSD 710M 0-4ml, Rouse Channel Sand 15-40ml. The Best Value is 0 and a usable maximum value is 15.

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IMPURITIES CONTAMINATES AND TESTING PROCEDURES

The Acid Demand Value test: The acid demand value is important because it displays the amount of alkaline materials that should not be present in washed and classified foundry silica sand. Minerals such as limestone and shell, (CaCO3), dolomite Ca/Mg CO3, Lime CaO.

The importance of the Acid Demand in testing should not be overlooked as it reveals various carbonates and salts that may be missed with a standard pH test. A high ADV will significantly shorten bench life in the cold box system and lead to pinhole defects in castings due to the production of CO2 gas evolution. Typical Values for Queensland silica Sands are: FSD 710M 04-ml, Rouse Channel Sand 1540-ml. The Best Value is 0 and a usable maximum value is 15.

The acid demand test can be obtained by the use of hydrochloric acid or Sulphuric Acid as per the BCIRA Broadsheet 210 -4 (1983).

Moisture: Moisture contents of 0.2% and above are detrimental to the overall quality of the Cold Box, Phenolic Urethane process, the water reacts with the hydroscopic poly-isocyanate part 2. The Bench life is considerably shortened, core strength is lowered and Flowability is reduced. Other key indicators are lower scratch hardness and core rigidity. In general terms there is a 30% loss of tensile strength for every 0.1% moisture increase! Moisture versus Tensile Strength05010015020025000.10.20.30.40.5Percent MoistureTensile Strength (PSI)

CONTAMINATES AND TESTING PROCEDURES cont...

The acid demand test can be obtained by the use of hydrochloric acid or Sulphuric Acid as per the BCIRA Broadsheet 210-4 (1983) Moisture: Moisture contents of 0.2% and above are detrimental to the overall quality of the Cold Box, Phenolic Urethane process, the water reacts with the hydroscopic poly-isocyanate part 2. The Bench life is considerably shortened, core strength is lowered and Flowability is reduced. Other key indicators are lower scratch hardness and core rigidity. In general terms there is a 30% loss of tensile strength for every 0.1% moisture increase! Moisture versus Tensile Strength05010015020025000.10.20.30.40.5Percent MoistureTensile Strength (PSI) CONTAMINATES AND TESTING PROCEDURES cont...

Ordinary Portland Cement

Cement can be defined as the bonding material having cohesive & adhesive properties which makes it capable to unite the different construction materials and form the compacted assembly.

Ordinary/Normal Portland cement is one of the most widely used type of Portland Cement.

The name Portland cement was given by Joseph Aspdin in 1824 due to its similarity in colour and its quality when it hardens like Portland stone.Portland stone is white grey limestone in island of Portland, Dorset.

Composition of OPC

The chief chemical components of ordinary Portland cement are:

1. Calcium 2. Silica 3. Alumina 4. Iron

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Ordinary Portland Cement

Cement can be defined as the bonding material having cohesive & adhesive properties which makes it capable to unite the different construction materials and form the compacted assembly.Ordinary/Normal Portland cement is one of the most widely used type of Portland Cement.The name Portland cement was given by Joseph Aspdin in 1824 due to its similarity in colour and its quality when it hardens like Portland stone.Portland stone is white grey limestone in island of Portland, Dorset.

Composition of OPCThe chief chemical components of ordinary Portland cement are:1- Calcium2- Silica3- Alumina4- Iron

Calcium is usually derived from limestone, marl or chalk while silica, alumina and iron come from the sands, clays & iron ores. Other raw materials may include shale, shells and industrial byproducts.

Basic Composition: Contents % CaO 60- 67 SiO2 17- 25 Al2O3 3 - 8 Fe2O3 0.5- 6.0 MgO 0.5- 4.0 Alkalis 0.3- 1.2 SO3 2.0- 3.5

The chief compound which usually form in process of mixing:

1-triclcium silicate (3CaO.SiO2) 2-Dicalcium silicate (2CaO.SiO2) 3-tricalcium aluminates (3CaO.Al2O3) 4-tetracalcium aluminoferrite (4CaO.Al2O3.Fe2O3)

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Continuous Carbon Fiber Glass

Basic Composition:

Contents % CaO 60-67 SiO2 17-25 Al2O3 3-8 Fe2O3 0.5-6.0 MgO 0.5-4.0 Alkalis 0.3-1.2 SO3 2.0-3.5

The chief compound which usually form in process of mixing:

1-triclcium silicate (3CaO.SiO2) 2-Dicalcium silicate (2CaO.SiO2) 3-tricalcium aluminates (3CaO.Al2O3) 4-tetracalcium aluminoferrite (4CaO.Al2O3.Fe2O3)

Continuous Carbon Fiber Glass

Fiber Type

Number of Filaments

Tensile Strength (ksi) (MPa)

Tensile Modulus* (Msi) (GPa

Strain** (%)

Weight/Length (g/m)

Density (g/cm3)

Standard Spool Size (lb)

AS4

3000 670 4619 33.5 231 1.8 0.210 1. 9 4.0 6000 640 4413 33.5 231 1.7 0.427 1.79 4.0 12000 640 4413 33.5 231 1.7 0.858 1.79 8.0

AS4C

3000 675 4654 33.5 231 1.8 0.200 1.78 4.0 6000 645 4447 33.5 231 1.7 0.400 1.78 4.0 12000 650 4482 33.5 231 1.8 0.800 1.78 8.0

AS4D 1200 700 4826 35.0 241 1.8 0.765 1.79 8.0 AS7 12000 710 4895 36.0 248 1.7 0.800 1.79 8.0 IM2A 12000 770 5309 40.0 276 1.7 0.446 1.78 4.0 IM2C 12000 830 5723 43.0 296 1.8 0.446 1.78 4.0 IM6 12000 830 5723 40.5 279 1.9 0.446 1.76 4.0 IM7

6000 800 5516 40.0 276 1.9 0.223 1.78 4.0 12000 820 5654 40.0 276 1.9 0.446 1.78 4.0

IM8 12000 880 6067 45.0 310 1.8 0.446 1.78 4.0 IM9 12000 890 6136 44.0 303 1.9 0.335 1.80 2.0 IM10 12000 1010 6964 45.0 310 2.0 0.324 1.79 2.0 HM63

12000 680 4688 64.0 441 1.0 0.418 1.83 3.0

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Manufacturing GRC

Glass fiber Reinforced concrete (GRC) is generally manufactured by either the «spray» process or the «premix» vibration casting process. The method chosen is normally dictated by factors such as strength requirements, size of mould, architects specification etc. As a general rule, larger items, such as building cladding panels, are normally «sprayed» whereas small items are manufactured from «premix» GRC.

Sprayed GRC is generally stronger than premix vibration cast GRC. The reasons for this are firstly that with sprayed GRC it is possible to achieve a fiber content of 5% - 6% whereas premix GRC is limited to around 3% - 3.5%. Secondly, Sprayed GRC has a lower water content than Premix GRC. Typical mix designs for sprayed and premix GRC materials are as follows:

Manufacturing GRC

Glass fiber Reinforced concrete (GRC) is generally manufactured by either the "spray" process or the "premix" vibration casting process. The method chosen is normally dictated by factors such as strength requirements, size of mould, architects specification etc. As a general rule, larger items, such as building cladding panels, are normally "sprayed" whereas small items are manufactured from "premix" GRC. Sprayed GRC is generally stronger than premix vibration cast GRC. The reasons for this are firstly that with sprayed GRC it is possible to achieve a fiber content of 5% - 6% whereas premix GRC is limited to around 3% - 3.5%. Secondly, Sprayed GRC has a lower water content than Premix GRC.

Typical mix designs for sprayed and premix GRC materials are as follows:

typical formulations sprayed GRC premix GRC sand* 50kg 50kg cement 50kg 50kg water+ 15-17 ltr 17-18 ltr plasticiser+ to manufacturers instructions polymer+ optional optional fiber+ 4-6% by

weight 2-3.5% of weight

*The sand used should have a particle size not exceeding approximately 1mm and should be well graded. Material passing sieve No. 100 should not exceed 10%. The sand should preferably be dry.

**Dependent on type of fiber and property requirements.

+The water/admixture/polymer content will need to be adjusted according to materials.

Sprayed GRC • The water and admixture (and polymer if used) are placed in a "high shear mixer" and the sand/cement are

slowly added until a smooth creamy slurry is achieved. The consistency of the slurry can be checked using a simple slump test kit. Mixing time is about 1 - 2 minutes.

• When ready the mix is transferred to a "pump/spray unit". The pump conveys the slurry at a regulated rate of

flow to the spray gun. At the spray gun fiber, in the form of a roving, is chopped to a length of approximately 32mm and added to the slurry. The two materials are projected onto the mould surface using an air supply from a compressor.

• The GRC material is sprayed and built up in thin layers until the required thickness is achieved - normally 10 - 15mm. Simple hand rollers are used to compact the material between layers.

• The product is left in the mould and covered with polythene to prevent moisture loss until the next day. The product is then demoulded.

HM63 12000 680 4688 64.0 441 1.0 0.418 1.83 3.0

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Sprayed GRC

• The water and admixture (and polymer if used) are placed in a «high shear mixer» and the sand/cement are slowly added until a smooth creamy slurry is achieved. The consistency of the slurry can be checked using a simple slump test kit. Mixing time is about 1 - 2 minutes. • When ready the mix is transferred to a «pump/spray unit». The pump conveys the slurry at a regulated rate of flow to the spray gun. At the spray gun fiber, in the form of a roving, is chopped to a length of approximately 32mm and added to the slurry. The two materials are projected onto the mould surface using an air supply from a compressor.

• The GRC material is sprayed and built up in thin layers until the required thickness is achieved - normally 10 - 15mm. Simple hand rollers are used to compact the material between layers.

• The product is left in the mould and covered with polythene to prevent moisture loss until the next day. The product is then demoulded.

• After demoulding the units are covered with polythene and allowed to cure for approximately 7 days. Alternatively, if a polymer curing compound is used in the mix the units can be exposed to the atmosphere immediately although it is advisable to keep them protected from direct sunlight or severe external conditions for a day or two. Reference should be made to the Polymer Supplier›s instructions.

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Premix GRC

• The sand and cement are mixed dry and then the water/admixture and polymer (if used) are added. Generally a two speed slurry/fiber blender mixer is used. With this type of mixer, the fast speed is designed to create a smooth creamy slurry. This takes about 1 - 2 minutes. The mixer is then switched to slow speed and fiber in the form of chopped strand (length approximately 13mm) is added slowly. The fiber is blended into the mix for approximately 1 minute. • Once the mix is ready, it is poured into moulds which are vibrated using a vibrating table.

• The product is left in the mould to set and is covered with polythene sheet to prevent moisture loss. The product is demoulded the next day.

• After demoulding the products are cured under polythene sheets to maintain moist conditionsfor approximately 7days. Alternatively a polymer curing compound can be used as described for the sprayed process.

sprayed premix

This first tech NOTE describes an evolutionary production technique – sprayed premix – which finds application for the manufacture of relatively small but intricate components, often as architectural details in house construction.

Sprayed premix is a relatively new method of producing GRC products and it can be used to replace or complement the traditional production methods of hand sprayed and vibration-cast premix. The fiber is added to the matrix during the mixing process and the mixed fiber and matrix are pumped to a spray gun and sprayed onto the mould.

The advantages compared to vibration cast are:

• Vibration-cast premix requires complex moulds, which as well as being expensive to produce are also time consuming to strip and reassemble.

• As sprayed premix, GRC can be sprayed directly onto vertical sides and mould returns; an inner mould as used in vibration-cast premix is not necessary.

• It is difficult to produce stone finishes with the vibration-cast process, and the range of products that can be produced is limited.

There are no such limitations with sprayed premix.

Tests using the same mix design and fiber content have shown that higher flexural strengths are obtained compared to vibration-cast premix. It is believed that this isdue to the spraying resulting in a more two-dimensional fiber orientation compared with the random three-dimensional array with conventional premix.

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Pigments

Pigments to British Standards BS 1041 or equivalent may be used to color the GRC, though special care is required to achieve uniformity of color in certain applications.

CURING OF GRC PRODUCTS:The hydration of cement is relatively slow process at ambient temperatures and for this reason concrete products are usually allowed to hydrate or cure for several weeks after casting to give full strength development.

GRC products are normally of comparatively thin section, manufactured with a lower water/cement ratio than most conventional concretes, and are prone to rapid drying. If this occurs before hydration is complete the cement never achieves its full strength and the properties of the GRC are adversely affected, so more attention to curing conditions is necessary.

Moist curing is made to ensure complete hydration. Products are kept moist immediately after manufacture and during the curing period. UCC, facility is capable on storing products in a humidity chamber or fogged area and total immersion in water. UCC storage areas are controlled areas and all weathering facilities are adopted by the products.

SURFACE FINISHESThere is a wide variety of available finishes with the possibilities being broadly similar to those for concrete.

A. Modification to the Surface Texture.

(a) Textured MouldsThe cement/sand slurry matrix of GRC has a very fine size and hence can accurately reproduce the characteristics of the mould surface against which it is produced. However, the extent to which the glass fiber is able to penetrate surface detail depends on the scale of the detail; as such, the surface layers of a heavily textured panel may consist of un-reinforced cement/sand mortar. It is therefore important that such layers are not included in the thickness of the component for design purposes.

(b) Post Treatment Processes1) Acid Washing e.g. hydrochloric acid.2) Light sand or grit blasting is a similar manner to concrete.3) The use of retarding systems on the mould surface, i.e. solutions, papers.

Figure 1 below :

With sprayed premix, the fiber is added to the matrix during the mixing proses and the mixed fiber and matrix are pumped to a spray gun and sprayed onto the mould.

Figure 2 below:

Comparison of sprayed premix/vibration cast premix.

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Quality Assurance

Quality control procedures have been established:- To ensure correct operation of the manufacturing process.- To ensure that correct material properties are being achieved- To assess final product.

These procedures may be generally described as follow:

A. Process Control Determination of- (1) Fiber output (from spray unit)(2) Slurry output (from spray unit)(3) Slump characteristics of slurry(4) Glass content of uncured GRC(5) Water/solids ratio of uncured GRC

Production of GRC is also controlled by keeping a check of such items as raw materials usage, thickness of product and final product weight.

B. Product ControlTest on cured GRC specimens take either from product or a test board representative of the product. Determination of:- (1) Dry and wet bulk density, water absorption and apparent porosity.(2) Limit of proportionality (LOP), modulus of Rupture (MOR) and directionality ratios.British Standard BS 6432 details test for 4,5,6 and 7. Test methods are also given in the GRCA, ASTM standards.

C. Component Inspection and TestingFinal product inspection for surface flaws, color, finish and overall product dimensions should always be carried out. In certain circumstances it may be necessary to mechanically test the finished product.

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Specifying GRC

Glass-fiber-reinforced concrete (GRC) is a versatile material, which is used on some of the world’s largest and most prestigious building projects and is gaining popularity with architects, contractors and house builders as a lightweight and durable alternative to more traditional architectural cast stone dressings. It is, however, vital that the specifier or user understands the need to specify the GRC technical advisor at The Concrete Society, reports.

It is important that GRC components are correctly designed and manufactured for their intended purpose with appropriate quality control procedures in place. GRC is a cement-based composite reinforced with special alkali-resistant glass fibers, which are blended throughout the concrete matrix.

The resulting

material has highly usable tensile, flexural and impact resisting properties, the precise level being a function of mix design and, most importantly, glass-fiber content.

Whereas traditional concrete is classified by its compressive strength, GRC is classified by reference to its characteristic flexural strength (termed in the industry as modulus of rupture or MOR).

For convenience of specification, GRC is graded into three categories, Grade 8, Grade 10 and Grade 18, each grade representing numerically the characteristic MOR value in MPa. Correct GRC manufacture requires that a regular testing regime is operated to measure and record MOR values (and other parameters) on a continuous basis.

Knowledge exists for GRC to be manufactured in accordance with the best practices developed in Europe, America, Asia and Australasia over the last 40 years.

The Specification for the manufacture, curing and testing of GRC products(1) is an important reference for ensuring good-quality GRC.

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ERECTION

Fixing the GRC to the building is basically the same as for ordinary precast concrete, by anchoring it to the building structure, but the anchoring system should be considered is design to allow the volumetric change movement of GRC and to carry the specific weights and forces occurred due to wind or any surcharge loads.

Small ornamental units can be connected with cast-in anchors, inserts, straps, wires or any mechanical fastener designed to withstand anticipated forces. Due to volumetric changes within GRC product and due to building movement, cracks in GRC joints will appear, unless the joints are sealed with elastomeric sealant such as silicones, urethanes or polysulfide›s. Sealants must be able to withstand anticipated joints movements.

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INSTALLATION PROCEDURES:

A. Coordinate required blocking for attachment of panels to substructure. Provide when necessary, wood preservative treated of metal stud framing as may be required to attached and reinforce panels for a solid installation.

Coordinate installation with any metal gutter lining work or flashing above and wood/metal substrates.

B. Erect panels plumb, square and true to line and level. Follow drawings with regards to installation clearances, notches and formation of panel-to-panel joints.

C. Install sealant, joint fillers and accessories as work progress, so as to make the work weather tight.

D. Provide each panel with joints such that adjacent panels mate to produce flush joints. Recess blocking or notch continuously behind each panel joint. Set panels to ensure a maximum joint thickness of 10mm.

E. Prepare each panel section for installation by carefully sanding joints and shrinkages where blocking occurs to assure a tight flush fit.

F. Fill joints with continuous bead of sealant. Tooling finished joints to a slightly concave profile ensuring complete filling and flush installation.

G. Carefully monitor ambient temperatures at time of panel installation and observe all panels’ clearances as recommended and detailed in drawings.

H. Do not cut or abrade finishes, which cannot be completely restored in the field. Installer to make small inconspicuous finish repairs using color matching fills finish. If repair is too large, panels are needed to be return to factory for alterations and/or replacements.

I. Use only connectors (stainless or galvanized steel) as approved and agreed upon with the Client. And which will develop the strength required as per calculation. Installer shall follow and use connectors as instructed and shown in the approved shop drawings.

J. Countersink all exposed fasteners. Patch all attachment holes with fill finish matching the panel color. Finish the attachment points so that there is no detectable difference in the completed panel surface.

K. Clean installed panel to remove all dirt, smudges and construction dirt. Use only those cleaning products and procedures as recommended.

UCC GRC panels are labeled, marked and numbered for ease of installation. Pre-determined fixing points and fixtures are distributed in the panel for the ease of assembly and installation.Every panel are designed and engineered to be cost effective for quick and easy installation with minimum labor. Pre-fitted bolt flanges (outside/inside) assemblies when required insure a perfect fit for the job.

Do not install panels under environmental conditions outside manufacturer’s absolute limits.

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HANDLING AND SHIPMENT

A. Transport, lift and handle units with care. Avoiding excessive stress and preventing damage by the aid of appropriate equipment.B. Store the delivered product in a clean dry area off the ground and protected from weather, moisture and damage. Storing the panels upright and not stacked unless it permitted.C. Store and dispose of solvent-based materials in accordance with the requirements of local authorities having jurisdiction.

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More about GRC ..

GRC, Glass Fiber Reinforced Concrete is a composite material consisting of hydraulic cement, fine silica sand mortar reinforced with alkali resistant glass fibers. It may contain additional filler materials and admixtures. Fiber content is typically 5% or 3.5% by weight depending on product application and production method.

Final properties of GRC depend on a wide range of variables such as follows:1. Method of Manufacture2. Mix formulation3. Fiber product – Type, Length and Orientation4. Admixtures5. other raw materials6. Meeting uccc requirements of specific application

GRC materials with a common aggregate: cement ratio of up to 1:1, incorporated with AR glass fiber and made by the spray and premix processes have been widely used for a number of years. Their properties and characteristics were extensively studied.

GRC is a composite material which combines the high compressive strength properties of cement mortars with significantly increased impact, flexural and tensile strengths imparted by the fiber reinforcement.GRC does not contain asbestos; it has good chemical resistance and will not rot or corrode. GRC is made of inorganic materials and will not burn, has negligible smoke emission and offers good fire resistance. GRC is made containing polymer materials which may affect the fire performance properties.There are two distinct methods of manufacture, spray and premix method.

Spray Method – spraying of fiber and slurry onto a mould by manual or mechanical means.Premix Method – premixing the fiber and slurry and then casting into a mould.

Spray Process typical products – architectural cladding panels, agricultural components, tanks, façade elements, ducting and formworks, cornices, capitals, friezes, etc.

Premix Process typical products – sunscreens, planters, electrical transformer housings, junction boxes, drainage components.

RAW MATERIALS

AR Glass FiberAlkali resistant glass fiber with high durability in cement. The fiber composition lies within a critical region of the Na2O-CaO-ZrO2-SiO2 system.

Some typical properties of AR Fiber are as follows:• Single filament tensile strength - 3.5 GN/m²• Strand tensile strength - 1.7 GN/m²• Young’s Modulus of Elasticity - 72.0 GN/m²• Specific Gravity - 2.68• Strain at breaking point (strand) - 2.4%• Filament Diameter - 13µm or 20µm

Product forms used in cement reinforcement are chopped strands, for use in premix GRC, and as reinforcement in render materials, and ravings, for use in the spray production of GRC and for chopping for use as chopped strands.

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Chopped strands consist of strands chopped into uniform lengths while maintaining the integrity of the original strands. They are available in lengths of up to 50mm of which 12mm and 25mm are standard lengths. Chopped strands are normally designated by length, by the Tex (mass in grams of a kilometer length) of the individual strands and by reference to their size coating. The size coating on chopped strand is designed to give resistance to mechanical damage in processing. Chopped strands are supplied packed either in boxes or bags, or in bulk shipments,

A Roving is a grouping of individual parallel strands wound as a bundle into a cylindrically shaped package containing typically 20kg of fiber. It maybe:

1) Chopped on site thus minimizing the difficulties in transporting, handling and feeding already chopped strands.

2) Chopped in a ‘gun’ and sprayed simultaneously with a matrix material to provide composites which maybe of complex profile.

Ravings are designated by the Tex of the bundle and the number of strands they contain and by reference to their size coating. Ravings are normally shrinking wrapped in plastic film and packed in cardboards cartons.

CementsThe most widely used cements in GRC manufacture are Ordinary Portland Cement (OPC) and Rapid Hardening Portland Cement (RHPC) and should be to British Standard Specification BS12 or equivalent.RHPC is chemically very similar to OPC but it is more finely ground and because of this develops strength more rapidly at early ages and is often preferred for GRC for this reason. It should be noted that the term ‘rapid hardening’ has a different meaning to the term ‘quick setting’. GRC made with rapid hardening cement stiffens and initially hardens at a similar rate to that of OPC: it is after the initial hardening that the strength gains more rapidly. It should stored and used in the same way as OPC. RHPC is slightly more expensive than OPC.

White Portland Cement is made from raw materials containing only a very small quantity of iron. It is used in GRC where a white or light colored finish is required. Because of this and the fact that white cement costs more than OPC, extra care must be taken in handling the cement to avoid contamination, and in the batching, mixing and transportation to ensure hat all equipment is kept clean. It is equally important to make sure that the finished GRC is protected against discoloration. The setting and strength development properties are similar to those of grey OPC and, apart from the extra care necessary, there is no difference in the methods of using it or in storage.

Care should be taken when curing white GRC because it gets dirty very easily in the early stages of its life and is very difficult to clean later.

Other types of cement, such as High Alumina Cement, Sulphate Resistant and Rapid Setting Cements maybe used in certain applications and should be to the relevant British Standard or equivalent. Care should be taken that the choice of cement is relevant and complies with statutory regulations.

It is important that cement is correctly stores. Cement must be kept dry, and damp air can be as harmful as direct moisture. Cement stored in bulk in a silo will be satisfactory up to about 3 months. Cement in normal 3-ply paper bags stored under good conditions can lose about 20% of its strength after 4 to 6 weeks.

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Fillers1. SandSilica Sands to the following specification are readily available.

a. All sand should be washed and dried – It will then contain less soluble matter and fine UCC ples, and also allow control of water: cement ratio.b. UCC shape and surface texture – BS 812UCC Shape – rounded or irregular preferred. (Flaky and/or elongated should be avoided)Surface Texture – smooth preferred. (Honeycombed should be avoided)c. Chemical Composition (%) – Sands of the following composition have been used in UK and have been found to be satisfactory.

1) Silica > 962) Moisture < 23) Soluble Salts (ie alkalies) < 14) Loss on Ignition < 0.55) Organic Matter - must not affect the setting of the cement.6) SO3 - 0.4 (4000ppm) max.m7) Cl – 0.06 (600ppm) max.m

d. Grading

1) Particle size – 1.2 mm max.m (i.e. 100%passing BSS 14, ASTM 16 sieve) for sprayed GRC 2.4mm max.m i.e.100% passing BSS 7 sieve) for premix GRC.

2) Fine fraction - max.m 10% passing 150µm (BSS100, ASTM 100 sieve)

The silica content of the sand need not necessarily be as high as 96%. There are good quality sands with much lower silica content which are suitable fo GRC manufacture.

The value for loss on ignition can be accepted up to 3%, providing the materials is hard, non-crushable, non-reactive and of similar shape and grading to that described above.

2. Crushed AggregatesMany varieties of aggregates used for concrete may be crushed to a suitable grading for use in GRC. Examples of such aggregates are marble, limestone and granite.

3. Pulverized Fuel AshPFA is a pozzolanic material and is the ash extracted from flue gases of boilers fired by pulverized coal. PFA should be to British Standard BS 3892 or equivalent. Blended PFA cements suitable for concrete manufacture are available in many countries. Typically contain 2535%- PFA.

WaterWater to be clean and free from deleterious matter and should meet British Standards BS3148 (Test on water for making concrete), or equivalent.

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AdmixturesStandard concrete admixtures or those specially formulated for GRC manufacture may be used as appropriate to the UCC process and to obtain the required properties of GRC. Admixtures are generally added to produce the following effects.

In manufacture of GRC -• Increasing the workability without increasing the water/cement ratio.• Improving the cohesion• Reducing segregation• Reducing bleeding• Retarding the setting (stiffening) process• Accelerating the setting (stiffening) process

On properties of hardened GRC. • Increasing the rate of early strength development• Increasing the strength• Decreasing the permeability• Improving fire resistance

Admixtures are added to mixes in small amounts and care must be exercised to ensure that only the correct dose as specified by the manufacturer is added. Calcium chloride is normally acceptable as an admixture except when metal fixings are used.Useful reference British Standard BS 5075 Concrete Admixtures.

PigmentsPigments to British Standards BS 1041 or equivalent may be used to color the GRC, though special care is required to achieve uniformity of color in certain applications.

Health Aspects of Raw Materials

A. Fiber – Fibers 13µ and 20µ diameter are substantially above the range of reparable UCC. Evidence to date has shown that these fibers cause no long term health hazard, although some temporary skin irritation may be experienced.

B. Other Component Materials – The manufacturer’s recommendations regarding the handling and use of these materials should be followed.

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REFERENCES:BS 12 - Specification of Portland Cement

BS 915 - High Alumina Cement

BS 1014 - Pigments for Portland Cement and products

BS 3148 - Methods of tests for water for making Concrete

BS 3892 - Pulverized Fuel Ash for use in Concrete

BS 4027 - Specification for Sulphate Resisting Portland Cement

BS 5075 - Concrete Admixtures

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Installation Material We Use

HLC-HSleeve anchor (hex head)

Head configuration: Hex headEnvironmental conditions: Indoor, dry conditionsType of fastening: Pre-fastening, Through-fastening

Technical DataHead configuration Hex headEnvironmental conditions Indoor, dry conditionsType of fastening Pre-fastening, Through-fasteningMaterial composition Steel, 8.8 grade, zinc-plated (min. 5 µm)Installation direction AllMaterial, corrosion Steel, zinc-plated

HLCSleeve anchor (hex head)

Head configuration: Hex headEnvironmental conditions: Indoor, dry conditionsType of fastening: Pre-fastening, Through-fastening

Technical DataHead configuration Hex headEnvironmental conditions Indoor, dry conditionsType of fastening Pre-fastening, Through-fasteningMaterial composition Steel, zinc-plated (min. 5 µm)Installation direction AllMaterial, corrosion Steel, zinc-plated

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HAS-E-FAnchor rod (5.8 hot-dip galvanized)

Anchor type: Off-the-shelf rodsHead configuration: Externally threadedEnvironmental conditions: Indoor, damp conditions, Outdoor

Technical DataAnchor type Off-the-shelf rodsHead configuration Externally threadedEnvironmental conditions Indoor, damp conditions, OutdoorType of fastening Pre-fasteningMaterial composition Steel, 5.8 grade, hot-dip galvanized (min. 43 µm)Installation direction AllPROFIS YesMaterial, corrosion Steel, sherardised / hot-dip galvanisedIn-service temperature - min. - 40 °C

HSTStud anchor

Head configuration: Externally threadedEnvironmental conditions: Indoor, dry conditionsType of fastening: Pre-fastening, Through-fastening

Technical DataHead configuration Externally threadedEnvironmental conditions Indoor, dry conditionsType of fastening Pre-fastening, Through-fasteningMaterial composition Steel, zinc-plated (min. 5 µm)Installation direction AllTested/approved for diamond drilling NoPROFIS YesLEED information available YesMaterial, corrosion Steel, zinc-plated

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HSAStandard stud anchor

Head configuration: Externally threadedEnvironmental conditions: Indoor, dry conditionsType of fastening: Pre-fastening, Through-fastening

Technical DataHead configuration Externally threadedEnvironmental conditions Indoor, dry conditionsType of fastening Pre-fastening, Through-fasteningMaterial composition Steel, zinc-plated (min. 5 µm)Installation direction AllTested/approved for diamond drilling YesProfis YesLeed information available YesMaterial, corrosion Steel, zinc-plated

HSA-FStandard hot-dip galvanized stud anchor

Head configuration: Externally threadedEnvironmental conditions: Indoor, damp conditionsType of fastening: Pre-fastening, Through-fastening

Technical DataHead configuration Externally threadedEnvironmental conditions Indoor, damp conditionsType of fastening Pre-fastening, Through-fasteningMaterial composition Steel, hot-dip galvanized (min. 35 µm)Installation direction AllTested/approved for diamond drilling YesLEED information available YesMaterial, corrosion Steel, sherardised / hot-dip galvanised

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HAC-10Anchor channel

Anchor type: Anchor channelEnvironmental conditions: Indoor, damp conditionsType of fastening: Pre-fastening

Technical DataAnchor type Anchor channelEnvironmental conditions Indoor, damp conditionsType of fastening Pre-fasteningMaterial composition Steel, hot-dip galvanizedWidth 26 mmHeight 17 mmMaterial, corrosion Steel, sherardised / hot-dip galvanised

HBC-A 4.6T-head bolt (galvanized) incl. hex nut

Anchor type: T-head boltEnvironmental conditions: Indoor, dry conditionsType of fastening: Pre-fastening

Technical DataAnchor type T-head boltEnvironmental conditions Indoor, dry conditionsType of fastening Pre-fasteningMaterial composition Steel, zinc-plated (min. 5 µm)Material, corrosion Steel, zinc-plated

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Joint Solutions Why Elastic Sealing?Building and civil engineering structures consistof individual elements which exhibit relativeMovements to each other. There are two kinds ofsuch movements:Advantages of elastic joint sealants In comparison to rigid materials (e.g. cement or mortar) high-performance elastic joint sealants by Sika are able to accommodate thermal and structural movements without breaking or loosing the adhesion to the building elements.

These sealants thus retain their original functionality throughout their whole life cycle and provide• Long-term tightness.• Expansion of building elements• Contraction of building elements• Shear loads

Joints and openings between construction elements can be found in different parts of a construction,e. g. between precast concrete elementsin facades, around windows and doors, at the connection between floors and walls, in storage tanks etc.

Joint sealants have to meet various requirements depending on the function and location of the respective joint.

The purpose of joint sealing generally is to:Prevent passage of media (air, water, chemicals, smoke etc.)Provide thermal and sound insulation Enhance the visual appearance of the whole construction Thermal movements Changes in temperature result in an expansion or contraction of the building elements, i.e.

Joints become larger (extension) or smaller (compression) continuously. Thermal movements.

are considerably in case of big elementsor when different materials are used (e. g. brick wall and vinyl window frame).Structural movements , These movements are caused by settlementsof the structure, vibrations or other loads (wind etc.) and consequently deform the joint .

Dimensions and hence may stress the sealing material significantly.Structural movements often result in shear stress acting on the sealant.

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REFERENCES:BRITISH STANDARD BS :

BRITISH STANDARDS INSTITUTION, BS EN 1169.

Precast concrete products. General rules for factory productioncontrol of glass-fiber reinforced cement. BSI, London, 1999.

BRITISH STANDARDS INSTITUTION, BS EN 1170.

Precast concrete products. Test method for glass-fibre reinforced cement. Part 1 – Measuring the consistency of the matrix. ‘Slump test’ method. Part 2 – Measuring the fiber content in fresh GRC, ‘Wash out test’. Part 3 – Measuring the fiber content of sprayed GRC. Part 4 – Measuring bending strength. ‘Simplified bending test’ method. Part5 – Measuring bending strength, ‘complete bending test’ method. Part 6 – Determination of the absorption of water by immersion and determination of the dry density. Part 7 –Measurement of extremes of dimensional variations due to moisture content. Part 8 – Cyclic weathering type test.

ASTM (the American Society for Testing and Materials)

Cement : ASTM C150 «Specification for Portland Cement.»Fine Aggregate : ASTM C144 «Specification for Aggregate for Masonry Mortar.»Glass Fibers : PCI MNL 13007- Second Edition.Concrete Pigment : ASTM C979 «Specification for Pigments for Integrally Colored Concrete.»Aggregate : ASTM C33 «Specification for Concrete Aggregates,» Flex Anchors : ASTM B633 for electro-deposited zinc.Steel : ASTM A446 Galvanized studs and track formed from steel Tube Steel Sections : ASTM A500 Grade B, or ASTM A513,

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Documents

Prequalification - storage.googleapis.com...manufacturing GRC. Glass fiber Reinforced Concrete (GRC) is a material which today is making a significant contribution to the economics,