report on glass fiber-reinforced concrete premix

ACI 549.3R-09

Reported by ACI Committee 549

Report on Glass Fiber-ReinforcedConcrete Premix

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Report on Glass Fiber-Reinforced Concrete Premix

First PrintingDecember 2009

ISBN 978-0-87031-354-7

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ACI 549.3R-09 was adopted and published December 2009.Copyright © 2009, American Concrete Institute.All rights reserved including rights of reproduction and use in any form or by any

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549.3R-1

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Report on Glass Fiber-Reinforced Concrete PremixReported by ACI Committee 549

ACI 549.3R-09

Glass fiber-reinforced concrete premix technology is becoming increasinglypopular worldwide for manufacture of precast concrete products used inindustrial, architectural, civil engineering, and construction applications.Glass fiber-reinforced concrete premix products provide a useful balance ofproperties such as strength, toughness, durability, moisture resistance,dimensional stability, fire resistance, and aesthetics. This report summarizesthe current knowledge of materials, manufacturing methods, engineeringproperties, and applications of glass fiber-reinforced concrete premix.

Keywords: cement-based composites; cement boards; cement panels;composite materials; concrete panels; ductility; durability; engineeringproperties; fiber-reinforced cement-based materials; ferrocement; fibers;flexural strength; glass fiber-reinforced concrete; glass fibers; manufac-turing methods; mesh reinforcement; premix; toughness.

CONTENTSChapter 1—Introduction and scope, p. 549.3R-2

1.1—Introduction1.2—Scope

Chapter 2—Notation, definitions, and acronymsp. 549.3R-2

2.1—Notation2.2—Definitions2.3––Acronyms

Chapter 3—Materials and mixture proportions of glass fiber-reinforced concrete premix, p. 549.3R-3

3.1—Types of premix3.2—Typical mixture ingredients3.3—Typical mixture proportions

Chapter 4—Properties of glass fiber-reinforced concrete premix, p. 549.3R-6

4.1—Influence of fiber content4.2—Influence of fiber length4.3—Influence of fiber orientation4.4—Influence of fiber geometry4.5—Influence of chopped fibers with reinforcing scrim

Corina-Maria Aldea† David M. Gale John L. Mulder Surendra P. Shah

P. N. Balaguru Graham T. Gilbert Antoine E. Naaman Yixin Shao

Hiram Price Ball, Jr.† Antonio J. Guerra Antonio Nanni A. Kumar Sharma

Nemkumar Banthia John Jones*† Nandakumar Natarajan Parviz Soroushian

Gordon B. Batson Katherine G. Kuder Omar A. Omar† R. Narayan Swamy

Neeraj J. Buch James R. McConaghy P. Paramasivam George J. Venta

James I. Daniel Barzin Mobasher† D. V. Reddy Robert C. Zellers

Sidney Freedman† Henry J. Molloy‡ Paul T. Sarnstrom

*Co-chairs of subcommittee responsible for preparing report.†Members of subcommittee responsible for preparing report.‡Chair of subcommittee responsible for preparing report.

Ashish Dubey*†

Chair



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549.3R-2 ACI COMMITTEE REPORT

4.6—Influence of mixture proportions and mixture ingredients4.7—Durability of glass fiber-reinforced concrete premix

Chapter 5—Manufacturing processes for glass fiber-reinforced concrete premix, p. 549.3R-9

5.1—Cast premix process5.2—Spray premix process5.3—Press-molded premix process5.4—Pultruded premix process5.5—Extruded premix process5.6—Types of equipment5.7—Quality control considerations

Chapter 6—Applications of glass fiber-reinforced concrete premix, p. 549.3R-16

6.1—Architectural products6.2—Industrial products6.3—Civil engineering products6.4—Landscaping products6.5—Surface bonding6.6—Stucco6.7—Shotcrete6.8—Glass fiber-reinforced concrete bagged products

Chapter 7—Summary, p. 549.3R-22

Chapter 8—References, p. 549.3R-22 8.1—Referenced standards and reports 8.2—Cited references

CHAPTER 1—INTRODUCTION AND SCOPE1.1—Introduction

The use of glass fiber-reinforced concrete started in thelate 1960s with the development and commercialization ofalkali-resistant (AR) glass fiber. The technology spreadrapidly throughout the world because of desirable physicalproperties and durability performance of products reinforcedwith AR glass fibers. Glass fiber-reinforced concretepremix, as known in the industry and presented in this report,is a material that incorporates AR glass fibers into the slurryduring mixing and slurry preparation. In glass fiber-reinforcedconcrete premix, fibers of various lengths from 0.25 to 1.5 in.(6 to 38 mm) and in concentrations of 0.25 to 4.0% by weightof the mixture are typically used and mixed together with thecementitious mixture while preparing the slurry. This fiber-reinforced slurry is then used to produce glass fiber-reinforcedconcrete premix products by selecting an appropriatemanufacturing process. Glass fiber-reinforced concrete premixproducts are now manufactured in more than 100 countries.

Specific property improvements obtained with glass fiber-reinforced concrete premix include superior crack resistanceand enhanced mechanical performance that includesimproved tensile, flexural, and impact strength behavior.Note that glass fiber-reinforced concrete premix differs fromanother class of material, herein called conventional GFRC,primarily in the method of delivering fibers into the slurryand the amount of fiber reinforcement in the composite.Conventional GFRC typically incorporates greater than 4%AR glass fibers by weight and, during production, keeps the

glass fibers and slurry separate until delivering both simulta-neously to the mold surface through a special spraying appa-ratus (ACI 544.1R and ACI 549.2R).

Glass fiber-reinforced concrete premix is a mixture of ARglass fiber, sand, cement, water, chemical and mineraladmixtures, and aggregate if required. Mixture proportionsare determined by the physical property requirements of theend product. Physical properties of glass fiber-reinforcedconcrete premix, such as tensile and flexural strength, areinfluenced by the fiber content, geometry, length, orienta-tion, and the water-cementitious material ratio (w/cm) of themixture. The maximum amount of fiber successfully incor-porated in the mixture is influenced by the fiber length,strand structure and integrity, and the ability of the mixer toefficiently disperse the fibers evenly throughout the matrix.Introducing over 4% of glass fibers by weight of the mixturedoes not significantly improve the mechanical strength of glassfiber-reinforced concrete premix composites. ConventionalGFRC generally provides higher mechanical strength andductility from its ability to incorporate higher fiber content,longer fiber lengths, superior two-dimensional fiber orienta-tion, and lower water content. Both types of manufacturingmethods are widely used commercially, and the choicebetween the two is primarily dictated by the required perfor-mance and aesthetical characteristics of the end product andapplication. The economics of manufacturing glass fiber-reinforced concrete premix are generally superior to that ofconventional GFRC, mainly due to the lower labor costs perunit area of manufactured premix product.

Several manufacturing processes for producing glass fiber-reinforced concrete premix products have been developed, suchas casting, spray premix, press molding, extrusion, and pultru-sion. Many new products have been designed and produced tocapitalize on the good performance of glass fiber-reinforcedconcrete premix. Glass fiber-reinforced concrete premix mate-rial and process technologies are commonly used for manufac-turing precast concrete products for industrial, architectural, andornamental applications. Examples include: trench lid coversfor underground electrical distribution lines, modular buildingpanels, decorative architectural products, terra cotta replace-ment products, and many other industrial products.

1.2—ScopeThis report introduces glass fiber-reinforced concrete premix

and reviews the state of knowledge regarding selection ofmaterials, mixture proportions, and manufacturing methods forproducing premix products. Also highlighted is a diverse rangeof glass fiber-reinforced concrete premix applications fromaround the world and dry-bagged premix materials that are usedin surface bonding, stucco, and certain shotcrete applications.The terms “glass fiber-reinforced concrete premix” and“premix” are used interchangeably throughout this report.

CHAPTER 2—NOTATION,DEFINITIONS, AND ACRONYMS

2.1—NotationVf = volume fraction of fibersw/cm = water-cementitious material ratio



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REPORT ON GLASS FIBER-REINFORCED CONCRETE PREMIX 549.3R-3

2.2—DefinitionsACI provides a comprehensive list of definitions through

an online resource, “ACI Concrete Terminology,” http://terminology.concrete.org. Definitions provided hereincomplement that resource.

acrylic co-polymers—co-polymer dispersions asdescribed in PCI MNL-128-01, Appendix F, or satisfyingASTM C260, C494/C494M, C618, or similar specificationsin the country of use.

alkali-resistant (AR) glass fiber—an alkali-resistantglass fiber using not less than 16% zirconia to provide alkaliresistance.

dry cure—curing without the addition of water.filament—a single glass fiber, sometimes called a mono-

filament.filamentizing—the dispersion of a multifilament strand

into individual filaments.glass fiber-reinforced concrete—a product using not less

than 4% AR glass by weight of cement in the mixture.glass fiber-reinforced concrete premix—a mixture of

chopped AR glass fiber, sand, cement, water, chemical andmineral admixtures, and aggregate if required. The AR glassfibers are added along with other raw materials duringmixing and slurry preparation.

glass fiber strand—a group of filaments of predeter-mined quantity (50, 100, 200, or 400 filaments per strand)bundled together to resist splitting (filamentizing).

high integrity—the resistance of the strand to split (separateor filamentize); also classified as non-dispersible.

mesh (or scrim)—structured form of glass reinforcementin which continuous strands (or yarns) are laid down toproduce a non-woven grid pattern.

roving—A number of parallel, continuous, not twisted,glass fiber strands bundled together and wound to form acylindrical package.

yarn—a bundle of multiple glass fiber strands that aretwisted together.

2.3––AcronymsAR = alkali-resistantFRP = fiber-reinforced polymerGFRC = glass fiber-reinforced concreteOPC = ordinary portland cementRHPC = rapid-hardening portland cement

CHAPTER 3—MATERIALS AND MIXTURE PROPORTIONS OF GLASS FIBER-REINFORCED

CONCRETE PREMIXThe materials and mixture proportions of glass fiber-rein-

forced concrete premix are selected to achieve the desiredmixture consistency to suit the production method used andto develop the design mechanical properties in thecomposite. Mixture ingredients should always comply withlocal regulations and state-of-the-art recommendations.When glass fiber-reinforced concrete premix products areproduced on an industrial scale, certificates of conformanceare normally obtained from the raw material suppliers forreview and proper documentation.

3.1—Types of premixThe five basic categories of premix are cast premix, spray

premix, press molding, extrusion, and pultrusion. Eachmanufacturing category has unique processing methods thatrequire variations in the typical mixture proportion. Thesand-cementitious material ratio and the w/cm typicallydiffer between the five categories. In the spray premix,pumping aids are normally used to produce a mixture that iseasier to pump and spray. Press molding is another verypopular processing method that is used to produce premixproducts on an industrial scale. The press molding processuses either a dry or a wet mixture for producing premixproducts. Wetter mixtures are commonly used in the pressmolding process because of the need to improve flow in themold. In such a scenario, dewatering is used during thepressing process to remove excess water from the mixture.Extrusion is another forming process that consists of forcinga highly viscous, dough-like mixture through a shaped die toform the desired shaped product. Thin, hollow sections ofpremix may easily be produced using the extrusion process.Pultrusion, which also uses continuous reinforcement, is yetanother premix manufacturing process that is used toproduce continuous linear-shaped parts. Each manufacturingprocess requires subtle changes to the mixture proportion tofacilitate processing and generate the desired physical prop-erties. Bagged dry mixtures of premix are also commerciallymanufactured for stucco, surface bonding, and shotcreteapplications.

3.2—Typical mixture ingredientsSection 3.2 describes the basic raw ingredients used for

producing premix products. Mixture ingredients reported areused worldwide to manufacture premix products. Note thatin some countries certain chemical and mineral admixturesare unavailable or too expensive. In such cases, the mixtureproportions are adjusted to allow product manufacturingusing the production process equipment available.

3.2.1 Cement—The most widely used cements in premixproduction are ordinary portland cement (OPC), rapid-hard-ening portland cement (RHPC), and white portland cement.The cements should conform to the relevant local standardsand specifications, such as ASTM C150/C150M in theUnited States. Fast-setting hydraulic cements are more finelyground and develop strength more rapidly. They are used toreduce set times and increase production rates of AR GFRCcomposites (Freiderich 2001; Gartshore et al. 1991; Molloyet al. 1994). White cement is normally used to produce deco-rative and architectural products. Other types of cements,such as high-alumina, sulfate-resistant, and rapid-settingcements, are used in certain applications (Molloy and Jones1993; Molloy and Peter 1998; ASTM C1157/C1157M;ASTM C1600/C1600M). Premix producers ensure that thechoice of cement is appropriate for the application andproduction process involved.

3.2.2 Sand—The choice of sand is an important aspect forpreparing glass fiber-reinforced concrete premix and shouldconform to ASTM C144. Silica sands are recommended andused where available, as their particle shape and grain size are



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ideal for premix production. The sand should be clean andgraded. A typical grading is shown in Table 3.1. Silica sandsare easier to pump, less abrasive on equipment, and less apt tocause blockage than crushed sand. Table 3.2 shows the typicalspecification of silica sand used for producing premix.

When sands other than silica are used, the producer shouldhave evidence of their suitability in the form of compositetest results for mechanical performance and durability. Thereare other high-quality sands with lower silica content availablethat are suitable for premix manufacture. The silica contentof these sands need not be as high as 96%. Loss on ignitionfor these sands is acceptable up to 3%, provided that thematerial is hard, non-crushable, non-reactive, and similar inshape and grading to the silica sand described in Table 3.1.

3.2.3 Alkali-resistant glass fiber—The AR glass fibersused to reinforce the premix should have a zirconia contentof at least 16% by weight (Majumdar 1970, 1985; Fyles et al.1986; PCI MNL 128). Table 3.3 provides the specificationfor AR glass fibers used in the premix. The cement solutionand concrete mortar are highly alkaline (typical pH > 12) andchemically aggressive. E-glass fibers, which are typicallyused as reinforcement in plastic products, if used in thehighly alkaline environment of cementitious materials,rapidly deteriorate and lose strength due to the alkalinechemical attack (Majumdar 1970).

The AR glass fibers are typically available in the form ofshort, chopped strands supplied directly by a glass fibermanufacturer. The fibers may also be chopped directly froma continuous roving by the premix manufacturer. Alkali-resistant glass fibers, specifically produced for use inpremix, come in the form of a high-integrity, non-dispersiblestrand. The strand, composed of 50 or more filaments, resistsfilamentizing (that is, splitting of individual filaments)during the mixing process. A loss of integrity of the strandbundle results in a loss of processability and workability ofthe mixture. The fiber amount and fiber geometry (fiberlength and number of filaments per strand) used in themixture significantly influence the mechanical strength of

the premix product. Physical properties of the premix may betailored by testing the finished product and optimizing theaddition of AR glass fibers in an iterative process.

3.2.4 Water—Clean, potable water should be used toprepare the cementitious mixture for producing premixproducts. The water should be of consistent temperature, ifpossible, to control or predict the setting behavior of thecementitious mixture.

3.2.5 Additives—Chemical and mineral additives, if available,are preferably used for manufacturing premix products.Standard additives, such as high-range water-reducingadmixtures, water-reducing admixtures, accelerators, acrylicco-polymer dispersions, pozzolans, and pigments, are used inpremix to achieve specific end results. Benefits provided byadditives include increased workability without an increase inthe w/cm, improved cohesion, reduced segregation, reducedbleeding, and retarded or accelerated setting times.

Additives are added in small measured amounts andcorrect dosage rates to achieve optimal results. Calciumchloride-based accelerators are not recommended if thepremix end product contains steel reinforcement or inserts.When co-polymer addition or other liquid additives are used,the water content of the additive is accounted for in thecalculation of w/cm.

3.2.6 Acrylic co-polymers—Acrylic co-polymer (alsoreferred to as co-polymer in the report) dispersions may beadded to the premix to eliminate wet curing (Daniel andPecoraro 1970; Ball 2005). Cementitious products arenormally moist cured to ensure proper hydration of thecement. Proper curing is especially essential for thin-sectionconcrete products. When acrylic co-polymer dispersions areadded to the mixture at recommended dosage rates, thehardened product forms a film within the matrix during the

Table 3.1—Typical silica sand gradationMesh size Percentage passing, %

No. 30 (600 μm) All

No. 40 (425 μm) 30

No. 50 (300 μm) 52

No. 70 (212 μm) 13

No. 100 (150 μm) 4

No. 140 (106 μm) 1

No. 200 (75 μm) Trace

Table 3.2—Typical silica sand specificationSilica content >96%

Moisture content <2%

Soluble salts <1%

Loss on ignition <0.5%

Sulfate ions (maximum) 4000 ppm

Chloride ions (maximum) 600 ppm

Table 3.3—Alkali-resistant glass fiber specification (ASTM C1666/C1666M)

Property Specification value Test method

Zirconia content Minimum 16% by weight

X-ray fluorescenceanalysis*

Density 167.0 ± 19 lb/ft3 (2.68 ± 0.3 g/cm3)

ASTM D3800

Tensile strength 145 × 103 to 246 × 103 psi(1.0 to 1.7 GPa)

ASTM D2256,ISO 3341, JIS R 3420

Filamentdiameter

31 × 10–5 to 118 × 10–5 in.(8 to 30 μm)

ASTM D578,ISO 1888, JIS R 3420

Roving tex ±10% of manufacturer’s nominal ASTM D1577,ISO 1889, JIS R 3420

Strand length ±0.118 in. (±3 mm)of manufacturer’s nominal

Caliper—average of20 measurements

End count ±20% of manufacturer’s nominal Physical count

Loss onignition <3% ASTM D4963,

ISO 1887, JIS R 3420

Strengthretention

Minimum value after 96 ±1 hour in water at 176 ± 2°F

(80°C ± 1°C)≥36,250 psi (250 MPa) forwater-dispersible strands≥50,750 psi (350 MPa) for

integral strands

EN 14649

*Any party interested in performing this test should contact an AR glass fiber manu-facturer before running it to avoid possible erroneous results.



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early stages of curing. The formation of this film significantlyreduces the surface permeability of the product and reducesloss of water by evaporation. This ensures that sufficientwater is retained and available in the product to achieveproper cement hydration. An additional benefit of addingacrylic co-polymer dispersions in the premix is the improve-ment in pumpability and workability obtained, even at loww/cm. Table 3.4 shows an example specification of co-polymer dispersion for use in premix.

3.2.7 Steel reinforcement—If the use of reinforcing bar isrequired for additional reinforcement, non-ferrous fiber-reinforced polymer (FRP) should be used (ACI 440R; ACI440.6). Also, all cast-in items, including inserts andattachments, should be non-ferrous, cadmium-coatedgalvanized steel, or stainless steel.

3.2.8 Pozzolanic materials—Metakaolin, microsilica,pulverized fly ash, and slag cement are pozzolanic materialsthat are commonly used to enhance the properties of ARglass fiber-reinforced cement-based materials (Bentur 1989;Marikunte et al. 1997; Purnell and Short 1998; Soukatchoffand Ridd 1991; Soukatchoff 1999). These pozzolanic materialswork by reacting with the free lime produced during thecement hydration process. This reaction process, known aspozzolanic reaction, produces additional cementitioushydration products that help further enhance strength anddurability of the premix (Molloy et al. 1993).

3.2.9 Pigments—Powder pigments or dispersions arecommonly used in the industry to produce colored premixproducts. Pigments are normally iron oxide-based, andtypically conform to ASTM C979.

3.3—Typical mixture proportionsMixture proportions presented in this report are for

informational purposes only. Producers typically developtheir own mixture proportions to accommodate theirmanufacturing process and raw material availability. Table 3.5shows typical mixture proportions used for producing castpremix and spray premix products. Mixture proportionspresented in this report are commonly employed by premixmanufacturers worldwide. Variations in mixture proportionsfrom manufacturer to manufacturer are possible due to localconditions and materials, type of manufacturing equipmentused, type of product produced, quality-control proceduresimplemented, and other conditions. The selection of productionmethod, mixture proportion, and fiber content are generallydecided after considering the engineering design of theproduct. It is possible to fix these first and then develop theproduct design.

An increase in flexural and tensile strengths generallyresults with an increase in fiber content. Beyond a certainfiber content, termed herein as “optimal fiber content,”however, a further increase in fiber addition makes littleimprovement in mechanical performance (Peter 2004). Theoptimal fiber content varies depending on the mixtureproportion and fiber type. The workability andcompactability of the mixture diminishes with the increase innumber of strands per unit weight of composite. Observe thata larger strand, that is a strand with a greater number of fila-

ments, provides a lower number of strands in the compositefor a given fiber content. Accordingly, the optimal fibercontent in the premix, to achieve satisfactory workabilityand compactability, increases with an increase in the strandsize. For example, the optimal fiber content for a 100-fila-ment strand is about 2 to 3% by weight of composite, whilethe same for a 200-filament strand ranges between 3 and 4%by weight of composite. Workability and compactability ofthe material may also influence the mechanical properties ofpremix composite as described later in Section 4.4.

3.3.1 Water-cementitious material ratio (w/cm)—Thew/cm is generally kept as low as possible, consistent withobtaining the required workability for the productionprocess involved. The total amount of water in the mixture(and the resulting w/cm) is also controlled by the use of high-range water-reducing admixtures. When chemical admix-tures are used, the water content of the admixture is typicallyadded to the mixture water content to obtain the total watercontent for the batch. The w/cm in the premix typicallyranges from 0.30 to 0.50.

3.3.2 Acrylic co-polymer content—The acrylic polymercontent is normally expressed as ratio of the weight of co-polymer solids to the weight of cementitious materials. Toachieve a satisfactory air cure, the acrylic co-polymercontent is typically in the range of 3 to 6%. Acrylic polymersalso have a plasticizing effect on the mixture. For certainmixture proportions and manufacturing processes, the additionof extra water-reducing admixture may not necessarily berequired when acrylic co-polymers are used in the mixture.

Table 3.4—Typical co-polymer dispersion specification

Compound typeAqueous thermoplasticco-polymer dispersion

Polymer type Acrylic co-polymer

Percent solids 44 to 55%

Appearance Milky white, creamy, free of lumps

Minimum film formation temperature 45 to 54°F (7 to 12°C)

Ultraviolet resistance Good

Alkali resistance Good

Table 3.5—Typical GFRPC premix mixture proportions

Ingredients Cast premix* Spray premix*

Cement 50 lb (22.7 kg) 50 lb (22.7 kg)

Sand 37 to 50 lb (16.8 to 22.8 kg) 37 to 50 lb (16.8 to 22.8 kg)

Water 15 lb (6.8 kg) 15 lb (6.8 kg)

High-range water-reducing admixture†

8 oz (227 g) 3 to 5 oz (85 to 142 g)

Chopped AR glass fibers 3 to 4 lb (1.4 to 1.8 kg) 3.5 to 4.5 lb (1.6 to 2.0 kg)

Co-polymer† 5 lb (2.3 kg) 5 lb (2.3 kg)

*The batch yield of a premix made with the above mixture proportions variesbetween 0.82 and 0.92 ft3 (0.023 and 0.026 m3).†Not an essential ingredient, but added to improve workability and mechanicalproperties.



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CHAPTER 4—PROPERTIES OF GLASS FIBER-REINFORCED CONCRETE PREMIX

Typical properties of glass fiber-reinforced concrete premixare shown in Table 4.1. For glass fiber-reinforced concretepremix, properties such as modulus of rupture, tensilestrength, impact strength, compressive strength, shearstrength, and surface and acoustic properties are influencedby the properties of the fibers and the matrix used to producethe composite. Chapter 4 discusses the influence of fibercontent, fiber length, fiber orientation, fiber geometry, use ofalternate reinforcements such as scrims and meshes, andmixture ingredients on the resulting properties of premix.

4.1—Influence of fiber content The maximum amount of fibers that may successfully be

incorporated in the mixture is influenced by the fiber length,the strand structure and integrity, and the ability of the mixerto efficiently disperse the fibers evenly throughout thematrix. The mechanical properties of the composite increasewith an increase in the fiber content in the matrix. It wasfound through testing, however, that introducing over 4% ofglass fibers by weight of the mixture does not significantlyimprove the mechanical strength of the premix composites(Peter 2004). At higher fiber contents, the fiber-to-fiberinteraction increases significantly, making it more difficultto mix and place the premix material. Moreover, at higherfiber content, the compaction and finishing of the cast mixturebecomes difficult, resulting in lower product density andinferior mechanical properties. The fibers to produce thesedata were composed of 200 monofilament strands, with eachmonofilament having a diameter of 13 microns. The curves inFig. 4.1 demonstrate that the flexural strength of premixcomposites increases with an increase in fiber content, butreaches a maximum at around 4% fibers by weight.

Figure 4.2 shows a typical load-versus-deflection curvefor flexural testing of premix. Point B on the curve is theyield point, also referred to as limit of proportionality (LOP)and Point C on the curve is the ultimate strength of thepremix composite. Testing of the composite shown in Fig. 4.2was performed according to ASTM C947.

4.2—Influence of fiber lengthThe length of chopped strands in commonly used commercial

premix ranges from 0.25 to 1.5 in. (6 to 38 mm). The fiberlength influences the tensile and flexural strengths of theglass fiber-reinforced concrete premix. Flexural strengthincreases with fiber length. Figure 4.1 illustrates the increasein flexural strength obtained with an increase in fiber lengthat different fiber contents. The test method used third-pointbending with a 8.86 in. (225 mm) span and test coupons 10.8 in.(275 mm) long, 2 in. (50 mm) wide, and 0.6 in. (15 mm)thick (NEG Report 1985).

The two curves labeled “Premix” show that the 1 in. (25 mm)long fiber provides higher strength than the 0.5 in. (13 mm)long fiber at any given fiber content. The curves labeled“Spray” refer to the performance of conventional sprayedglass fiber-reinforced concrete composites. Figure 4.1 showsthat an increase in fiber length leads to higher flexural

strength for the composite. Longer fibers are generally moredifficult to mix and place in premix. This characteristic putsa limit on an increase in strength that may realistically beachieved as a result of increase in the fiber length. The curvelabeled “Scrim TD5x5” in the figure relates to a premixcomposite that uses glass fiber scrim. The performance ofthis type of composite is discussed in greater detail inSection 4.5.

4.3—Influence of fiber orientationFiber orientation in the premix composites is significantly

influenced by the type of premix process used to produce theproduct. The manufacturing processes that lead to a three-dimensional fiber orientation yield relatively lower

Table 4.1—Typical premix properties(PCI MNL128-01)*

Properties Measured values at 28 days

Dry density 110 to 130 lb/ft3

(1750 to 2100 kg/m3)

Compressive strength 6000 to 9000 psi (41.4 to 62.0 MPa)

Flexural

Yield† 700 to 1200 psi (4.8 to 8.3 MPa)

Ultimate strength 1450 to 2000 psi (10.0 to 13.8 MPa)

Modulus of elasticity 1.45 to 2.9 × 109 ksi (10.0 to 20.0 GPa)

Direct tension

Yield‡ 600 to 900 psi (4.1 to 6.2 MPa)

Ultimate strength 600 to 1000 psi (4.1 to 6.9 MPa)

Strain to failure 0.1 to 0.2%

Shear In-plane 600 to 1000 psi (4.1 to 6.9 MPa)

Coefficient of thermal expansion at 77 to 115°F (25 to 46°C)

(at 50 to 80% relative humidity)

12 × 10–6 in./in./°F(20 × 10–6 mm/mm/°C)

Thermal conductivity 3.5 to 7 BTU/in./hr/°F(0.5 to 0.6 W/m/°C)

*These are typical values and are not to be used for design purposes. Each manufacturertests its own composites and uses testing results for design purposes. Composite proper-ties are influenced by raw materials used, mixture proportions, and productionmethod involved.†The term “flexural yield (point)” is sometimes referred to as limit of proportionality(LOP) and is defined as the elastic limit of the composite. The portion of the curveafter LOP is not a true plasticization as in the case of steel.‡The term “tensile yield (point)” is sometimes referred to as bend over point (BOP)and is defined as the elastic limit of the composite. The portion of the curve after BOPis not a true plasticization as in the case of steel.

Fig. 4.1—Influence of fiber length and content on flexuralstrength (MOR) (NEG Report 1985).



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composite mechanical strengths, whereas the processes thatlead to a more two-dimensional fiber orientation yieldrelatively higher composite mechanical strengths.

Premix material is produced by mixing all basic ingredientsfirst and then adding the fibers near the end of the mixingcycle. In cast premix, the material thickness is achieved withone pour, whereas in the sprayed premix, the same result isachieved with multiple spray passes. The cast premix leads to amore three-dimensional fiber orientation as compared with thesprayed premix, which has a more two-dimensional orientationof fibers. Other manufacturing processes, such as extrusion,also influence the fiber orientation. In the extrusion process, thefibers tend to orient along the flowing axis of the slurry.

4.4—Influence of fiber geometryFiber geometry involves two features: 1) number of filaments

per strand, and 2) the filament diameter. The AR glass fiberstrand is an assemblage of multiple filaments. Filamentdiameter is controlled by the glass manufacturer, and may bevaried from 13 to 20 µm. During the manufacturing of glassfibers, multiple filaments are bundled together using an organicsizing (a bonding agent) to form a strand. Two strand configu-rations are commonly produced: 100 and 200 filaments perstrand. It is the fiber strands, and not the individual filaments,that become the primary reinforcing elements in premix. Highintegrity of strand ensures that the individual filaments in astrand do not separate during mixing. For a given fiber contentby weight, the 100-filament strand configuration wouldprovide twice the number of strands (or reinforcing elements)compared to the 200-filament strand configuration.

Figure 4.3 illustrates the effect of one aspect of fibergeometry on composite flexural strengths, namely, numberof filaments per strand (Peter 2004). Two types of strand arecompared: 100 and 200 filaments/strand; each containing13 micron diameter filaments. The figure shows that for thesame fiber content by weight, the composite with 100 fila-ments/strand has higher flexural strength than that with 200filaments/strand. This behavior is valid only up to approx-

imately 3% fiber content by weight. With further increase infiber content, the composite with 100 filaments/strandbegins to exhibit increasingly poor material compaction,leading to a decline in composite flexural strength. On theother hand, for the composite with 200 filaments/strand,material compaction and resulting flexural strength begins todiminish at around 4% fiber content by weight.

Differences in filament diameter affect mostly workabilityof the composite. The use of 13 micron filaments in thestrand provides a softer reinforcement, allowing it to easilyconform to mold shapes. On the other hand, the use of alarger 20 micron filament yields a much stiffer strand. Stifferstrands are commonly used for producing products withsimple shapes or details. The stiffer strand, however, basedon 20 micron filaments, is much easier to pump at higherfiber contents (3 to 4% by weight) and is preferred for thespray premix process (Section 5.2).

4.5—Influence of chopped fiberswith reinforcing scrim

Scrims, also known as mesh, are a structured form of glassreinforcement in which continuous strands (or yarns) are laiddown to produce a grid pattern. Typically, the grid pattern iscomposed of continuous strands laid in perpendicular direction.The intersecting oriented strands of the scrim are eitherwoven or heat bonded. The heat-bonded construction isrelatively less expensive to produce commercially. Continuousyarns are normally used to produce the woven structure. Anopen-weave construction of scrim is necessary to allow thecementitious matrix to pass through and achieve good scrimembedment. Figure 4.4 illustrates two examples of scrimconstructions. Other scrim constructions are also possible.The bidirectional construction of the scrim provides a moredirectional reinforcement than the reinforcement matscomposed of random, chopped strands. The flexuralstrengths of composites may be increased significantly byincorporating scrim to the tensile face of the composite.

Table 4.2 illustrates the effect of adding scrim to thesurface of premix composites (Molloy et al. 1995). Twoscrims were used in the investigation: one with an opening of

Fig. 4.2—Typical flexural load-versus-deflection curve forglass fiber-reinforced concrete premix.

Fig. 4.3—Effect of fiber geometry on flexural strength(Peter 2004).



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0.25 in. (6 mm) and weight of 0.48 oz/ft2 (146 g/m2), and theother with an opening of 0.375 in. (10 mm) and weight of 0.26oz/ft2 (79 g/m2). Both scrims used in the examples wereproduced using the heat-bonding process. Figure 4.5 shows aschematic of test panels used in the investigation with scrimadded to the face. As noted in Table 4.2, even a single layer ofscrim placed on the tensile surface may significantly increasethe flexural strength of the composite. Premix compositeswith low fiber content and using 0.5 in. (13 mm) long fibershave been found to have improved flexural strengths as aresult of incorporating scrim on the surface (Peter 2004).

It is important to observe that the addition of scrim toeither cast or spray premix enhances the flexural and tensilestrengths. A variety of combinations of different types of

chopped strands and scrims are possible for use as compositereinforcement. Testing should be performed with variouscombinations of chopped strands and scrims to optimize andachieve the design physical performance for the composite(Molloy et al. 1995).

4.6—Influence of mixture proportionsand mixture ingredients

The use of proper mixture ingredients and mixture propor-tions is essential for obtaining satisfactory physical propertiesfor premix composites. Appropriate production practices, suchas proper mixing, casting, consolidating, and implementationof proper quality control measures, are important for producingquality products with predictable properties.

Table 4.2—Influence of scrim (mesh) on mechanical properties of premix panels (Molloy et al. 1995)

Panel IDType of scrim

Number of scrim layers per panel face

Number of panel faces with scrim layers

Chopped strand amount, % by weight

Face mixture

Modulus of rupture, psi (MPa)

Strain to failure Face in tension

A TD 5x5 1 1 3.00 No 2774 (19.1) 0.175 Scrim face

B TD 5x5 2 1 3.00 No 4014 (27.7) 0.213 Scrim face

C TD 5x5 1 2 3.00 No 2560 (17.7) 0.102 Either face

D TD 5x5 2 2 3.00 No 3114 (21.5) 0.153 Either face

E TD 5x5 1 2 3.00 No 1712 (11.8) 0.165 Either face

F TD 5x5 2 2 3.00 No 3411 (23.5) 0.230 Either face

G TD 10x10 1 2 3.00 No 2028 (14.0) 0.140 Either face

H TD 10x10 2 2 3.00 No 2430 (16.8) 0.167 Either face

I TD 5x5 1 1 3.00 Yes 800 (5.5)1531 (10.6)

0.1500.068 Face mixture premix

J TD 5x5 2 1 3.00 Yes 1434 (9.9)1237 (8.5)


K TD 5x5 1 2 3.00 Yes 1102 (7.6)2549 (17.6)


L TD 5x5 2 2 3.00 Yes 1453 (10.0)3134 (21.6)


Fig. 4.4—Schematic illustrations of scrim (mesh).

Fig. 4.5—Schematic of test panel configuration.



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To ensure consistent properties and performance, eachcomponent of the mixture proportion is accurately weighedin premix manufacture. The w/cm typically ranges between0.30 and 0.50, depending on the process and product design.Excessive water content leads to reduced product density,increased porosity, and reduced flexural and compressivestrengths. As noted previously, glass content is one of themost critical parameters controlling the mechanical propertiesof premix. Due to the availability of glass fibers in numerousstrand configurations and lengths, the proper choice of glassfiber is important to positively influence properties of boththe wet and the cured mixture.

Cement/sand ratio also influences the physical propertiesof the premix. As the sand-cement ratio increases, the flexuralstrength and shrinkage typically decreases. In premix, theoptimum compromise between composite strength,shrinkage, and workability is obtained by using a cement/sand ratio that typically ranges from 0.75 to 1.0, by weight.Figure 4.6 illustrates the influence of sand content on materialshrinkage (PCI MNL 128). The results shown in this figureare for 28-day-old composites.

Irreversible drying shrinkage occurs during the curingstage of the composite and is primarily dependent on thecement/sand ratio and the water/cement ratio (w/c). Subsequentmoisture content changes, due to wetting and drying, cause areversible volume change. Volume change is largelydependent on the cement/sand ratio and decreases with age.

4.7—Durability of glass fiber-reinforced concrete premix

Premix cement-based composites are reinforced with ARglass fiber. The necessity of using an AR glass fiber wasinitially demonstrated by the British Research Establishment(BRE) and corroborated by other testing facilities(Majumdar 1970; Majumdar and Laws 1991). ASTM C1560duplicates the accelerated aging procedure used by theselaboratories. This accelerated test demonstrates that usingstandard borosilica glass (or E-glass) results in severeetching of the filaments, thereby reducing the tensile strengthof the reinforcement. In comparison, the AR glass is notetched and damaged by the alkali environment of the cement.Accelerated aging tests performed on glass fiber-reinforcedconcrete premix composites show little or no change in flex-ural strength with time (Marikunte 2005; Peter 2005).

Cementitious composites reinforced with AR glass fibersare being used worldwide to produce a variety of productsfor different market sectors because of their good strengthand durable properties. Because of enhancements inmechanical and durability performance obtained with ARglass fibers, lighter and more economical premix productdesigns may be created. Examples of different applicationsof glass fiber-reinforced concrete premix are illustrated inChapter 6.

CHAPTER 5—MANUFACTURING PROCESSES FOR GLASS FIBER-REINFORCED CONCRETE PREMIX

Chapter 5 introduces different manufacturing methods andvarious types of equipment used in the industry to produce

premix products. Different types of premix products capableof being produced using each manufacturing process aredescribed. Reasons for choosing a certain manufacturingprocess to produce a specific product are explained. Someproducts may be manufactured using different processes, butthere is generally one process that is most preferable,depending upon the characteristics and complexity of theproduct design, production volume and efficiency desired,and raw materials involved. High-quality premix productsare produced in a covered facility with the necessary electric,water, and compressed air supplies. The manufacturingfacility should be organized to facilitate efficient movementof raw materials and finished products.

Figure 5.1 shows the typical steps involved in the productionof premix products. The starting point for all processes is themixing area. Here, the raw materials are weighed beforemixing according to the mixture proportion. An example ofa typical mixing sequence is as follows:

1. Weigh or batch all materials;2. Add liquids to mixer and operate at a slow speed (typi-

cally 300 to 500 rpm)*;3. Add sand;4. Add cement and increase mixer speed to high speed

(typically 1000 to 1800 rpm)*;5. Mix for 20 to 30 seconds;6. Reduce mixer speed to slow (typically 300 to 500 rpm)*;

and7. Gradually add fiber to the mixer and mix until dispersed

(mixing typically not to exceed more than 1 minute).

Excessive mixing may damage the reinforcing fiber strandand cause it to split into individual filaments. The splitting offilaments in a strand has an adverse influence on both theslump of the mixture and composite physical properties.After the mixing cycle is complete, the premix is transferredinto the mold either manually or by pumping through a

*These mixing speeds are relatively fast compared to those typically used in theconcrete industry, but glass fiber-reinforced concrete and glass fiber-reinforcedconcrete premix are different from standard concrete; they have high cement content,typically 1:1 sand to cement ratio by weight, and contain no large aggregate. Experi-ence has shown that these high mixing speeds are necessary to provide the thoroughlyand uniformly mixed material necessary to produce products with satisfactory andconsistent quality. Conventional concrete mixers do not provide the required qualityof premix composites.

Fig. 4.6—Influence of sand content on shrinkage behavior(PCI MNL-128-01).



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peristaltic pump (Fig. 5.2). These pumps work on the principleof squeezing material through a heavy duty rubber hose bymeans of a carousel of squeeze-wheels that rotate andsequentially press against the rubber tube, propelling thematerial through the pump. Peristaltic pumps are preferredbecause they will pump the premixes with up to 4% fibercontent, by weight, with minimal fiber damage or mixturesegregation). The premix is either cast into the mold andvibrated (Section 5.1) or is sprayed into the mold (Section 5.2).Vibrating the mold during casting improves the materialflow and mold fillout. Vibration also helps to consolidate thematerial and improve the aesthetical and physical characteris-tics of the product. When spraying premix, the matrix isrolled out with serrated rollers to reduce the entrapped airand consolidate the material.

The correct selection type of mold is important because ofits effect on finished product quality and cost. Woodenmolds, for example, are usually best suited for customproduct manufacturing. The manufacture of repetitive standardproducts, where production volumes are high and long moldlife is required, usually favors investment in molds made ofFRP, vacuum-formed thermoplastic, or steel. Polyurethaneor silicone rubbers are used to produce products that are highlydetailed with intricate design patterns.

Fig. 5.1—Typical steps for production of glass fiber-reinforced concrete premix products.

Fig. 5.2—Peristaltic pump.Copyright American Concrete Institute Provided by IHS under license with ACI Licensee=University of Texas Revised Sub Account/5620001114, User=erur, ert


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After depositing and compacting material in the mold, theproduct is allowed to set and harden before being demolded.Demolding time is established based on strength developmentof the product. Demolding and handling the product tooearly may induce undesirable cracking and damage. Afterremoving the product from the mold, the mold is cleaned andcoated with a release agent (when used) to prepare for next use.

The demolded product is then moved to a curing area.Proper curing is an important step in assuring that expectedproperties are developed in the product. Curing is accomplishedusing recommended methods, such as water or air curingwith the use of a co-polymer. Wet curing is accomplished bykeeping the product wet for at least 7 days. Alternately, theproduct may be air cured if the co-polymer is incorporated inthe mixture.

Quality control is an essential aspect of any good manufac-turing practice. Quality-control procedures are implementedto maintain consistency in raw materials and to ensure thatmanufactured products meet the design properties andspecifications. Most manufactures use a variety of quality-control methods to control and monitor product quality. Theextent and sophistication of quality-control proceduresimplemented varies from manufacturer to manufacturer.

5.1—Cast premix processCast premix process is the most common production

method for producing premix products worldwide. The castpremix process has numerous features of value to the manufac-turer. The cast premix process produces very little waste duringmanufacturing, leads to finished products of consistent quality,and allows the use of unskilled labor for the casting operation.

The selection of the cast premix process for manufacturinga specific product is determined by its shape and size. Forexample, consider a product design of a flower pot that is12 in. (300 mm) tall and 10 in. (250 mm) in diameter with asmooth appearance on the exterior and the interior surfaces.The spray premix process would be ruled out because it isnot possible to spray inside the mold. The cast premixprocess is a good choice for producing such a product. Theproduct is cast using matched molds and selecting a mixtureproportion that have good flow characteristics to easily fillout the mold.

The cast premix usually involves vibrating the mold or thetable that supports the mold. Vibration is provided to bothmove the material to fill the mold and expel the entrapped airin the material to achieve proper compaction. When usingvibration, the manufacturer varies the amplitude, frequency,or both, of the vibrator so that the mixture is vibrateduniformly to eliminate dead spots in the mold that may causevariation in density and physical properties. The use of self-consolidating mixtures is growing for the production of castpremix composites.

In the production process of cast premix, manufacturerspractice important principles that are outlined in Fig. 5.3. Inopen molds, the mixture is first cast in the center and thenallowed to flow outward. In closed two-part molds, themixture is cast from one side and is then allowed to flowthrough while being mechanically vibrated (where available)

to help reduce the entrapped air and to push air out of themold (Jones 2005). On completion of casting, the exposedsurface is floated and excess material removed. The productis then usually covered with sheet plastic or wet burlap andallowed to cure. If the product is produced using a closedmold, the inner plug is removed early, while still green, toreduce shrinkage cracking around the inner plug.

A test board for quality-control testing is typically castusing the same mixture and casting method as used for thecommercial product. The test board is identified and storedin the same manner as the commercial product. Testing todetermine physical properties is accomplished after thecuring period. The results are examined and documented toensure the required properties are developed.

5.2—Spray premix processThe spray premix process was developed to improve the

efficiency of producing large, flat products that have at leastone good surface and do not require higher physical propertiesassociated with conventional sprayed glass fiber-reinforcedconcrete. The mixture in the spray premix process isproduced in the same manner as the cast premix processexplained in the previous section. The mixed material is thendelivered to a peristaltic pump (Fig. 5.2); from there, it ispumped through a hose to a special spray nozzle (Fig. 5.4).The spray nozzle atomizes and deposits the slurry onto themold surface (Jones 2005). The thickness is built up inlayers, with each layer being compacted using a grooved orspring roller. In the case of decorative products, which repre-sent the majority of premix products, a face coat is firstsprayed onto the mold surface to provide the desired color.

Spray premix uses basically the same mixture proportionas cast premix, but it yields higher flexural strengths, asdemonstrated in Fig. 5.5. The results shown in this figure arefor 28-day-old composites. This is because the sprayingresults in a more planar or two-dimensional fiber orientationas compared with the three-dimensional fiber orientationobtained with conventional cast premix (Peter 2004).

Figure 5.6 shows a photograph of the spray premix processwherein a column form is being sprayed using premix material.

5.3—Press-molded premix process Press molding is used for high-volume production of

premix products, particularly those with three-dimensionalshapes. The press-molding process uses a high w/cm mixture(typically 0.40 to 0.50). Such wet mixtures are commonlyused in the press molding process because of the need forimproved flow in the mold. The required fluidity is achievedby incorporating excess water, flow aids, or both, such aswater-reducing admixtures in the original mixtures. Thematerial is pressed in the mold to squeeze out excess water.The compaction provides higher density and improved greenstrength. Enhanced green strength of the pressed compositeallows removal of the product from the mold immediatelyafter pressing. This significantly reduces the number ofmolds that are required compared with the spray or castprocesses, where the part remains in the mold until it hascured sufficiently and gained enough strength to permit



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demolding and handling. Minimizing the number of moldsmay substantially reduce capital costs in high-volumeproduct manufacture. Figure 5.7 shows a press developed inGermany that is being used to produce a variety of productsintended for commercial applications (Jones 2005).

Figure 5.8 shows a press mold open at the start of the pressmolding operation for producing a box (Jones 2005). First,the flat steel plates that form the outer perimeter of the boxare brought together by hydraulic rams. The corners sealautomatically. The premix material may be charged into the

mold by injecting it into the cavity of the closed mold suchthat it flows throughout the mold cavity. Alternatively, thepremix material may be placed in the open press, after which

Fig. 5.3—Procedure for casting premix.

Fig. 5.4—Premix spray gun.

Fig. 5.5—Flexural strength (MOR) of vibration cast versusspray remix (Peter 2004).



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the inner mold is lowered by mechanical means to force thematerial to fill the mold cavity. The product shape determineswhich method is used. The inner mold tool is covered with adeformable sleeve that acts to compress the filled material(Fig. 5.9). The purpose of the sleeve is to give the premix afinal pressing after the mold is closed. This is done byapplying air or hydraulic pressure between the sleeve and theinner mold. The pressurized deformation of the sleeve

further compacts the material and forces it to fill out themold. To allow dewatering, a filter element is placed asshown in Fig. 5.9. The excess water squeezed out of thepremix flows into the filter element and out of the press. Inthe final operation, pressure is released from the sleeve, andthe inner mold part is raised (Fig. 5.8). The outer sides of thetool are then opened, as shown in Fig. 5.8 (Jones 2005).

5.4—Pultruded premix processThe pultrusion process is one of the most cost-effective

methods for the production of composite materials. It is acontinuous process that produces little waste material. Inconventional pultrusion process involving thermoset resins,fiber reinforcement is pulled through multiple steps, startingfrom pulling through a resin impregnation bath to coat thereinforcement with resin, through preform plates to shapethe fiber/resin composite, and finally through a heated die tocure the resin. A cured part of desired shape requiring nofurther processing exits from the die. The pultrusion processmay be used to fabricate a wide variety of shapes. It alsoallows producing composites with higher fiber volume andsuperior mechanical properties.

Fig. 5.6—Spray premix process wherein a column form isbeing sprayed using premix material.

Fig. 5.7—A press developed in Germany that is used toproduce products intended for commercial applications(Jones 2005).

Fig. 5.8—A press mold open at the start of the press moldingoperation for producing a box (Jones 2005).

Fig. 5.9—Schematic description of a press mold.



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Academic and industrial research has adapted theconventional pultrusion process to produce fiber-reinforcedcementitious composites. The pultruded premix process wasidentified as a promising process technology to producecement-based products reinforced with chopped and/orcontinuous AR glass fibers for applications such as wallpanels, exterior siding, and fence products.

The advantage of using fabric reinforcements is theimprovement in mechanical properties obtained by theplacement of fabrics at strategic locations in the composite.Unidirectional and bidirectional fabric constructions allowdevelopment of tensile properties in one or two directions.This feature makes production of flat sheets attractive usingmanufacturing processes, such as pultrusion. A laboratory-scale pultrusion process was developed (Mobasher et al.1997; Mobasher and Pivacek 1998) to produce cementcomposites with continuous filaments (filament windingtechnique). In this development, a significantly improvedperformance for cement-based composites containing 5%AR glass fiber (expressed as volume fraction) was obtained.

Unidirectional AR glass fiber composites achieved tensilestrength up to 2900 psi (20 MPa) compared with an averagetensile strength of approximately 900 to 1500 psi (6 to 10 MPa)for conventional premix.

A schematic of the pultrusion process is presented in Fig. 5.10(Peled and Mobasher 2005). In this process, the fabric ispassed through a slurry infiltration chamber and is thenpulled through a set of rollers to squeeze and distribute thepaste between the fabric openings while removing the excessivepaste. Each cement board is made with a predeterminednumber of layers of fabric. Other products with continuouslinear shapes may be produced using this process.

The testing results for the pultruded products determinedthat the best mechanical performance was achieved for ARglass fabric composites containing a high content (60%) offly ash as a cement substitute (Peled and Mobasher 2005).The mechanical properties of the composites investigatedwere found to be significantly influenced by the matrixformulation, matrix rheology, and the intensity of the pressureapplied after the pultrusion process. Superior tensilebehavior, in both strength and toughness, was found with thepultruded AR glass fabric reinforced composites comparedwith the conventional chopped AR glass fiber-reinforcedconcrete that contained fibers at a 5% volume fraction (Vf =5%) (Fig. 5.11). The theory of composites relies on fibervolume fraction as it relates to the mechanical performanceof the composite. Academic studies, therefore, as reportedin this section, typically express fiber dosage by volumefraction. From a practical point of view, it is difficult to workwith fiber dosage by volume fraction. In the premix industry,therefore, fiber dosage is usually expressed by weight frac-tion of the composite. Note that for normal density premix,the glass fiber dosage expressed in terms of volume fractiontends to be close to the weight fraction.

5.5—Extruded premix process Extrusion is a forming process that consists of forcing a

highly viscous, dough-like mixture through a shaped die.The extrusion process is continuous and more simple to usethan other conventional methods, making it suitable forindustrial production. The manufacturing process involvespremixing the raw materials, extruding the premixedcementitious mixture to form the desired product, and finallycuring the extruded product. Organic and inorganic additivesare required to modify the rheology of the uncured premixmatrix to successfully accomplish the extrusion processing.

5.6—Types of equipmentThere are various types of equipment required for

processing materials used for premix operations. The equip-ment basically falls into two categories: mixing equipmentand placing equipment. Mixing may be done in standardconcrete mixers, but is more efficiently done in thosespecially designed for premix. A typical premix slurry mixeris a high-shear mixer with variable speed capability.Shearing the material initially at higher speeds provideslump-free homogeneous slurry for spraying, while shearingthe material at lower speeds allows introduction of the

Fig. 5.11—Comparison of tensile behavior of compositeswith different fabric types made by pultrusion process andconventional glass fiber-reinforced concrete (Peled andMobasher 2005).

Fig. 5.10—Schematic description of pultrusion process(Peled and Mobasher 2005).



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chopped strands with minimal damage and filamentization(splitting of strand into individual filaments). A smallmixing unit may be manually fed and controlled (Fig. 5.12).A more sophisticated mixing system may be semi-automatic,as shown in Fig. 5.13. Completely automatic systems thatdischarge directly into molds are also available, and are incommercial use as shown in Fig. 5.14. A fiber feeder (Fig.5.15) allows chopped strands to be accurately and automati-cally metered into the mixer.

Peristaltic or progressive cavity pumps, as shown inFig. 5.2, are used to transport the premixed slurry to themold or to supply the slurry to the spray guns. Variouspump sizes are available, and choice depends upon productionvolumes desired. A spray gun is illustrated in Fig. 5.4.Vibrating tables and hand vibrators are used and recommendedto consolidate the mixture into the mold and removeentrapped air.

5.7—Quality control considerationsFor producing a consistent, high-quality product, a well-

planned and executed quality-control program is recom-mended. There are two parts to the program: one to determineand control mixture proportion components, and the other todetermine and control finished product properties.

Certificates of conformance are typically obtained fromthe raw material suppliers for review and proper documentation.Cement should satisfy required local specifications, such asASTM C150/C150M in the United States. The AR glass fibershould contain no less than 16% zirconia (Majumdar 1970,1985; Fyles et al. 1986; PCI MNL 128) and should conform toASTM C1666/C1666M standard or other relevant localspecifications. Sand should conform to ASTM C144 with apredetermined sieve analysis and composition.

Fig. 5.12—Variable-speed high-shear mixer. Fig. 5.13—Semi-automatic premix mixing equipment.

Fig. 5.14—Automatic mixing plant.Copyright American Concrete Institute Provided by IHS under license with ACI Licensee=University of Texas Revised Sub Account/5620001114, User=erur, ert


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Process checks typically include mixture component weights,slump test, glass content test, and thickness and geometricaldimension checks. Product test samples for physical testing aremanufactured and cured with standard production material.Test samples are tested for flexural yield strength, flexuralultimate strength, density, and, where necessary, compres-sive strength. Curing methods used are documented.

For testing product physical properties, the smallproducers often use independent testing facilities to conductthe test and report the results. It is essential that this informationis documented properly and accompanied with relevantproduction records. The larger producers usually have testingcapabilities of their own. There are some basic equipmentrequirements for the laboratory, such as a weighing apparatusto weigh mixture components, scales with capability ofweighing to an accuracy of 0.1 lb and 0.1 g, a muffle furnacewith 932°F (500°C) capability with forced air circulation fordrying the glass reinforcement samples to measure glassfiber content, and a slump test kit to measure slurry slump(PCI MNL-130).

CHAPTER 6—APPLICATIONS OF GLASS FIBER-REINFORCED CONCRETE PREMIX

Glass fiber-reinforced concrete premix products are used inarchitectural, industrial, decorative, and recreational applica-tions around the world. The manufacturing method is chosenbased on design considerations, product quality desired, andquantity of product required. Chapter 6 presents importantapplications of glass fiber-reinforced concrete premix.

6.1—Architectural productsThe ability of the premix matrix to flow into intricate cavities

in complex molds and maintain composite strength in thinsections provides the designer with a material that is verysuitable for producing lightweight decorative shapes andfaces. The ability to spray premix materials provides amethod of producing shapes more rapidly. The followingexamples illustrate the design flexibility and possibilities

with glass fiber-reinforced concrete premix to produce avariety of architectural products.

The sun shades shown in Fig. 6.1 were produced from apremix using a semiautomatic casting process. A vibratingtable is used for good consolidation and compaction of thematerial in the mold and to obtain a finished product withsuperior aesthetical characteristics.

The cornice replacement shown in Fig. 6.2 illustrates theability of premix to replicate complex carved shapes. Fibersin the premix provide the strength and toughness required bythe designer to satisfy stresses caused by weather andbuilding movement. Product was produced using castpremix and vibrated to ensure that the mixture flowed intothe complex shapes of the face.

The terra cotta replacement product shown in Fig. 6.3 wasproduced using a spray premix with rubber molds. Mold shapeswere produced using the original terra cotta where possible.

Use of a spray premix to produce architectural panels isgrowing. The panels shown on a building in Fig. 6.4 wereproduced using form liners to develop the decorative face.Spray premix was used to manufacture the panels. Strengthrequirements of the panels dictated that the engineer use thespray premix because of its superior properties. The use of

Fig. 5.15—Automatic chopped strand feeder mounted onmixer.

Fig. 6.1—Sun shades produced from a premix using a semi-automatic casting process.

Fig. 6.2—Glass fiber-reinforced concrete premix cornicereplacement, United States.



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the spray premix process also allowed for faster manufacturecompared with the cast process.

Figures 6.5 and 6.6 demonstrate applications of premix toproduce lightweight decorative panels with intricate design

patterns. Panels were produced using spray premix andrubber form liners to achieve the required decorative face.

Use of premix for roofing tiles is shown in Fig. 6.7. Theuse of premix roofing tiles is increasing due to the durability,

Fig. 6.3—Glass fiber-reinforced concrete premix terracotta replacement, United States.

Fig. 6.4—The panels shown on this building were producedusing form liners to develop the decorative face.

Fig. 6.5—Demonstration of applications of premix to producelightweight decorative panels with intricate design patterns.

Fig. 6.6—Another example of premix applications that producelightweight decorative panels with intricate design patterns.

Fig. 6.7—Use of premix for roofing tiles.

Fig. 6.8—Glass fiber-reinforced concrete premix drainagetrough cover, South Africa.



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lightweight, and non-flammability characteristics of thefinished product. This application, which is used in manycountries, is popular in the United States, England, Scotland,Japan, and South Africa.

6.2—Industrial productsThe use of premix in industrial products began in the

United States in the late 1960s when a company redesigneda precast concrete trench lid cover using premix. The originaldesign of a concrete trench lid cover required heavy equipmentfor lifting and installation. The product redesign usingpremix reduced the weight of the product significantly to 90 lb,which is about one-quarter the weight of a regular concretelid, allowing it to be easily installed by two individuals. Theredesign trend continued worldwide, and consequently, thereinforced premix is commonly used for trench liners, electricalpanels, drain pipe, distribution boxes, drainage trenches, andother applications. In some countries where wood is scarce,premix is used to produce many housing components such aswindow surrounds, window sills, footing panels, roof tiles,exterior panels, and other applications. The ability to designcomponents to replace wood and other materials is a signifi-cant advantage of the premix material system. Many smallconcrete products, such as drainage pipes, use glass fiberreinforcement to minimize shrinkage cracks and reducedamage incurred during production and shipping.

The drainage trough and covers shown in Fig. 6.8 and 6.9were produced using the cast premix process accompaniedwith vibration to consolidate the mixture in the molds.

Products required for the electrical distribution industryare usually specified to be nonflammable. When possible,the product weight is also a major consideration. Figure 6.10shows a distribution box base being installed by two men,illustrating its lightweight characteristic. This product ismanufactured using the spray premix process accompaniedwith the use of vibrating tables to achieve proper consolidationof the material in the molds.

6.3—Civil engineering productsThe use of premix in the construction of major concrete

installations has capitalized on the lightweight feature of thepremix products. Of particular interest in Europe is the useof premix for stay-in-place formwork construction. Thisapplication saves a great deal of construction time andprovides a smooth or decorative surface on the underside ofbridge and tunnel interior surfaces. Pioneered in England,the volume of product used for this application continues togrow worldwide.

With the increasing mobility of the world population andthe phenomenal increase in the number of petroleum-powered vehicles, the noise level generated by the vehicleshas become a serious problem. Most countries facing thisproblem have resorted to noise barriers installed along busy

Fig. 6.9—Glass fiber-reinforced concrete premix trenches and covers, United States.

Fig. 6.10—Glass fiber-reinforced concrete premix distributionbox base, United States.

Fig. 6.11—Glass fiber-reinforced concrete premix noisebarrier, France.



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highways to reduce the noise pollution to adjacent areas. Theuse of premix to produce noise barriers provides the architectwith an opportunity to design a lightweight, attractive, andefficient product. Different types of noise barriers are used invarious countries. The noise barrier shown in Fig. 6.11 wasproduced using premix cast into molds on vibrating tables toachieve proper consolidation of the material in the mold.Rubber liners were used to develop the face configuration.

With the increasing cost of energy, the incentive to produceenergy-efficient houses continues to challenge engineers.The house shown in Fig. 6.12 through 6.15 illustrates onetype of premix solution. In this type of construction, calledpier-and-beam construction, the insulated premix panelsoccupy the space between the piers. The panels wereproduced using a spray premix process by spraying thepremix into a mold, adding the precut and formed foam insu-lation, and then spraying over the remaining exposed face.This method was used to produce exterior wall panels,ceiling, and roof panels (Jones 2006).

The decorative fireplace shown in Fig. 6.16 is an exampleof the type of premix decorative products used in residentialconstruction. The large size of these units allows use of thespray premix process to produce these products.

6.4—Landscaping products The use of premix for manufacturing landscaping products

takes advantage of the material’s ability to telegraph intricatedesigns with great fidelity. Additionally, the strength of thematerial allows lighter-weight units than standard concrete.The flexibility of either casting or spraying the productmakes the process very attractive to both small and largemanufacturers.

Premix, either sprayed or cast, conforms well in complexshaped molds, and is popular in the manufacture of decorativeshapes. The artificial rock shown in Fig. 6.17 was producedfrom premix, and duplicates the original rock by usingrubber molds. This allowed the structure to be produced inpanels at a manufacturing plant and delivered to the site forerection. This product is custom-made and uses both sprayand cast premix. For this type of application, the pigmentsare usually added to the mold before the premix is applied.

The large tree planter shown in Fig. 6.18 was producedusing spray premix. The spray premix process could be usedto manufacture this product because of the large physicalsize of the object. This popular product is produced in manydifferent sizes.

6.5—Surface bondingThe surface-bonding method of construction is unique in

the concrete block industry. It was developed by the U.S.Department of Agriculture in the early 1960s to provide thehousing industry with an inexpensive method of producingbuildings using existing materials and construction method-ology. The current method of erecting a concrete blockbuilding is to use mortar courses between the blocks. Thisyields a wall strong in compression, but weak in flexure.Many cracks may be seen along the mortar courses in blockwalls. To eliminate these cracks and provide a wall strong incompression and flexure, the building process was modified.The mortar course between the blocks was eliminated in thesurface-bonding system. The surface bonding techniqueproduces a wall with more than twice the flexural strength ofstandard block walls. Field experience with the surface-bonding technique of construction also indicates that erection

Fig. 6.12—Glass fiber-reinforced concrete premix engineeredpanelized house during erection, United States.

Fig. 6.13—Glass fiber-reinforced concrete premix engineeredpanelized house.

Fig. 6.14—End view of glass fiber-reinforced concrete premixengineered sandwich panel.



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using this system is significantly faster than the standardconstruction.

In surface-bonding construction, the work begins withplacing a concrete slab or footing as done in normal practice.A mortar course is then laid on the floor to begin the first rowof concrete blocks. Each block is placed on the mortar andleveled. No mortar is placed between the blocks. Eachsuccessive block course is dry-stacked without mortar. Asmall amount of mortar is used to level a block if required.The wall is built to a first level of 8 to 10 ft (2.4 to 3 m). At thatpoint, a mortar is mixed using 2% of glass fibers by weight. Thewall is wetted, and a layer of glass reinforced mortar is applied

Fig. 6.15—Completed house using glass fiber-reinforced concrete premix, United States.

Fig. 6.16—Glass fiber-reinforced concrete premix decorativefireplace, United States.

Fig. 6.17—Glass fiber-reinforced concrete premix artificialrock, Cyprus.

Fig. 6.18—Glass fiber-reinforced concrete premix large treeplanter, Japan.



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1/4 in. (6 mm) thick to both inside and outside surfaces. Thismay be sprayed, and then troweled to fill in the intersticesbetween the blocks and allowed to set overnight. Thefollowing day, a second layer is applied to provide asmoother appearance. The second application may also besprayed. The wall is kept wet for 7 days for adequate curing.The corners and door edges are reinforced by insertingreinforcing bar vertically in the block holes and then filledwith concrete and consolidated with a vibrator. For two-storybuildings, columns are placed in the blocks using the samemethod as the corner columns. The top course uses U-blocksreinforced with reinforcing bar and placed full with concrete.

6.6—StuccoConventional stucco requires that the stucco be built up in

three layers or steps. Each layer is left for several days to dry outand shrink before the next layer is applied. This is necessary tocontrol cracking so that the finish coat is basically crack free.One-step stucco eliminates two steps in one approach, byincorporating AR glass fibers to reinforce the stucco and reducecracking. Although the initial material cost is higher, one-stepstucco offers significant savings in labor and application time.One-step stucco with AR glass fiber enables the building tomeet building code fire-rating regulations.

6.7—ShotcreteAR glass fiber-reinforced, dry-premixed shotcrete formu-

lations are commercially available for construction appli-cations. One application of shotcrete is in repairing spalledconcrete structures, as shown in Fig. 6.19. This is a commonproblem in concrete structures caused by corrosion of

reinforcement and freezing and thawing of concrete with aninsufficient air void system. The AR glass fibers in shotcretereinforce the matrix and prevent shrinkage cracking. Thefibers also help to improve the freezing-and-thawingperformance of the material (Takeuchi 2003). Shotcreteprovides a protective cover to the reinforcing steel, whichbecomes exposed when the original concrete spalls. Figure 6.20illustrates the use of shotcrete to repair damaged concrete atChicago O’Hare International Airport.

Figure 6.20 shows a shotcrete mixture being sprayed ondamaged areas. The spray-applied shotcrete is troweled toprovide a smooth surface, as shown in Fig. 6.21.

Fig. 6.19—Freezing-and-thawing spalling damage ofstructural concrete, United States.

Fig. 6.20—Shotcrete repair of parking garage usingglass fiber-reinforced concrete premix, United States.

Fig. 6.21—Completed repair of parking garage usingglass fiber-reinforced concrete premix, United States.



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6.8—Glass fiber-reinforced concretebagged products

Dry-bagged premix materials that contain glass fibers arecommercially available for use in a variety of applications.Bagged premix products provide crack-resistant concrete forpatios, driveways, and other residential projects.

CHAPTER 7—SUMMARYThis report provides practical information about glass

fiber-reinforced concrete premix, including a comprehen-sive compilation of international data and referencesoriented toward increasing the awareness of producers, engi-neers, specifiers, and end users about premix technology andits use in a variety of applications. Topics covering funda-mental principles of materials, mixture proportions, proper-ties, manufacturing processes, and applications of premixwere reviewed.

The premix manufacturing processes described includedcast premix, spray premix, press molded premix, extrusion,and pultrusion. It was shown that the properties of premixcomposites are influenced by various factors, includingmixture proportion, fiber content, fiber length, fiber geometry,fiber orientation, and use of reinforcement combinationssuch as chopped fibers and continuous fiber meshes. Premixproducts were shown to have significant advantages overconventional precast concrete products. Premix products arelightweight, easy to handle and install, and resistant tofreezing-and-thawing damage and spalling. Different premixproducts and applications described herein illustrated thesebenefits. Premix products were shown to be advantageous ina variety of applications including architectural, industrial,civil engineering, landscaping, stucco, and shotcrete. Ingeographical areas where wood is scarce, premix technologyhas successfully been applied to produce many housingcomponents, including window surrounds, window sills,roof tiles, and exterior façade panels. The ability to designcomponents to replace wood and other materials is a significantadvantage of premix technology. Photographs presentedrepresented a small selection of popular applications ofpremix from around the world.

Significant research and commercial efforts continueworldwide in the areas of developing new and optimizedmixture proportions, improving processing techniques andequipment, and developing new product and applications forglass fiber-reinforced concrete premix.

CHAPTER 8—REFERENCES8.1—Referenced standards and reports

The standards and reports listed below were the latesteditions at the time this report was prepared. Because thesedocuments are revised frequently, the reader is advised tocontact the proper sponsoring group if it is desired to refer tothe latest version.

American Concrete Institute

440R Report on Fiber-Reinforced Polymer (FRP)Reinforcement for Concrete Structures

440.6 Specification for Carbon and Glass Fiber-Reinforced Polymer Bar Materials forConcrete Reinforcement

544.1R Report on Fiber Reinforced Concrete549.2R Report on Thin Reinforced Cementitious Products

ASTM InternationalC144 Standard Specification for Aggregate for

Masonry MortarC150/C150M Standard Specification for Portland CementC260 Standard Specification for Air-Entraining

Admixtures for ConcreteC494/C494M Standard Specification for Chemical

Admixtures for ConcreteC618 Standard Specification for Coal Fly Ash and

Raw or Calcined Natural Pozzolan for Usein Concrete

C946 Standard Practice for Construction of Dry-Stacked, Surface-Bonded Walls

C947 Standard Test Method for Flexural Propertiesof Thin-Section Glass-Fiber-ReinforcedConcrete (Using Simple Beam With Third-Point Loading)

C979 Standard Specification for Pigments forIntegrally Colored Concrete

C1157/C1157M Standard Performance Specification forHydraulic Cement

C1560 Standard Test Method for Hot Water Accel-erated Aging of Glass-Fiber ReinforcedCement-Based Composites

C1600/C1600MStandard Specification for Rapid HardeningHydraulic Cement

C1666/C1666MStandard Specification for Alkali Resistant(AR) Glass Fiber for GFRC and Fiber-Rein-forced Concrete and Cement

D578 Standard Specification for Glass Fiber StrandsD1577 Standard Test Methods for Linear Density

of Textile FibersD2256 Standard Test Method for Tensile Properties

of Yarns by the Single-Strand MethodD3800 Standard Test Method for Density of High-

Modulus FibersD4963 Standard Test Method for Ignition Loss of

Glass Strands and FabricsD4969 Standard Specification for Polytetrafluoro-

ethylene-(PTFE) Coated Glass Fabric

European Committee for Standardization (CEN)EN 14649 Test Method for Strength Retention of Glass

Fibres in Cement and Concrete (SIC Test)

International Organization for Standardization (ISO)ISO 1887 Textile Glass—Determination of Combus-

tible-Matter ContentISO 1888 Textile Glass—Staple Fibres or Filaments—

Determination of Average DiameterISO 1889 Reinforcement Yarns—Determination of

Linear DensityCopyright American Concrete Institute Provided by IHS under license with ACI Licensee=University of Texas Revised Sub Account/5620001114, User=erur, ert


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ISO 3341 Textile Glass—Yarns—Determination ofBreaking Force and Breaking Elongation

Japanese Standards AssociationJIS R 3420 Testing Methods for Textile Glass Products

Precast/Prestressed Concrete Institute (PCI)MNL-128 Recommended Practice for GFRC PanelsMNL-130 Manual for Quality Control of Plants and

Production of Glass Fiber Reinforced ConcreteProducts

These publications may be obtained from these organizations:

American Concrete Institute38800 Country Club DriveFarmington Hills, MI 48331www.concrete.org

ASTM International100 Barr Harbor DriveWest Conshohocken, PA 19428www.astm.org

European Committee for Standardization (CEN)Avenue Marnix 17B-1000 BrusselsBelgiumwww.cen.eu

International Organization for Standardization (ISO)1, ch. de la Voie-CreuseCase postale 56CH-1211 Genéva 20Switzerlandwww.iso.org

Japanese Standards Association4-1-24 Akasaka Minato-kuTokyo 107-8440Japanhttp://www.jsa.or.jp/default_english.asp

Precast/Prestressed Concrete Institute (PCI)209 W. Jackson Blvd.Chicago, IL 60606www.pci.org

8.2—Cited referencesACI Committee 544, 1996, “Report on Fiber Reinforced

Concrete (ACI 544.1R-96),” American Concrete Institute,Farmington Hills, MI, pp. 24-39.

Aldea, C.; Marikunte, S.; and Shah, S. P., 1998, “ExtrudedFiber Reinforced Cement Pressure Pipe,” Advanced CementBased Materials Journal, V. 8, pp. 47-55.

Ball, H., 2005, “25 Years of Polymer Modified GRC:Reasons for its Use,” GRCA Conference, Hong Kong,pp. 72-96.

Bentur, A., 1989, “Silica Fume Treatments as Means forImproving Durability of Glass Fiber Reinforced Cements,”Journal of Materials in Civil Engineering, V. 1, No. 3,pp. 167-183.

Daniel, J., and Pecoraro, M., 1982, “Effect of (Forton)Polymer on Curing Requirements of AR Glass FiberReinforced Cement Composites,” Report to Forton, Inc.,Construction Technology Laboratories, Skokie, IL.

Freiderich, T., 2001, “Rapid Production Method for ThreeDimensional GRC Products,” Glass Fibre Cement AssociationCongress, Dublin, Ireland, pp. 181-188.

Fyles, K.; Litherland, K. L.; and Proctor, B. A., 1986, “TheEffect of Glass Fibre Compositions on the Strength Retentionof GRC,” Proceedings of RILEM Symposium on Developmentin Fibre Reinforced Cement and Concrete, RILEM TechnicalCommittee 49 TFR, V. 2, Sheffield, UK.

Gartshore, G.; Kempster, E.; and Tallentire, A. G., 1991,“A New High Durability Cement for GRC Products,” GRCAConference, Maastricht, Netherlands, pp. 3-12.

Harmon, T.; Molloy, H.; and Jones. J., 1994, “Glass FiberReinforced Concrete with Improved Ductility and LongTerm Properties,” Thin Reinforced Concrete Products andSystems, SP-146, P. Balaguru, ed., American ConcreteInstitute, Farmington Hills, MI, pp. 79-90.

Jones, J., 2005, “Properties, Manufacturing Processes,and Applications of Premix Glass-Fiber ReinforcedConcrete,” ConMat’05—Construction Materials, Perfor-mance, Innovations, and Structural Implications,Vancouver, BC, Canada, pp. 1-14.

Jones, J., 2006, “Premix Glass-Fiber ReinforcedConcrete—Production Processes and Product Applications,”Concrete Plant International, Issue 5, pp. 66-70.

Majumdar, A., 1970, Proceedings of the Royal Society,A319, London, England, 69 pp.

Majumdar, A. J., 1985, “Alkali-Resistant Glass Fibers(Chapter 2),” Handbook of Composites, V. 1: Strong Fibers,W. Watt and B.V. Perov, eds. Elsevier Science Publishers BV.

Majumdar, A. J., and Laws, V., 1991, Glass Fibre ReinforcedCement, BSP Professional Books, Oxford, London, 208 pp.

Marikunte, S., and Hiranya, A., 2005; “Durability ofPremix Glass Fiber Reinforced Cement Composites(GFRC),” ConMat’05—Construction Materials, Performance,Innovations, and Structural Implications, Vancouver, BC,Canada, pp. 1 to 9.

Marikunte, S.; Aldea, C.; and Shah, S. P., 1997, “Dura-bility of GFRC Composites: Effect of Silica Fume andMetakaolin,” Journal of Advanced Cement Based Materials,V. 5, No. 3/4, pp. 100-108.

Mobasher, B., and Pivacek, A. 1998, “A FilamentWinding Technique for Manufacturing Cement BasedCross-Ply Laminates,” Journal of Cement and ConcreteComposites, V. 20, pp. 405-415.

Mobasher, B.; Pivacek, A.; and Haupt, G. J., 1997,“Cement-Based Cross-Ply Laminates,” Journal of AdvancedCement Based Materials, V. 6, pp. 144-152.

Molloy, H. J., and Jones, J., 1993, “Application andProduction Using Rapid Hardening Hydraulic Cement



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Composites,” Proceedings of 9th Biennial Congress of theGRCA, Copenhagen, Denmark, pp. 3/5/I to 3/5/VIII.

Molloy, H. J., and Peter, I., 1998, “New Matrices: AnOverview,” GRCA Conference, Cambridge University,Cambridge, England, Section III/5 pp. 1-11.

Molloy, H.; Harmon, T.; Jones, J.; and Sone, H., 1995,“Thin Concrete Panels Produced with AR Glass ChoppedStrand and Scrim,” GRCA 10th Biennial Congress, Strass-bourg, France, Section I/7, pp. I-X.

Molloy, H. J.; Jones, J.; and Harmon, T., 1993, “GlassFiber Reinforced Concrete with Improved Ductility andLong Term Properties,” GRCA Conference, Section 2/1,Copenhagen, Denmark, pp. 1-9.

NEG Report, 1985, “Properties of GRC by SprayMethod,” Report, Nippon Electric Glass Co. Ltd., Japan.

Peled, A., and Mobasher, B., 2005, “Pultruded Fabric-Cement Composites,” ACI Materials Journal, V. 102, No. 1,Jan.-Feb., pp. 15-23.

Peter, I., 2004, “Advances in Premix,” Proceedings of the13th International Congress of the International GlassfibreReinforced Concrete Association, Section IV, Barcelona,Spain, pp. 1-6.

Peter, I., 2005, “Sprayed Premix, The New GRC,”Proceedings of the 14th International Congress of the

International Glassfibre Reinforced Concrete Association,Paper #3, Hong Kong, Nov., pp. 17-23.

Purnell, P., and Short, N. R., 1998, “Durability of GRC Madewith New Cementitious Matrices,” International GRCACongress—1998, Cambridge, UK, Session 3, Paper 2, pp. 1-8.

Shao, Y.; Marikunte, S.; and Shah, S. P., 1995, “ExtrudedFiber-Reinforced Composites,” Concrete International,V. 17, No. 4, Apr., pp. 48-52.

Soukatchoff, P., 1999, “A Major Improvement in theLong-Term Strength and Toughness of GFRC,” High-Performance Fiber-Reinforced Concrete Thin Products,SP-190, A. Peled et al., eds., American Concrete Institute,Farmington Hills, MI, pp. 165-182.

Soukatchoff, P., and Ridd, P. J., 1991, “High DurabilityGlass Fibre Reinforced Cement Using a Modified Cementi-tious Matrix,” 8th Biannual Congress of GRCA, Maastrict,NL, pp. 37-44.

Srinivasan, R.; DeFord, D.; and Shah, S. P., 1999, “TheUse of Extrusion Rheometry in the Development ofExtruded Fiber-Reinforced Cement Composites,” ConcreteScience and Engineering, V. 1, pp. 26-36.

Takeuchi, Y., 2003, “Freeze Thaw Resistance of PremixGRC,” Proceedings of the 13th International Congress ofthe International Glassfibre Reinforced Concrete Association,SectionVI/2, Barcelona, Spain, pp. 1-6.



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As ACI begins its second century of advancing concrete knowledge, its original chartered purposeremains “to provide a comradeship in finding the best ways to do concrete work of all kinds and inspreading knowledge.” In keeping with this purpose, ACI supports the following activities:

· Technical committees that produce consensus reports, guides, specifications, and codes.

· Spring and fall conventions to facilitate the work of its committees.

· Educational seminars that disseminate reliable information on concrete.

· Certification programs for personnel employed within the concrete industry.

· Student programs such as scholarships, internships, and competitions.

· Sponsoring and co-sponsoring international conferences and symposia.

· Formal coordination with several international concrete related societies.

· Periodicals: the ACI Structural Journal and the ACI Materials Journal, and Concrete International.

Benefits of membership include a subscription to Concrete International and to an ACI Journal. ACImembers receive discounts of up to 40% on all ACI products and services, including documents, seminarsand convention registration fees.

As a member of ACI, you join thousands of practitioners and professionals worldwide who share acommitment to maintain the highest industry standards for concrete technology, construction, andpractices. In addition, ACI chapters provide opportunities for interaction of professionals and practitionersat a local level.

American Concrete Institute38800 Country Club DriveFarmington Hills, MI 48331U.S.A.Phone: 248-848-3700Fax: 248-848-3701

www.concrete.org





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The AMERICAN CONCRETE INSTITUTE

was founded in 1904 as a nonprofit membership organization dedicated to publicservice and representing the user interest in the field of concrete. ACI gathers anddistributes information on the improvement of design, construction andmaintenance of concrete products and structures. The work of ACI is conducted byindividual ACI members and through volunteer committees composed of bothmembers and non-members.

The committees, as well as ACI as a whole, operate under a consensus format,which assures all participants the right to have their views considered. Committeeactivities include the development of building codes and specifications; analysis ofresearch and development results; presentation of construction and repairtechniques; and education.

Individuals interested in the activities of ACI are encouraged to become a member.There are no educational or employment requirements. ACI’s membership iscomposed of engineers, architects, scientists, contractors, educators, andrepresentatives from a variety of companies and organizations.

Members are encouraged to participate in committee activities that relate to theirspecific areas of interest. For more information, contact ACI.

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