6 Innovative Uses of GRC in Architecture

Glass Reinforced Concrete (GRC) is facilitating a revolution in architecture as architects and engineers alike are presented with a material that can be used to bring even the most ambitious of projects to life.

Known for its durability, sustainable attributes, lightweight nature, and mouldability, GRC provides the designer with a complete technology that few other materials can match for versatility. Whether used for producing prefabricated panels for modular construction, or aesthetic and functional elements for landscape design, GRC is redefining the standards of modern architecture across the globe.

Find out how architects are utilising this phenomenally versatile and durable material in their projects to create breath-taking structures that seem to transcend the capabilities of modern architecture and construction.

1. Facade Cladding

The lightweight and durable nature of GRC makes it perfectly suited for fa?ade cladding. Intricate and textured exteriors can be produced using GRC which demonstrate superior weather resistance for a range of climates.

Fa?ade cladding panels are generally manufactured by the Traditional Hand Spray method, where GRC is sprayed onto a mould using spray equipment such as the Concentric Spray Gun. This method can produce high-performance materials from which panels with extremely thin, lightweight sections are achievable. Approximately 80% lighter than pre-cast steel reinforced concrete cladding, GRC panels allow for easier and more cost-effective installation, further emphasising the practical and versatile use of this remarkable material.

Both functional and aesthetically versatile, architects can bring their unique visions to life in the form of visually appealing structures. Just take a look at AARhus in Aarhus, Denmark (pictured above). Designed by BIG & Gehl Architects, the vision behind the project was to embody the soul and architectural spirit of the city of Aarhus. The decision was made to shape the building as two A’s – functioning as a new hallmark and as a way of welcoming visitors to the city. By opting for the use of GRC fa?ade panels, the architects were able to maintain their creative vision and explore a range of design choices that may otherwise have not been possible.

GRC manufacturers, BB fiberbeton were called in to produce the fa?ade elements, utilising a combination of embedded inserts and steel brackets along with recessed holes and plugs to deliver a concealed and easy installation. This methodology resulted in a striking structure that appears monolithic and requires no technical maintenance.

2. Interior Design

Whether designing for private homes or commercial buildings, architects can rely on GRC as a functional and aesthetically versatile material to produce all manners of interior elements. From sleek, fire-resistant wall panels to customisable countertops and inventive furniture, GRC can be shaped and moulded by the will of an architect into all manners of innovative creations to add unique visual interest to interior spaces.

Not only does the material offer the possibility of a wide array of shapes and textured finishes, but also offers numerous practical advantages due to its lightweight yet durable attributes, including resistance to movement, shrinkage, flames, and long-term cracks and chipping.

This combination of practical and aesthetic benefits makes GRC a cornerstone in interior design, demonstrating characteristics that allow for the material to blend with any design theme, offering endless possibilities for innovative and stylish room décor.

Many companies around the globe are creating immaculate elements for interior design but one such company that is consistently producing incredible products is Concrete Carrot.

Based in Penarth, Wales, Concrete Carrot are specialists in all things concrete. Creating a range of products including countertops, furniture, sinks, basins, fireplaces, decorative panels, the team utilise a range of materials to craft these pieces. GRC remains a steadfast material in their lineup due its ability to mimic surface textures and finishes, lightweight characteristics, and durable attributes.

You can view their portfolio of work on their website at: www.concretecarrot.co.uk

3. Decorative Features

GRC’s mouldability makes it ideal for crafting intricate architectural details and ornate decorative elements. These products remain easy to handle and erect thanks to GRC’s remarkably light weight which allows for architects to add detailed mouldings, elaborate patterns, and unique sculptures to both the exterior and interior of buildings.

The unrivalled freedom of creative design that GRC offers means that architects can include an endless variety of decorative features to add depth and character to already impressive structures.

We like to demonstrate GRC’s ability to form decorative features in our demonstration days here at Power-Sprays by using rubber moulds to cast panels featuring intricate designs and patterns as shown above.

The process begins with a sculpted gypsum panel from which the rubber mould is cast using a material such as Fleximould . Once this has been demoulded it can be used repeatedly in casting GRC panels by pouring the mixture directly onto the mould and allowing it to cure. Once cured and demoulded, we’re left with a flawless replication of the original sculpture featuring the lightweight and durable benefits of GRC.

If you’re interested in booking a demonstration day to learn more about how to use our equipment and how to get the most out of your GRC manufacturing process, get in touch today:

[email protected]

4. Landscape Design

Possessing unparalleled weather resistance and aesthetic adaptability, GRC remains a first choice for outdoor applications, facilitating all manners of creative possibilities for landscape features. The material’s ability to be shaped into a wide variety of shapes and surface finishes allows for designers to create features that mimic materials such as stone or wood whilst reaping the benefits of GRC’s lightweight and resilient characteristics.

GRC’s green credentials make it a favoured choice for environmentally conscious landscape design. Used in public parks, private gardens, and urban spaces as outdoor furniture, planters, sculptures, and water features, GRC contributes to the aesthetic appeal of outdoor spaces.

This beautiful Fish Fountain (pictured above) is one such unique application of GRC in landscape design. Produced by Al Tasnim Enterprises for a private villa in Azaiba, Muscat, Sultanate of Oman, the choice was made to use GRC as an alternative to marble due to traditional marble sculptors being hard to come by. A single fish sculpture was first created using gypsum and from there a rubber mould was formed. Three casts were made and joined together to create the fountain and all necessary pipes and nozzles were cast within while the GRC was being sprayed.

Thanks to GRC’s ability to mimic textures and surface finishes, the final product was a stunning replication of a traditional marble water feature, produced far more efficiently in comparison with traditional marble sculpting techniques and which demonstrates unparalleled resilience to the elements.

5. Modular Construction

As the construction industry advances, new, more efficient techniques are continuously sought after. Modular construction has seen a rise in recent years, aided by GRC’s lightweight and modular nature. Panels can be prefabricated off-site, reducing construction time and labour costs whilst also reducing wastage through consistent quality checks that may be absent when producing panels on-site where defects or poor-quality panels are prevalent.

This streamlined approach to construction aligns with an increased demand for sustainable building practices and the need for rapid, efficient construction procedures, making GRC a cornerstone material in contemporary prefab and modular building projects.

A recent example of this efficient approach to construction is the extension of ExCel London (pictured above) where GRC specialist McCormick Construction have installed a stretch of brick-faced GRC arches as part of a 25% expansion of the original 100,000m2 exhibition and conference facilities. By using GRC, panels could be fitted to the existing structure without the need for reinforcement of the building’s foundations whilst also cutting down on additional material usage such as concrete or steel. Moreover, the fast installation time of the GRC panels meant there was minimal disruption to the ExCel Docklands which is a public footway and could not be shut down whilst construction was taking place.

6. Restoration and Preservation

As well as being used in the formation of modern, contemporary creative endeavours, GRC has also proven itself invaluable in the preservation of existing architecture. By replicating the appearance and texture of heritage materials, GRC can seamlessly restore aged facades, decorative embellishments, and ornamental features, making it indispensable in restoring old buildings where maintaining historical accuracy is essential.

The material’s lightweight nature makes it perfect for adding structural support without imposing significant additional load, while its longevity and durability ensures long-lasting protection against weathering and environmental damage. These characteristics of structural endurance ensures the continuity of global heritage without compromising modern performance standards.

A remarkable example of GRC’s ability to effectively restore historical structures is Shepard Hall (pictured above), the original main building of The City College of New York. In 1986, The Stein Partnership (now Elemental Architecture LLC ) were commissioned to investigate strategies for reconstructing the envelope of Shepard Hall, a 36,000m2 gothic revival structure built in 1907 and consisting of more than 72,000 individual pieces of architectural terra cotta which were incorporated into the exterior structural masonry walls.

The reconstruction required precise replication of the terra cotta's detail and solidity while incorporating a system to accommodate building movement, which had previously caused significant damage. The solution involved removing all terra cotta and replacing it with brick or stone set about 10 cm behind the finished surface. GRC replicas of the terra cotta forms were then attached to the new masonry using a system of galvanized steel channels and clips, allowing adjustment in three planes to ensure accuracy and durability.

The implementation of GRC into this project proved integral to replicating the extremely fine details of the thousands of unique sculptural features in Shepard Hall, creating a visual unity despite the fragmented construction sequence and passage of time. The use of GRC proved a highly appropriate choice and has since validated it as the material of choice for complex historic reconstruction, a practice that is becoming increasingly widespread.

Conclusion

Glass Reinforced Concrete is truly revolutionary in architecture. The material’s versatility, durability, and aesthetic flexibility has allowed for architects to push creative boundaries further than ever before, underscoring GRC’s remarkable impact on the industry.

From creating intricate fa?ade claddings and decorative features to enabling efficient modular construction and aiding in heritage restoration, GRC is an indispensable material that meets the needs of modern architecture. Its lightweight, mouldability, and resilience make it a sustainable and innovative choice for various applications, ensuring that both contemporary designs and historic preservations can benefit from its unique properties.

As architects, engineers, and builders push the boundaries of creativity and performance, GRC stands poised for even greater expansion in the shaping of the global architectural landscape and we look forward to seeing the innovative GRC applications that the future holds.

Learn more about Glass Reinforced Concrete and its remarkable properties in our GRC Guide:

www.power-sprays.com/grc-guide