GFRC (Glass Fiber Reinforced Concrete) Mix: (by Expressions LTD)

Equipment Needed: 5 Gallon Buckets. Heavy Duty Electric Mixer and Paddle Mixing
Blade. Scale. Measuring Cup(s). Hopper Sprayerand Air Compressor. Compaction
Roller(s).

FACE COAT:

Add 2.95 kg. water (about 3 quarts) to a clean 5 gallon bucket.

Add 1.13kg. of Polyplex Curing Aid.
Add 29.57 ml of SP 7000 Super Plasticizer.
Mix in 10.65kg. of #30-#60 Silica Sand (#30-60 is the sand size/mesh, and available
at most local hardware stores or masonry supply). Make sure sand is washed (no
dust).
Mix in 7.93kg. Portland Cement (white or gray, available at your local hardware
store)
Mix in 2.72kg. Vitro Minerals Pozzolans (VCAS). (If unavailable, VCAS can be
substituted with 2.72kg. of Portland Cement if- for a total of 10.65kg. Portland
Cement, and no VCAS)
Optional: Mix in any Integral Color, if desired.
Add extra water if needed, in small amounts, until mix is creamy.
Let mix 'set' (usually about 5 minutes) and then remix briefly.
Spray Face Coat of this mix over the mold/form work using a Hopper Sprayer. Face
coat should be @ 3/16" thick. (Clean sprayer immediately after use).
Allow face coat to sit long enough to stiffen, but remain moist (Time varies, usually
15-30 minutes).

BACKER LAYERS:

Backer mix uses the same formula as above, with addition of fiber:
Slowly mix in 1.6 lbs. of 3/4" Length AR Glass Fibers.
Hand lay the fiber-rich backer mix over the surface of the mold/form at 4.76 mm to
12.7 mm thickness.
Use Compaction Rollers to even out this layer, condense, and remove any air pockets.
Place a second backer layer, again 9.52 12.7mm thickness, and compact with
rollers.
Finished piece should be 19.05mm thick at a minimum, 25.4 thick is better.

EXTRA REINFORCING:

Extra Reinforcing: Fiberglass Scrim Fabric can be placed between GFRC Backer
layers.
o Fiberglass Scrim will help increase overall strength and flexibility. Ideal for
reinforcing around integral concrete sinks.
o Try to keep Scrim 12.7mm away from the Face Coat, to avoid ghosting (faint
lines showing an image of something buried in the concrete).
o A second layer of Scrim can be laid down over the final coat of GFRC, and
lightly rolled down into the cement surface.
COVERAGE, WEIGHT, COSTS:

Face Coat Batch: Covers approx. 24 sq. ft. @ 3/16" thickness.

Backer Layer Batch: Covers approx. 12 sq. ft. @ 3/8" thickness.
Weight:
o At 3/4" thickness: 7.5 lbs per sq. ft.
o At 1" thickness: 11 lbs per sq. ft.
Material Cost:
o At 3/4" thickness: @$4 per sq. ft.
o At 1" thickness: @$5.40 per sq. ft.
o *Costs based on pricing for the following quantities:
5 Gallons Polyplex - $139.09
5 Gallons Riteks SP 7000 - $179.09
50 lbs. Sand - $4.00
94 lbs. Portland Cement - $11.40
50 lbs. VCAS - $50 (buying VCAS will reduce costs significantly)
44 lbs. Chopped AR 3/4" Fibers - $144.09

Strength Testing:

What is the strength of this GFRC recipe? This question is a tough one because of different
cements, sand, admixtures and shop variables across the land that cant be pre-controlled.
That said, please review the data from the PCI Manual 128 Glass Fiber Reinforced Concrete
Panels. Appendix J- Premix GFRC Table J.1. Typical Range of Premix Properties.

Density (dry) 110 to 130 (pcf) (most generic

mix designs @ 1:1 cement/sand ratio around the 127 pcf)
Compressive Strength..6000 to 9000 (psi)
Flexural Yield (first crack)700 to 1200 (psi)
Ultimate (Flexural Ultimate).. 1450 to 2000 (psi)

Again, depending on the materials used, W/C ratio of the mix, we can assume the
following.

1. 3 days.40%
2. 7 days.60%
3. 14 day90%

These are guides onlyeach producer should make test boards and have the mix evaluated.