How to Use GFRC - Glass Fiber Reinforced Concrete

When someone says fiberglass, we think of insulation or boats or Corvettes, but maybe we should think of concrete. Technically, fiberglass is simply very fine glass fibers. The material used to make boats or other products, although called fiberglass, is really glass fiber reinforced plastic-glass fibers in a polymer matrix. If, instead of the polymer, we use portland cement and sand, the resulting material is glass fiber reinforced concrete--GFRC or sometimes GRC (the Brits call it glassfibre reinforced concrete).

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The problem with using glass fibers as reinforcement for concrete is that glass breaks down in an alkaline environment--and there's almost nothing more alkaline than concrete. You may have heard of concrete being damaged by alkali-silica reactivity (ASR) when there is reactive silica in the aggregate. Glass is primarily silica. The original GFRC in the s rapidly lost strength as the glass was destroyed by the alkaline environment. In the s alkali-resistant (AR) glass fibers were perfected by Owens-Corning and by Nippon Electric Glass (NEG) leading to a rapid increase in applications.

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GFRC has been used for the past 30 years to produce many concrete products, especially thin architectural cladding panels, but also for ornamental concrete such as domes, statues, planters, and fountains. Recently, decorative concrete artisans have discovered the benefits of GFRC for decorative panels (such as fireplace surrounds), concrete countertops, and artificial rock work.

Glass Fiber Reinforced Concrete

MANUFACTURING GFRC PIECES

There are three methods for making concrete elements using GFRC: traditional hand spray-up, vibration casting, and sprayed premix.

• The traditional, and perhaps still the best, way to manufacture precast GFRC elements is by hand spraying the GFRC into a mold. This is how most precast GFRC architectural cladding panels are made and also most ornamental precast GFRC. With the direct spray-up method, you need a concentric chopper gun, which is fed by a spool of GFRC roving pulled into the chopper gun and blended at the nozzle. This mix has a higher fiber content (4 to 6%) than can be achieved with premix and is the recommended method for larger panels. It does, however, require experienced workers, expensive equipment, and rigorous quality control.
• Vibration casting uses premixed GFRC poured into a mold and vibrated to achieve consolidation. This is a much simpler method, but requires water-tight molds and doesn't work well with rock molds.
• Sprayed premixed GFRC, with chopped fibers in the mix, requires a peristaltic pump and a special spray head. This method requires less expertise than the hand spray-up method and results in higher strengths than with vibration casting.

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Most decorative GFRC pieces, especially countertops, or fireplace surrounds are made using a two-layer approach. The facing layer is the thin decorative layer and the backup layer is thicker and contains the glass fibers.

• The face coat is normally sprayed into the mold using a drywall hopper gun. This layer is about 1/8 to 3/16 inch thick.
• "One square foot of countertop requires only about 2 pounds of concrete mixture for the face coat," said Mike Wellman, Concast Studios, Oceana, Calif. "It's pretty thin so with my mixer I'm able to do a 200 square foot job--about the biggest kitchen there is. This allows me to do the whole thing with one batch to insure color consistency."
• "We let the face coat set to where it's moist but won't move-about ½ hour to 1 hour," said Wellman.
• The GFRC backer coat is then placed. Most decorative contractors either pour this layer or trowel it on by hand. The thickness of this layer is in the range of ¾ to 1 inch, depending on the size of the panel and the loads it will be carrying.
• The GFRC layer is typically placed in two layers of about 3/8 inch and compacted using rollers or a vibrating table.
• Mixers for GFRC need to provide a lot of shear at both low and high mixing speed-high for the low water-cement ratio concrete mix then low to prevent breakage when the glass fiber is added. Power-Sprays is a British company, represented in the U.S. by NEG America, that specializes in GFRC equipment. They make an excellent upright mixer. You can also use a handheld mixer, such as those from Collomix or even a mixer blade on an electric drill. "The limitation for most guys is having a mixer that can mix enough volume and has the power to mix fiberglass in well," said Wellman.
• With the polymer addition, GFRC sets fairly quickly. Depending on conditions, panels can be stripped and polished within 24 hours, although Wellman waits 3 days for the concrete to gain nearly its full strength

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MAKING GFRC DECORATIVE

GFRC panels can be given nearly any decorative treatment as normal concrete. The application dictates what works best:

Ornamental architectural accents can be created with GFRC. J&M Lifestyles in Randolph, NJ

• Architectural panels are often cast using various form liners. The surface finish can be sand blasted, acid etched, or polished. Various tints of gray, white, and buff can be achieved using colored cements or pigments.
• Many GFRC ornamental pieces are shot or cast using white cement and light color tints. Stone or clay brick pieces can be embedded in panels, although consideration should be given to the differential shrinkage characteristics of the different materials. Many different architectural features are best produced using GFRC.

GFRC countertops can be finished using virtually any decorative concrete techniques. Absolute ConcreteWorks in Seattle, WA

• Countertops are typically made using a face coat and a solid integral color is often the method of choice. "We use integral color in the face coat," said Mike Wellman, Concast Studios, Oceana, Calif. which makes countertops and fireplace surrounds. "Sometimes we will do an acid stain but the majority of our clients stick with the straight integral color." Wellman typically polishes the countertop to a high gloss finish, but offers many varieties. Read more about Concast Studios' work.

Although the structure for this climbing wall has all of the appearance of real rock, modular handholds are attached for climbing. Eldorado Wall Co.

• Countertops can be produced without the facing coat, although if polished the fibers will be visible. "Some of our customers like the fibers to show," said NEG America's Mike Wellman. "If it's acid etched or acid washed, they don't mind the fibers and they actually blend in with the color."
• With face coats, broadcasting aggregate or embedding decorative elements is a good choice. "Since I'm spraying in the initial face coat I'm able to broadcast aggregate in which lets me get flowing movement," said Wellman. "I can sprinkle in glass or seashells and when polished and exposed it gives the illusion of movement. With wet cast it's trickier to get that movement and make it look good."

Artificial rocks require artistry in color application to obtain a realistic appearance. Synthetic Rock Solutions in Amity, OR

• Rock features typically use GFRC panels that are sprayed against molds made using real rock features. Steve Holmes, vice president of Eldorado Wall Company, a Boulder, Colo. maker of rock climbing walls, says that the first coat they spray has no glass fiber. "The chop gun has mud-only and mud-and-glass triggers. The first thin coat has no fibers then we bring the thickness up to ¾-inch nominal with the GFRC mix."
• To create rocks, the GFRC panels are mounted on a structural steel framework. "The panels can be oriented in different directions," said Eldorado Wall's president John McGowan, "then we plaster the seams and sculpt them to blend the panels into a rock feature." To create the patches, said Holmes "we place lath and rebar into the seams then start with a scratch coat then apply the sculpt coat. This is done with a field mix based on a shotcrete recipe." Coloring the rocks is done with a variety of techniques Eldorado has developed over the years.
• Jim Jenkins of JPJ Technologies teaches artificial rock making. His method, however, does NOT use GFRC but rather a composite fiber-reinforced polymer concrete material that he invented and has perfected. "Our panels are ¼ to ½-inch thick," said Jenkins, "where a GFRC panel will be 1-1/2-inch thick. Our material can be cut easily with a circular saw and yet is stronger than GFRC. The seams between panels are patched with the same material used to make the panels so they behave, look, and stain the same." A sister company, Synthetic Rock Solutions, sells premanufactured rock panels that can be used to assemble rock features.

Fireplace surrounds are an ideal application for GFRC. Sierra Concrete Designs

• Coloring rock and water features entails a lot of artistry. Multiple colors and techniques are blended to produce realistic color, as described in "Geo-Illusions" in the December /January issue of Concrete Décor.
• Ornamental GFRC fireplace surrounds have become very popular, due to their light weight and durability. Check out what Sierra Concrete Designs does with this application in the article Surrounding Fireplaces With Beautiful Decorative Concrete Work.

When it comes to innovative construction solutions, Glass Fiber Reinforced Concrete (GFRC) is revolutionizing the way we build. Whether you’re a contractor, property owner, or architect in Long Island, Brooklyn, Queens, or the Bronx, understanding the benefits and applications of GFRC can help you make smarter, more durable building choices. At the Mudjacking Contractor, we specialize in advanced concrete technologies and are proud to be a trusted name in structural and aesthetic concrete solutions throughout New York City.

In this blog, we’ll take a deep dive into glass fiber reinforced concrete—what it is, how it works, where it’s used, and why it might be the best choice for your next project.

What is Glass Fiber Reinforced Concrete?

Glass Fiber Reinforced Concrete (GFRC) is a high-performance concrete composite that incorporates alkali-resistant glass fibers as a reinforcement material. Unlike traditional reinforced concrete that relies on steel bars or mesh, GFRC uses fine glass fibers evenly distributed throughout the mixture.

The result? A lightweight, durable, and versatile concrete solution that boasts impressive tensile strength and superior crack resistance. GFRC is especially ideal for architectural and decorative elements, but its structural potential is increasingly being recognized across the construction industry.

Why Choose Glass Fiber Reinforced Concrete?

There are several compelling reasons to consider glass fiber reinforced concrete for your residential, commercial, or municipal project in the New York metro area:

1. Lightweight but Strong

GFRC is significantly lighter than traditional concrete, which makes transportation, handling, and installation much easier—especially in dense urban areas like Brooklyn, Queens, and The Bronx. Despite its lower weight, it offers excellent structural integrity.

2. Crack and Impact Resistance

Thanks to the continuous glass fibers throughout the matrix, GFRC has increased resistance to cracking, chipping, and surface degradation, which is crucial for longevity in the ever-changing New York weather conditions.

3. Flexibility in Design

GFRC can be molded into intricate shapes and textures, making it the material of choice for architectural facades, wall panels, custom trims, and decorative features. This makes it especially popular in Long Island estates and boutique commercial properties in Brooklyn and Queens.

4. Sustainability

GFRC uses less cement and water than traditional mixes and often incorporates recycled materials, reducing environmental impact. Its durability also means fewer repairs and replacements over time.

5. Corrosion-Free

Unlike steel reinforcement, glass fibers do not corrode. This means GFRC structures enjoy a longer service life, especially in areas prone to moisture or coastal exposure, such as Long Island.

Applications of Glass Fiber Reinforced Concrete

At the Mudjacking Contractor, we’ve seen firsthand how GFRC has enhanced both residential and commercial projects across NYC’s boroughs. Some of the most common applications include:

✔ Architectural Cladding

GFRC panels are widely used for exterior wall cladding due to their aesthetic appeal and structural reliability. Their lightweight nature also reduces the load on the building’s foundation.

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✔ Facades and Wall Panels

Especially in Brooklyn and Queens, GFRC allows for custom designs that mimic natural stone, wood, or other high-end finishes—perfect for modern and historic buildings alike.

✔ Countertops and Sinks

The decorative possibilities of GFRC make it an excellent material for custom countertops, sinks, and even furniture in upscale residential and commercial interiors.

✔ Landscape Elements

Retaining walls, planters, and water features made from GFRC offer both form and function in landscaping projects throughout Long Island and The Bronx.

✔ Reinforced Concrete Pipes

GFRC is now being adapted for reinforced concrete pipes, which are used for stormwater management and sewer systems. These pipes are lighter, easier to install, and offer superior resistance to corrosion and cracking.

Comparing GFRC with Traditional Reinforced Concrete

Let’s break down how glass reinforced concrete stacks up against traditional reinforced concrete:

Feature Traditional Reinforced Concrete Glass Fiber Reinforced Concrete Weight Heavy Lightweight Reinforcement Steel rebar or mesh Alkali-resistant glass fibers Corrosion Risk High in moist environments Minimal Flexibility in Design Limited High Durability Good, but steel may rust Excellent Cost Lower upfront cost Higher upfront, but long-term savings

While GFRC may have a slightly higher initial cost, the long-term performance, reduced maintenance, and faster installation make it a cost-effective solution over time.

Why GFRC is Ideal for New York’s Unique Needs

Cities like Brooklyn, Queens, Long Island, and The Bronx present unique challenges—limited access, historic preservation, urban density, and harsh weather conditions. Here’s how glass fiber reinforced concrete rises to the occasion:

• Urban Infrastructure: Lightweight GFRC panels can be hoisted and installed without cranes, perfect for narrow NYC streets.
• Historic Restoration: With its moldability and texture-matching capabilities, GFRC is perfect for restoring architectural details in landmark buildings.
• Coastal Areas: In places like Long Island, the non-corrosive nature of GFRC makes it ideal for seaside applications.
• Speed of Construction: Faster installation times reduce disruptions—key for high-traffic urban zones in Queens and the Bronx.

How The Mudjacking Contractor Leads in GFRC Installation

We are proud to be industry leaders in innovative concrete solutions. Our team combines technical expertise, hands-on experience, and a commitment to quality that sets us apart across New York City’s five boroughs.

Here’s what makes us different:

• ✔ In-depth GFRC Consultation and Design Services
• ✔ Custom GFRC fabrication and installation
• ✔ Experience working on both modern and historic properties
• ✔ Dedicated to safety, code compliance, and aesthetic excellence
• ✔ Serving residential, commercial, and municipal clients

Whether you’re planning a façade update in Brooklyn, a landscape project in Long Island, or a municipal infrastructure upgrade in The Bronx, The Mudjacking Contractor is the name to trust.

Reinforced Concrete Pipes: A New Frontier

One of the exciting developments in glass fiber reinforced concrete is its integration into reinforced concrete pipes. Traditionally made using steel-reinforced concrete, pipes for storm drains and sewers are now being manufactured using glass reinforced concrete for added durability and reduced weight.

These GFRC pipes are:

• Easier to transport and install
• Highly resistant to chemical attacks
• Ideal for aging infrastructure upgrades in urban areas

As infrastructure in Queens and the Bronx continues to be modernized, reinforced concrete pipes made from GFRC will likely become the standard.

Final Thoughts

Glass fiber reinforced concrete isn’t just a buzzword—it’s the future of smart, sustainable, and stunning construction. From artistic architectural elements to resilient infrastructure components, GFRC offers unmatched value and versatility.

If you’re looking for a trusted partner in Long Island, Brooklyn, Queens, or the Bronx, the Mudjacking Contractor is here to help you explore how glass reinforced concrete can elevate your next project. Contact us today for a free consultation and see how innovation meets expertise.

Let’s Build Stronger, Smarter, and Longer-Lasting Together.

Frequently Asked Questions 

1. What is glass fiber reinforced concrete (GFRC)?

GFRC is a type of concrete that incorporates alkali-resistant glass fibers instead of traditional steel reinforcements. This results in a lightweight, strong, and durable material suitable for architectural and structural applications.

2. How is GFRC different from traditional reinforced concrete?

Unlike traditional reinforced concrete, which uses steel rebar, glass reinforced concrete uses glass fibers to provide tensile strength. This makes GFRC lighter, more resistant to cracking and corrosion, and easier to shape into complex forms.

3. What are the benefits of using glass fiber reinforced concrete in New York’s climate?

GFRC is highly durable and resists moisture, freeze-thaw cycles, and salt corrosion, making it ideal for the varied climate of Long Island, Brooklyn, Queens, and the Bronx.

4. Is glass fiber reinforced concrete strong enough for structural applications?

Yes, GFRC offers excellent tensile and flexural strength. While commonly used in architectural panels, it’s increasingly being adapted for structural uses, especially in lightweight reinforced concrete pipes and facade systems.

5. Can GFRC be used for custom architectural designs?

Absolutely. GFRC is extremely moldable, making it ideal for custom facades, trims, columns, and decorative panels. Its flexibility in shape and texture makes it a favorite among architects.

6. How long does GFRC last compared to traditional concrete?

GFRC can last decades without significant wear, especially since it doesn’t rust like steel-reinforced concrete. This makes it a cost-effective long-term investment for both residential and commercial buildings.

7. What maintenance does GFRC require?

Minimal. GFRC is resistant to cracking, staining, and weather damage. Occasional cleaning and resealing, depending on the application, are usually all that’s needed to keep it in top shape.

8. Is GFRC environmentally friendly?

Yes. GFRC uses less cement and water and often incorporates recycled materials. Its long lifespan also reduces the need for repairs and replacements, lowering its overall environmental impact.

9. Can GFRC be used in infrastructure like sewer or drainage systems?

Yes, GFRC is being used to manufacture reinforced concrete pipes due to its light weight, high durability, and corrosion resistance, making it ideal for stormwater and sewage systems in urban areas like Queens and The Bronx.

The company is the world’s best GFRC Construction supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

10. Who installs glass fiber reinforced concrete in Long Island, Brooklyn, Queens, and The Bronx?