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TABLE OF CONTENTS
PART 1 GENERAL............................................................................................................... 1
1.05 DEFINITIONS......................................................................................................... 3
2.03 FORMWORK........................................................................................................ 12
3.02 PREPARATION.................................................................................................... 18
3.07 REPAIRS.............................................................................................................. 21
PART 1 GENERAL
A. The extent of precast glass fiber reinforced concrete, (GFRC) work is shown on the
Contract Drawings.
B. This Section establishes the criteria for materials, mixes, evaluation, fabrication, and
installation of Glass Fiber Reinforced Precast Concrete (GFRC).
1.04 REFERENCES
A. The referred codes and standards are intended to provide an acceptable level of
quality for materials, products and workmanship. In case of conflict between these
standards and the text of this Specification, the Specification text shall govern.
B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment, materials and
processes conforming to one group of codes and standards.
9. ASTM C948 Standard Test Method for Dry and Wet Bulk Density,
Water Absorption and Apparent Porosity of Thin
Sections of Glass Fiber Reinforced Concrete
13. ASTM C1228 Standard Practice for Preparing Coupons for Flexural
and Washout Tests on Glass Fiber Reinforced
Concrete
17. ASTM G152 Standard Practice for Operating Open Flame Carbon
Arc Light Apparatus for Exposure of Non-metallic
Materials
E. BS British Standards
1. PCI MNL-117 Manual for Quality Control for Plants and Production
of Architectural Precast Concrete Products
1.05 DEFINITIONS
F. portland cement: A hydraulic cementing material for mortar and concrete, resulting
from grinding and pulverising the burned calcareous or lime bearing materials with
argillaceous or other silica, alumina and iron oxide bearing materials (clinker), with
the addition of gypsum or its derivative or water or both.
G. precast: A member or element that is cast and cured in other than its final position;
the process of placing and finishing precast concrete.
1.06 SUBMITTALS
A. The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 01330, the following items for review and approval before commencing
Work:
1. Product Data
2. Shop Drawings
3. Samples
d) The Royal Commission's review of samples will be for color, texture and
general appearance. Compliance with other requirements is the
responsibility of the Contractor and subject at all times to further
approval by the Royal Commission.
A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing such as to achieve the
specified quality to the approval of the Royal Commission in accordance with
SECTION 01450.
C. Test boards shall be produced in parallel with the first and last panel fabrication for
each day’s production by each spray team, and for each newly batched concrete
mixture. In order to provide initial production compliance, an initial increased rate of
production test boards may be required.
D. Test boards shall be large enough to enable test coupons to be cut from boards
without using the area at the perimeter of the test board for respective test methods
and procedures.
E. Each test board shall be stored with the respective panel production and shall be
marked with the same identification. When the production panels are removed from
curing, the test board shall be transferred to the quality control area for testing.
F. Quality control of the GFRC units produced shall be carried out by monitoring test
results on a statistical basis. Samples for glass content determination shall be taken
from the test board immediately after spraying.
G. Within 48 hours after cure schedule, test boards shall be cut into test coupons and
the flexural yield and ultimate strength as well as the density shall be measured.
H. Compliance
1. Results of the individual test boards’ mean values will be treated statistically
for compliance with the following conditions:
a) No single test board mean result shall fall below 85% of the
Characteristic Value.
I. Non-Compliance
1. Where test boards do not comply with the specified performance requirements,
the fabricated panels identified with the test boards shall be deemed to be
defective and shall not be incorporated in the work. Costs for defective
products shall be borne by the Contractor.
K. Quality Assurance
1. Codes and Standards shall comply with the applicable provisions of the
following codes, specifications, and standards, except as otherwise shown or
specified:
3. Contractor
B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.
A. Fabricator Qualifications
B. Qualifications of Erector
A. GFRC precast units shall be designed for the following installed loads:
2. Roof panels shall be designed for 960 Pa live load (downward) and 720 Pa for
uplift on enclosed structures or 1200 Pa uplift on unenclosed structures.
B. Stresses shall be calculated using working stress methods and compared with the
allowable stresses shown below:
C. The allowable stresses for load combinations including wind loads may be increased
by one-third.
D. The live plus dead load deflection shall be calculated and held to 1/360 times and span
length for sandwich panel construction. For other types of construction the deflection
shall be held to 1/180 times the span length. Young's modulus used for calculating
deflection shall be 9000 MPa.
E. Anchorage shall be designed to support the above loadings. The safety margin factor
for installed anchorage, ultimate failure load/working load shall be 7 for load
combinations including wind and 10 for load combinations.
A. The Contractor shall deliver, handle and store equipment and material units in
accordance with SECTIONS 01650 and 01660, as well as the following
requirements:
1. Transport, lift and handle units with care, avoiding excessive stress and
preventing damage; use appropriate equipment.
2. Deliver precast glass fiber reinforced concrete (GFRC) units to Project site in
quantities to assure scheduling and uniformity of overall color and texture of
installation.
4. Lift and support units into place only at the designated lifting points.
PART 2 PRODUCTS
2.01 GENERAL
A. All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.
1. Cement
a) Portland Cement
1) ASTM C150, Type II or Type I/II convertible, having a maximum
tricalcium aluminate content of 8% or complying with
BS EN 197-1 and conforming to the above sulfate resistance
requirements.
b) Use only 1 brand and type of cement during fabrication of units, unless
otherwise acceptable to the Royal Commission.
c) Use "buff" or "grey" colored portland cement for concrete mix to match
the Royal Commission's control sample.
2. Aggregates
c) Fine Aggregate
1) Manufactured sand shall not exceed 20% by weight of the total
mix and have 98% minimum silica content by weight; moisture
content not to exceed 2%, particle size between 0.15 and 1 mm.
3. Fibers
4. Mixing Water
5. Admixtures
a) General
1) Use water-reducing and retarding admixtures in strict compliance
with the manufacturer's directions for climatic conditions prevailing
at the time of placing. Adjust quantities of admixtures as required
to maintain quality control.
2) Admixtures to increase cement dispersion or provide increased
workability for low-slump concrete may be used subject to the
Royal Commission's acceptance.
b) Water-Reducing Admixture
1) ASTM C494M, Type A.
c) Retarding Admixture
1) ASTM C494M, Type B.
d) Calcium Chloride
1) Do not use calcium chloride.
2. The glass fiber and cement slurry shall be metered to the spray head at rates
to achieve the mix proportion and glass content. These shall be checked prior
to spray up of each panel in accordance with Pilkington's test methods
CEM/QC/002 and 003. Distribution of the fiber in the mix shall be controlled so
as to be as uniform as practical.
4. Mist coats consisting of the concrete mixture without fibers may be spray
applied onto mold surfaces. The thickness of this coating shall not exceed
0.5 mm at maximum in order to avoid an unreinforced surface. Spray-up of the
main body of material shall proceed before the mist coat has set.
7. All hand forming of intricate details, incorporation of liners and forms and over-
spray shall be carried out prior to initial set of the GFRC material to ensure
complete bond.
C. Glass fiber reinforced precast concrete units shall comply with the following
performance requirements:
1. Glass Content
a) Not less than 5% by weight, not more than 5.3% by weight of mixture in
accordance with wash-out method ASTM C1228.
4. Dry Density
5. Weather Resistance
2.03 FORMWORK
1. Provide forms or molds and, where required, form and mold facing materials of
metal, plastic, wood, or other acceptable material that are non-reactive with
GFRC and will produce the required finish surfaces.
4. Ensure that molds are adequately cured to eliminate shrinkage and distortion.
5. Ensure that formwork or molds are reserved and maintained at the plant during
the construction period so as to provide a means for fabrication of additional
GFRC units which may be damaged during installation and construction
activities.
6. Allow the Royal Commission to inspect formwork and molds prior to GFRC unit
fabrication.
B. Steel Plates
C. Anchor Bolts
1. ASTM A307, low-carbon steel bolts, regular hexagon nuts and carbon steel
washers, galvanized.
D. Connection Accessories
G. Bearing Pads
1. Provide bearing pads for precast concrete units as indicated on the Contract
Drawings. Bearing pads may, subject to the Royal Commission’s approval, be
one of the following types:
a) Elastomeric Pads
1) Vulcanized, chloroprene elastomeric compound, molded to size or
cut from a molded sheet, 70 shore A Durometer, ± 5%.
a) Density : 40 kg/m3
1. Prepare GFRC mix design using a uniform spray mixture of glass fibers and
cement matrix. The mix design shall be determined by the glass fiber
reinforcement manufacturer and the precast GFRC manufacturing facility
personnel.
3. Submit written reports to the Royal Commission of proposed mix prior to start
of precast GFRC unit production. Do not begin concrete production until mixes
and evaluations have been reviewed.
2. Laboratory and plant test data for revised mix designs and strength results
must be submitted to and accepted by the Royal Commission before using in
fabricating the units.
2.07 FABRICATION
A. Fabricate precast GFRC units complying with the manufacturing procedures, quality
B. Fabricate units straight, smooth, and true to size and shape, with exposed edge and
corners precise and square unless otherwise indicated. Precast GFRC units which
are warped, cracked, broken, spalled, stained, or otherwise defective will not be
acceptable.
C. Fabricate sandwich panels in 3 layers. Spray an initial layer of glass fiber concrete
matrix followed by application of board type insulation or insulating concrete. Apply
an enclosing layer of glass fiber concrete matrix over the insulation.
1. Minimum thickness of GFRC matrix and inset of insulation from edges of form
shall be as shown on the drawings. If not shown, submit Shop Drawings for
review and approval by the Royal Commission.
2. Bonded units of GFRC matrix and insulation shall meet and be subject to
specified performance requirements.
D. Built-In Items
E. Anchorage
1. Provide metal plates, slip angles, seat angles, anchors, dowels, cramps,
hangers, and other miscellaneous metal shapes necessary for securing
precast GFRC units to supporting and adjacent members.
F. Initial Set
G. Demolding
2.08 FINISH
A. Fabricate precast GFRC units with one of the following exposed surface finishes, as
shown on the Contract Drawings or instructed by the Royal Commission:
3. Smooth surface finish free of pockets, sand streaks, and honeycombs, with
uniform color and texture to match Royal Commission's control sample.
4. Textured surface finish imparted by form liners or inserts with surfaces free of
pockets, streaks, and honeycombs, providing uniform color and texture to
match the Royal Commission's control range of samples.
A. Cement Grout
2.10 TOLERANCES
A. Fabrication Tolerances
1. Comply with the following dimensional requirements for precast glass fiber
reinforced concrete units.
c) Maximum Out of Square with Major and Minor Axes Measured at the
End of the Minor Axis: 3 mm in 3 m or part thereof.
2.11 IDENTIFICATION
PART 3 EXECUTION
A. The Contractor shall examine all parts of the supporting structure, precast units, and
the conditions under which the precast GFRC concrete work is to be erected.
B. The Contractor shall not proceed with the installation until unsatisfactory conditions
have been corrected.
3.02 PREPARATION
A. The Contractor shall deliver anchorage items embedded in other construction before
the start of such work. The Contractor shall provide setting diagrams, templates,
instructions, and directions required for installation.
B. The Contractor shall verify dimensions of supporting structures at the Project site and
adjust final Shop Drawings to reflect actual field dimensions.
3.03 INSTALLATION
A. The Contractor shall install precast GFRC members plumb, level, and in alignment
within PCI MNL-117 specified erection tolerances, except as modified herein.
C. Maintain horizontal and vertical joint alignment and uniform joint width as erection
progresses.
D. Installation Tolerances
1. The Contractor shall install precast GFRC units without exceeding the
following tolerance limits:
2. The Contractor shall install precast panels so that joints between panels are
within the following limits:
E. Bearing Pads
1. Install flexible bearing pads where indicated, as precast units are being
erected.
2. Set pads on level, uniform bearing surfaces and maintain in correct position
until precast units are placed.
F. Accessories
1. Install clips, hangers, and other accessories required for erection of precast
GFRC units to supporting members and back-up materials.
H. Repair damaged metal surfaces by cleaning and applying a coat of liquid galvanizing
repair compound to galvanized surfaces and compatible primer to painted surfaces.
I. Power-Actuated Fasteners
1. After precast GFRC concrete units have been placed and secured, grout open
spaces at connections and joints as follows:
d) Keep grouted joints damp for not less than 24 hours after initial set.
Promptly remove any grout material from exposed surfaces before it
hardens.
K. Cleaning
1. Clean exposed facings to remove dirt and stains which may be on units after
erection and completion of joint treatment.
3. Do not use cleaning materials or processes which could change the character
of exposed GFRC unit finishes.
A. Conduct inspections, perform testing, and make repairs or replace unsatisfactory pre-
cast GFRC units to comply with PCI MNL-117 and as stipulated in par. 3.07.
Limitations as to the amount of patching which will be permitted are subject to
acceptance of the Royal Commission.
4. Failure of GFRC units to comply with the performance and design calculation
requirements.
C. The Contractor shall be responsible and pay for costs of corrections and
replacements of the precast GFRC units.
A. No field openings shall be made unless approved by the Royal Commission prior to
construction. All openings shall be made with either power saws or core drills.
B. Cracks, spalls and sharp corners created by field cutting shall be ground, eased, and
patched with acceptable epoxy resin type bonding and patching compounds.
A. The elements shall comply with the durability and corrosion protection requirements
of SECTION 03310.
3.07 REPAIRS
B. Any major job-site and fabrication shop repair shall be inspected and approved by
the Royal Commission prior to the repair. The Contractor shall replace with new all
shop repaired elements not approved by the Royal Commission.
END OF SECTION