G.R.C: Cladding Systems

On top of the mixing platform, GFRC mix components are assembled.The mixer and pump hopper are positioned for maximum efficiencySpecified quantities of water and Forton® VF-774 are pumped directly into the mixer.Proportional quantities of sand and Portland cement are added to the mixer.All components are thoroughly mixed. Plasticizer is added as neededThe slurry is dispensed into the pump hopper that feeds the spray gunAn initial (face) coating of mix is applied to the form surface.Note: No glass fiber is used in this layer.The first layer of mix is lightly brushed to ensure even coverage and remove entrapped air.An second layer without fiber is applied to the form surface.The second layer is lightly brushedSubsequent layers will be applied with a backup mix gun with an integral glass chopper.Strands of AR glass roving are fed through the chopper gun.The gun chops fiber into short pieces while simultaneously spraying slurry.The gun is set to blend a precise amount of fiber (5% by weight) with the slurry.An initial layer of backup mix is applied to all surfaces.Compaction rollers are used to coat all glass fibers with cement, remove entrapped air and consolidate the composite.Additional Backup mix is applied by hand to corners, return edges and revealsAn second layer of backup mix is applied to all surfaces.The layer is compacted.Additional layers of backup mix are sprayed and compacted to build to an ultimate thickness of .75 in. (19 mm).A depth gauge is pressed through the mix to ensure proper thickness is achieved.The GFRC cornice is ready to receive the steel support frame.The steel frame is built in-house.The support frame is carefully lowered into place just above the wet concrete.Measurements are take to confirm proper positioning of the frame.The frame is temporarily tacked in place with screws.Pre-welded steel flex anchors attach the frame to the GFRC skin.Pre-welded steel flex anchors attach the frame to the GFRC skin.Each flex anchor is covered with a GFRC bonding pad.The bonding pad has the same 5% glass ratio as the backup mix.The bonding pads are carefully placed onto the flex anchors and smoothed.Once all bonding pads are applied, the GFRC is allowed to cure overnight.The piece will also be covered in plastic sheeting during this time (not shown).The following day, a lift crane is attached to the steel frame.The GFRC cornice is slowly lifted away from the form.The piece is transported to the storage yard, where it is-post-finished, fully cured and prepared for shipping.Completed pieces, loaded and ready to be shipped to the jobsite.The installed GFRC cornices.Special Thanks To: GFRC Cladding Systems