SPECIFICATION FOR THE DESIGN AND MANUFACTURE OF …

SPECIFICATION FOR THE DESIGN AND

MANUFACTURE OF ULTRA HIGH-QUALITY

GLASS FIBRE REINFORCED CONCRETE

CLADDING ELEMENTS

Publication Date: January 2020

Document Reference: QMSD149

Version: European 13

Status: Issue

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© GRC Synergies Ltd 2020. All rights reserved

Copyright Notice

This specification is Copyright © GRC Synergies Ltd 2020 and protected under UK and international laws.

This specification may be used and reproduced for the purpose of instruction and reference, subject to the

following conditions:

• You must only use or reproduce this specification in connection with GRC products, including when purchasing, using and specifying GRC products;

• You must not use or reproduce this specification for any other commercial purpose, including as supporting content for any other commercial products;

• You may not modify, alter, transform, build upon or create derivative works based upon this specification; and

• This notice must appear on all complete or partial copies of this specification which you create.

If you wish to use or reproduce this specification in any way which is not permitted by this notice or under

applicable copyright laws, please contact [email protected]

GRC Synergies Ltd

Fairfax House, 6A Mill Field Road, Cottingley Business Park, Cottingley, Bingley. West Yorkshire BD16 1PY United Kingdom

mailto:[email protected]

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Section 1: Definition

A cladding panel or any other architectural feature manufactured from glass-fibre reinforced concrete and

produced using the Spray Process system as detailed in EN 1169 and EN 15191. The items may be of any

shape, dimension, colour or texture with engineer designed structural rigidity provided by either:

Geometric Shape with formed rib profiles or similar

Factory fitted galvanized, stainless steel or aluminium stud frame system

Separate aluminium horizontal/vertical rail system.

Section 2: Standards

The following published standards, specifications or publications are applicable to meeting the requirements of

this document

ISO 9001: 2015 Quality Management Systems – Requirements

ISO 17021-1: 2015 Conformity assessment. Requirements for bodies providing audit and certification

of management systems

ISO 17025:2017 General requirements for the competence of testing and calibration laboratories

EN 1169:1999 General rules for factory production of glass-fibre reinforced cement

EN 15191: 2009 Classification of glass fibre reinforced concrete performance

EN 1170-1:1998 Measuring consistency of matrix – ‘Slump test’ method

EN 1170-2 :1998 Measuring fibre content in fresh GRC – ‘Wash out test’

EN 1170-3: 1998 Measuring fibre content of sprayed GRC

EN 1170-5: 1998 Measuring bending strength ‘Complete bending test’ method

EN 1170-6: 1998 Determination of the absorption or water by immersion and determination of dry

density

EN 1170-7: 1998: Measurement of extremes of dimensional variations due to moisture content

EN 1170-8: 2008 Cyclic weathering type test

EN 933-1:2012 Tests for geometrical properties of aggregates Part 1: Determination of particle

size distribution – Sieving method

EN 1097-5:2008 Tests for mechanical and physical properties of aggregates Part 5 – determination

of water content by drying in ventilated oven.

EN 12390-2: 2019 Making and curing of concrete cubes for testing

EN 12390-3: 2019 Testing concrete cubes for compressive strength

EN 1305:2007+A1: 2009. Classification of reaction to fire performance

EN 197-1: 2011 Cement. Composition, specification and conformity criteria for common cements

EN 15422:2008 Specification for glass fibres for reinforcement of mortars and concrete.

EN 12878:2014 Pigments for colouring of building materials based on cement and/or lime.

Specifications and methods of test.

PD CEN/TR 15739: 2008 Concrete finishes – Identification

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GRCA Specification 2017 Specification for the Manufacture, Curing & Testing of Glass fibre Reinforced

Concrete (GRC) Products

PCI MNL-130-09: 2009 Manual for quality control for plants and production of Glass Fibre Reinforced

Concrete Products

SAMSA-LOI Standard Tests – Loss on Ignition

Section 3: Terms & Abbreviations

The following terms and abbreviations are used throughout this document

Acid Wash A process where finished GRC products have hydrochloric acid applied to remove the

outer cement paste in order to provide a texture similar to cut natural stone

Additive Product that may be added by weight to matrix to improve performance

Admixture Product added to matrix in less than 5% by weight to improve performance

As Cast GRC product subject to no finishing treatment when removed from mould

AR Fibre Alkali resistant glass fibre roving or chopped fibres manufactured to be resistant to alkali

based cementitious matrix

Bag & Bucket A simplified test to calibrate slurry and fibre output to meet the required fibre content

required by the mix design.

CAB Conformity Assessment Body accredited by an ILAC or IAF Accreditation Body

Characteristic The value of a property above which 95% of the population of all possible

measurements of that property are expected to lie.

Customer The person or organisation placing an order to purchase GRC products

Engineer A qualified structural engineer responsible for the design of the GRC components

Facing Coat Outer surface layer to provide visual finish, often contains decorative aggregates and

pigments.

Factory Tests Tests carried out on wet GRC in a dedicated factory test area

FEA Finite Element Analysis

GFRC Glass fibre Reinforced Concrete (Asia/Australia/South America/United States)

GRC Glass fibre Reinforced Concrete (United Kingdom/Europe/Middle East)

GRCA The International Glassfibre Reinforced Concrete Association (Global)

Grit Blast A process where finished GRC products are blasted using high pressure equipment and

suitable abrasive mediums to remove the outer cement paste in order to provide a texture

similar to cut natural stone

IAF International Accreditation Forum

ILAC International Laboratory Accreditation Cooperation

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Laboratory Tests Tests carried out by an ILAC accredited laboratory (CAB) as part of the quality control

process

LDM Laboratory Developed Method

LOP Limit of Proportionality – bending stress at which the composite exceeds its elastic limits

– sometimes referred to as yield strength

Manufacturer The company manufacturing the GRC products.

MOR Modulus of Rupture – bending strength at which the fibre reinforcement fails – sometimes

referred to as ultimate strength

PCI Precast/Prestressed Concrete Institute (USA)

QMS Quality Management System

Premix Process Process where pre-chopped AR fibre is added to a cementitious slurry during the mixing

operations

Spray Process Process where AR fibre is chopped from a roving feed to pre-set lengths and

simultaneously sprayed with the cement slurry into open moulds using a specialist

concentric gun.

Retarder A product applied to mould surfaces which prevents the outer layer of cement paste from

fully hydrating. When removed by high pressure jet wash the uncured cement paste is

also removed providing a texture similar to natural stone. Retarders can also be

admixtures added to the matrix.

Roving AR Fibres supplied wound together to provide a cylindrical continuous feed of fibres to a

specialist spray gun

SAMSA Silica and Moulding Sands Association (UK)

Sample Board A sheet of GRC manufactured using either Premix or Spray process for the purpose of

providing specimens for testing

Specimen Sections taken from a test board or product for test purposes. Also referred to as coupons.

Touch Test A test employed in the manufacture of GRC to ensure that any applied GRC layers are

not being added to a matrix which is too dry to adhere to the next applied sprayed layer

Type Test A test carried out on a particular GRC mix formulation or combination of facing coat and

GRC to determine certain physical properties. Data from type testing is used as

characteristic material properties within the engineering analysis

UKAS United Kingdom Accreditation Service

VMU Visual Mock-up

ɣb The safety factor applied during engineering analysis allowing for differences between

manufactured sample boards and full-sized manufactured sections.

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Section 4: Compliance

The manufacturer must operate a Quality Management System conforming to the requirements of ISO 9001:

2015. The system is to be accredited by a Conformity Assessment Body who themselves are accredited to the

requirements of ISO 17021:2015 by an IAF signatory body. The scope of the QMS included within the

certification must specifically provide for the manufacture of GRC products.

The QMS must include a process provision whereby daily random quality audits are carried out by a person or

persons who are employed by a third-party company. This clause does not preclude the requirement for ongoing

and documented quality control by production staff.

The manufacturer must have a contract or contracts with an external testing laboratory for all testing

requirements contained with the following sections of this specification. The laboratory must be a Conformity

Assessment Body accredited by an ILAC Accreditation Body member as compliant to ISO 17025:2017

(Competency of Testing and Calibration Laboratories). The schedule of accreditation must cover the appropriate

testing detailed within this specification.

Such testing applies to the following sections of this specification.

Accredited Laboratory Type Testing (Section 5)

Raw Materials (Section 10)

Facing Coat Mixes (Section 11)

Accredited Laboratory QC Testing (Section 22)

Accredited Laboratory Validation Testing (Section 23)

A schedule of all required testing under this standard is summarised in Addendum A

Section 5: Accredited Laboratory Type Testing

All the following type tests are to be carried out prior to the commencement of the engineering design by a

laboratory who must be a Conformity Assessment Body accredited by an ILAC Accreditation Body member as

compliant to ISO 17025:2017 (Competency of Testing and Calibration Laboratories). The schedule of

accreditation must cover the appropriate testing to be carried out.

The characteristic flexural strengths of the specific GRC mix to be used in the engineering design are to be

determined at LOP (Limit of Proportionality) and MOR (Modulus of Rupture) levels from results obtained on a

minimum of 50 test results carried out in accordance with EN 1170-5: 1998 at 1, 7 and 28 days of age. These

represent the GRC at the following critical points

1 Day Demoulding and initial handling

7 Day General age at which GRC is transported to site

28 Day Age at which GRC has reached approximately 95% of its maximum strength

The tests shall be carried out on samples manufactured over separate and consecutive days. All test data

should be no more than 12 months old.

The number of test results required is therefore 3 groups of 50 (150). This should be regarded as a minimum in

determining the flexural strength properties using established mathematical methods of calculating characteristic

value

The characteristic axial pull-out capacity of any embedded anchors is to be provided based on a minimum of 50

test results carried out in accordance with GRC Synergies Laboratory Developed Method 1201. The tests shall

be carried out on samples manufactured over separate and consecutive days. The tests are to be on the specific

type of anchors and GRC mix to be used within the project. All test data should be no more than 12 months old.

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The number of test results should be regarded as a minimum in determining the pull-out properties using

established mathematical methods of calculating characteristic value

The dimensional movement of the GRC mix is to be measured in accordance with EN 1170-7: 1998. Where a

facing coat is being used to provide an architectural finish, the test must be carried out on the appropriate

facing/GRC mix combination. Modifications, omissions or deviations to the test standard are permitted provided

the requirements of ISO 17025: 2017 Section 7.2.2 are met and documented. The test report shall be no more

than 12 months old

The ageing characteristics of GRC mix are to be cyclic weather tested in accordance with EN 1170-8: 2008.

Modifications, omissions or deviations to the test standard are permitted provided the requirements of ISO

17025: 2017 Section 7.2.2 are met and documented. The test report shall be no more than 12 months old. This

test is not required for manufacture of products produced using the Premix process as defined in EN 15191:

2009.

The structural GRC mix shall be tested to permit classification of reaction to fire performance in accordance with

EN 1305:2007+A1: 2009. Note additions of colouring pigments or variations to any other raw materials in either

type of quantity will require a separate test. The test shall be no more than 60 months old. The tested GRC mix

should be classified as A2 or higher.

It is important to recognise that all above type testing is carried out on the actual mix to be used. Using test

results from mix designs which deviate in any way from those being used on the project are strictly prohibited

under this specification. Note the addition of colouring pigments to a base GRC mix design is considered a

separate mix design and will require full type testing as detailed above.

Individual test results and the method of calculating the characteristic value are to be made available to the

engineer.

Section 6: Visual Mock-Up (VMU)

Prior to the commencement of any manufacturing a visual mock-up is to be produced and shipped to site for

client approval. The mock-up shall consist of at least 4 panels which are dimensionally representative of those

to be used on the works

Prior to delivery to site one of the panels is to be deliberately damaged and repaired using the approved factory

procedure.

The mock-up will be used as benchmark for colour and texture variation.

Section 7 Design Engineering

The design must be carried out by an engineer, technician or designer who has a practical understanding and

the necessary experience in the manufacture and installation of GRC cladding panels. All designs are to be

supported by engineering analysis/calculations to verify that the design of the GRC elements and associated

fixings are capable of sustaining all imposed stresses and loads.

The engineering analysis/calculations must be carried out by a suitably qualified and experienced person. They

must hold a university degree in civil or structural engineering which is recognised by institutions such as the

Institute of Structural Engineers or other similar national bodies. A minimum of 12 months experience in

engineering GRC cladding elements manufactured using the Spray Process is also required

All GRC designs and structural analysis, along with support/restraint systems, must be reviewed by a separate,

independent and similarly qualified civil or structural engineer but with a minimum of 60 months experience

working with Spray Process GRC.

All material properties used in the design engineering process are to be those derived from testing as detailed

in Section 5. These and other critical information regarding the material are to be submitted on the form detailed

in Addendum B prior to the commencement of the design engineering works.

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The appropriate factors of safety are to be applied to the works as determined by the engineer based on a

statistical analysis of the test results as detailed in Section 5 of this specification

If a stud frame system is to be used within the fabrication of the elements the choice of material will be determined

by the client in collaboration with the Engineer.

All support and restraint brackets and systems are to be designed to resist all imposed static and live loads. The

choice of material will be determined by the client in collaboration with the Engineer

All fixings of the GRC elements are to accommodate the volumetric movement of the GRC as determined by

type testing as detailed above.

Section 8: Plant Facilities

The production site must be suitably organised allowing for safe and compliant working conditions.

Storage facilities must be provided for all raw materials which prevent any ingress of water, moisture or other

contaminates. Stock rotation systems must be in place to avoid out of date materials being used in the production

process.

The facility must always have the capability of maintaining temperature above 10⁰C and ensuring products are

protected from any drying winds or rain during the production and initial curing period.

A suitable testing area should be provided in order all required factory tests on wet GRC detailed in Section 21

of this specification can be carried out.

Section 9: Moulds

Moulds should be manufactured from materials suitable to provide dimensionally stable products meeting the

requirements of Table 4. Stricter tolerances may be required and should be agreed between the customer and

the manufacturer. Consideration must always be given to the choice of mould material and the expected

movement in the GRC.

Moulds should be constructed fully in accordance with the fabrication details provided by the designers/engineer.

Where moulds are manufactured by external suppliers, they should be dimensional checked by a person

independent from the mould supplier prior to being released into the production cycle. A further check should be

made daily prior to the commencement of casting operations.

The finished moulds should be manufactured to allow the production of cladding elements meeting the

requirements of Table 4

Section 10: Raw Materials

All cement is to fully meet the requirements of EN 197-1: 2011 and be certified by the manufacturer/supplier as

being compliant to this standard. Evidence of confirmation compliance within the last twelve months shall be

sought and retained.

Any Silica Sands used within the mix design are to fully meet the requirements of Table 1 below

Silica content is to be declared by the supplier. Evidence of confirmation compliance within the last twelve

months shall be sought and retained.

All other properties of silica sand are to be confirmed by testing on receipt of consignments in accordance with

Table 1 below by a laboratory who must be a Conformity Assessment Body accredited by an ILAC Accreditation

Body member as compliant to ISO 17025:2017 (Competency of Testing and Calibration Laboratories). The

schedule of accreditation must cover the appropriate testing detailed in the table below

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Table 1

Property Requirement

Silica Content >96%

Moisture Content to BS EN 1097-5: 2008

< 2%

Loss on Ignition to SAMSA LOI Test

<0.5%

Coarse Fraction (% total weight passing a 710micron sieve) to BS EN 993-1: 2012

<0.5%

Fine Fraction (% total weight passing 150micron sieve) to BS EN 993-1: 2012

<2%

All alkali resistant glass fibres must comply to the requirements of EN 15422:2008 and be certified by the

manufacturer/supplier as being compliant to this standard. Evidence of confirmation compliance within the last

twelve months shall be sought and retained.

Each delivery of AR fibres must be accompanied by a manufacturers quality control certificate confirming the

following:

Name of manufacturer

Product reference code

Production LOT no

Date of manufacture

Zirconia content

Tex

Moisture content

The LOT number of the fibre used for each day’s production is to be recorded.

Any polymer is to meet the requirement of Table 2 below and be certified by the manufacturer/supplier as being

compliant to this standard. Evidence of confirmation compliance within the last twelve months shall be sought

and retained

Table 2

Compound Type Aqueous thermoplastic polymer dispersion

Polymer Type Acrylic based

Solids content 45-55%

Minimum film formation temp As manufacturer’s instructions

Alkali resistance Declared by manufacturer as suitable for use within GRC matrix

Any pigments used within the mix are to meet the requirements of EN 12878:2014 and be certified by the



All additives and admixtures are to meet applicable national standards. and be certified by the



All deliveries of any raw material used in the production process must be recorded and cross referenced to

supplier’s delivery note.

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Raw materials are always to be stored internally with any minimum storage temperatures as detailed by the

supplier maintained through a documented process and with a suitably calibrated measuring device.

A system of stock rotation must be in place to ensure oldest deliveries are used prior to later deliveries

No change of raw material during the manufacturing of any given project is permitted unless such supplies

become unavailable.

A specimen of all raw materials is to be taken on delivery and retained in accordance with Table 3 below.

Table 3

Item Amount Retain

Cement 5kg 1 month

Silica Sand 5kg 1 month

Polymer 1kg 6 months

Additives and Admixtures

0.5kg 6 months

AR Fibres 0.5Kg 6 months

Proof of all deliveries and purchases is to be retained for 10 years for external inspection if required

Section 11: Facing Coat Mixes

Where a facing coat is being used to provide a suitable architectural finish then the combination of this facing

mix and the GRC mix must be fully developed and validated by comprehensive testing. All testing with exception

of GRC Synergies LDM 1203 is to be carried out by a laboratory who must be a Conformity Assessment Body

accredited by an ILAC Accreditation Body member as compliant to ISO 17025:2017 (Competency of Testing

and Calibration Laboratories). The schedule of accreditation must cover the appropriate testing to be carried

out.

The entire supply of any decorative aggregates to be used in the facing mix are to be obtained prior to

commencement of manufacture for any specific project

Any decorative aggregates used in the facing mix are to be tested on receipt in accordance with EN 1097-5:

2008 to determine water content. The water/cement ratio of the facing mix is to be consistent with that of the

GRC as detailed in Section 12 below and maintained throughout the project

All aggregates are to be sieve tested on receipt in accordance with EN 993-1 2012. The nominal maximum size

of any coarse aggregates shall not be larger than 4mm. Material finer than that passing a 75-micron sieve shall

be limited to 1%

Test specimens shall be manufactured in accordance with EN 12390-2: 2019 and tested for compressive

strength in accordance with EN 12390-3:2019. The minimum strength requirement is to be 30N/mm²

Water absorption is to be determined in accordance with EN 1170-6: 1998

Prior to commencement of manufacture two full sized GRC panels are to be manufactured and tested in

accordance with GRC Synergies LDM 1203 (based on PCI MNL-130-09 Division 5). Bowing between the two

panels should be similar. Factory testing is permitted for this aspect of the development process

Records of all facing mix testing must be kept on file and be updated when there is any change to any of the

raw materials or mix proportions.

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Section 12: GRC Mixes

The appropriate mix design is to be available at the mixing station.

A suitable mixer designed for the specialist mixing of GRC is to be used with a display showing current required

to maintain constant mixing speeds which must also be displayed.

Raw materials are to be weighed using equipment which is calibrated as being accurate to 1% of the required

amount.

All weighing and batching equipment must be calibrated annually by a Conformity Assessment Body accredited

by an ILAC Accreditation Body member as compliant to ISO 17025:2017 (Competency of Testing and Calibration

Laboratories).

In the period between such calibrations the manufacturer is to carry out internal calibrations using certified

weights on at least a monthly basis. Any equipment falling outside calibration is to be immediately taken out of

service and re-calibrated.

A slump test is to be performed on every mix in accordance with EN 1170-1: 1998. The result of this test is to

be recorded on a daily mixing sheet along with a record of the amps drawn at a fixed speed. The spread of slurry

is not relevant to the quality of the GRC however consistency within 2 rings is critical. Any mixes not meeting

this consistency must be not be used in the production of GRC products.

Section 13: Pre-start calibrations (not applicable to Premix Process)

The equipment used to spray the cementitious matrix and alkali resistant fibres is to be calibrated prior to use

every day. In the event of any breakdowns or down time due to welfare breaks etc. recalibration is required.

Alteration to pump speeds or air pressures is prohibited without further calibration.

Calibrations are to be carried out in accordance with EN 1170-3:1998 although a simplified method (Bag &

Bucket) is permitted as detailed in Section 5 of the standard. Such a method is detailed in the International

GRCA published Methods of Testing Part 1.

The deviation from the stated target fibre content permitted under this specification is +/- 0.2% of the required

fibre percentage (i.e a fibre content of 5% can fall within the range 4.8%-5.2%)

All calibration operations are to be recorded in the daily production log and observed by the independent

quality control person as detailed in Section 4

Section 14: – Sample Boards

Sample boards are to be produced every day for testing to EN 1170-2:1998 and EN1170-5:1998. The

dimensions of the test boards and the extracted specimens shall meet the requirements of the relevant

standard. Production methods shall follow exactly the same processes and procedures as used in the

manufacture of finished products.

The follow boards are to be manufactured

1 x Board for determining fibre content of fresh GRC (wash-out test) – EN 1170-2:1998

1 x Board for 1-day flexural testing – EN 1170-5: 1998



The time of production of the test boards should be varied each day along with the operators spraying and

compacting. A full record of time of production and involved operatives must be maintained.

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The production of the test boards is to be observed by the independent quality control person as detailed in

Section 4 to ensure that the production techniques replicate exactly those used to produce manufactured

products.

Section 15: Production Operations

Prior to production commencement the temperature and relative humidity of the production plant are to be

recorded using calibrated equipment in order to provide robust traceability in the event of any non-

conformities. Production must only take place between 10⁰C - 35⁰C unless chilled water is being used when

higher maximum temperatures are permitted.

Moulds should be checked for dimensional variations allowing production of products meeting the

requirements of Table 4

Spraying and compacting of the GRC material is only to be undertaken by competent operatives who have

received suitable training in the application methods required. Training records are always to be available for

inspection.

The use of twin head spray guns is not permitted.

Any required facing coat is to be applied evenly using a specialist facing coat or hopper gun designed for the

operation. Corners must be suitably compacted using a brush, trowel or similar.

Facing coat thickness must be measured at least once per 0.5m². A record should be kept on the daily production

sheet once this process has been completed.

The facing coat must NOT be allowed to dry before the first layer of GRC is applied. This should be confirmed

using the Touch Test

When using the spray process method, the GRC is to be applied using industry best practice in layers not

exceeding 5mm. Each layer is to be fully compacted before the next is applied using suitable spring rollers.

On completion of the various layers the thickness must be confirmed as meeting design requirements at least

once per 0.5m². High spots/low spots must be adjusted accordingly.

Tolerances for the thickness of the facing coat/GRC must meet the requirements of Table 4

Note – It is good practice that design of dead load support fixings is based on weights derived from maximum

thicknesses as above

Once the spraying of the GRC skin is completed any rib formers, stud frames or anchor pads must be applied

before any film formation of the structural layers. If further over spraying of rib formers etc. is required, this

must be carried out immediately again ensuring that there has been no film formation of the GRC. Such

overspray must be depth checked to ensure the requirements of the engineering design are met.

All rib formers are to be produced from a semi-rigid or rigid material. In addition, all material from which the rib

formers are produced is to be classified as either A1 or A2 in accordance with EN 1305:2007+A1: 2009.

The positioning of any stud frames must be carefully controlled to ensure that no gravity or restraint anchors

are touching/digging into the surface of the GRC.

On completion of the spraying operations the completed panel is to be covered with a light gauge polythene

sheet to prevent moisture loss prior polymer film formation

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Section 16: Demoulding & Curing

Products are to be left for a minimum of 12 hours at temperatures between 10⁰C and 35⁰C. before demoulding.

All demoulding procedures are to be in accordance with those determined by the design engineer to avoid over

stressing. Suitable lifting beams or frames are to be used.

Panels that rely on a separate horizontal/vertical framing system which is not fitted until the installation process

must be immediately rotated to either a portrait or landscape orientation to avoid stresses being introduced

into flat panels which may exceed the elastic limit of the material.

After the units are demoulded suitable traceability labels are to be affixed to the products which provide as a

minimum.

• Date cast

• Product reference

• Item weight.

Once demoulded products are to be stored internally at a temperature of between 10⁰C and 35⁰C for a minimum

of 36 hours.

Section 17: Finishing

Finishing techniques will be dependent on the requirements of the customer and may include as cast, grit

blasted, acid washed or mould applied retardant.

In all cases the finish must replicate any visual mock-up samples supplied and agreed before work starts.

Finishing is not to be undertaken until the products are sufficiently cured.

After finishing the products are to be fully inspected to ensure full visual and dimensional compliance to the

VMU and this specification.

Section 18: Applied Sealant

Unless specifically not required by the customer the architectural surface should be protected with an applied

hydrophobic sealant. Where the design is for an open joint rainscreen system is we recommend the rear of the

products are also protected.

The manufacturer’s instructions for application must be precisely followed paying specific attention to moisture

content, air temperature and relative humidity using calibrated equipment. The surface of the GRC element

must be checked for dust or other contaminants prior to application.

Products may not be released until the sealant is fully dried in accordance with the manufacturer’s instructions.

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Section 19: Dimensional Tolerances

The finished products are to meet the dimensional tolerances detailed in Table 4 below

Table 4

Length and height <3000mm +/- 3mm

Length and height >3000mm +/- 3mm per 3000mm with a maximum permitted 6mm

Edge Returns +/5mm – 0mm

Angular variation of moulded returns +/-1mm per 75mm

Thickness – facing coat + 2mm – 0mm

Thickness – Structural GRC +3mm – 0mm

Position of stiffening ribs +/- 10mm

Depth of stiffening ribs +10mm – 5mm

Vertical and horizontal length alignment of stud frames members

6mm per 3000mm

Spacing of stud frame cross members +/- 10mm

Squareness of stud frame (difference in diagonals)

10mm

Overall lengths of frame +/- 10mm

Variation from squareness 3mm per 2000mm or 6mm whichever is greater

Bowing L/250

Openings within panel face +/- 5mm

Location of opening within panel face +/- 3mm

Position of cast in anchors etc. +/- 6mm

Section 20: Packing & Transportation

Finished goods are to be packed on/in metal stillages, wooden crates or pallets. Each element is to be

separated from the next using suitable non-staining packers. The packing methodology must allow air

circulation around the units.

The packing methods must ensure that once the stillages, crates or pallets are loaded onto the delivery vehicle

load restraint straps do not come into contact with the GRC element to avoid any possibility of stresses being

incorporated into the product.

Flat panels that rely on the use of rail systems on site to provide rigidity must be packed in either portrait or

landscape orientation. Horizontal packing of such units is not permitted.

Section 21: Factory QC Testing

Testing of the EN 1170-2: 1998 sample board detailed in Section 14 is to be carried out every day with results

maintained in a suitable manner to allow rolling characteristic values to be determined.

The wash out test is to be completed at the factory in accordance with EN 1170-2:1998. The test may be

deviated or modified to permit the use of higher temperatures of up to 300⁰C allowing faster drying of fibres.

All drying, weighing and measuring equipment must be calibrated annually by a Conformity Assessment Body

accredited by an ILAC Accreditation Body member as compliant to ISO 17025:2017 (Competency of Testing

and Calibration Laboratories).

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Section 22: Laboratory QC Testing

All testing detailed within this section is to be carried out by a laboratory who must be a Conformity Assessment

Body accredited by an ILAC Accreditation Body member as compliant to ISO 17025:2017 (Competency of

Testing and Calibration Laboratories). The schedule of accreditation must cover the appropriate testing to be

carried out.

The flexural strength is to be determined by testing the three test boards to EN 1170-5:1998 on a daily basis.

The following omissions to the test method are permitted under this specification.

• There is no requirement to immerse specimens in water prior to testing due to polymer content of the

mix design

• There is no requirement to determine water content.

Once per week specimens are to be taken from one of the manufactured sample board and tested to BS EN

1170-6:1998.

A weekly test is to be carried out to determine the axial pull off strength of any embedded anchors or fixing

inserts. The strengths attained must meet the requirements used within the engineering calculations. This test

board is to be produced under supervision of the the independent quality control person as detailed in Section

4.

The test method to be used is GRC Synergies Laboratory Developed Method 1201:2018.

All the above results are to be entered into the characteristic analysis maintained by the manufacturer. All test

results must exceed those used within the engineering calculations produced for any given project.

Section 23: Laboratory Validation Testing

All testing detailed within this section is to be carried out by a laboratory who must be a Conformity Assessment

Body accredited by an ILAC Accreditation Body member as compliant to ISO 17025:2017 (Competency of

Testing and Calibration Laboratories). The schedule of accreditation must cover the appropriate testing to be

carried out.

It is a requirement of this specification that testing is carried out on manufactured products to determine that the

quality control measures have resulted in goods which meet the declared flexural strengths.

Any manufactured unit which is rejected due to a visual defect only is to be set aside and 8 number specimens

removed by cutting with a suitable masonry saw. The dimensions of these specimens are defined in BS EN

1170-5. The sampling of the specimens from the manufactured units should be recorded.

These specimens are to be tested at 28 days of age with results maintained allowing comparison with testing of

boards manufactured for testing in accordance with BS EN 1170-5 as defined in Section 22 at same age.

The minimum number of such testing is to be 3 number per 120 manufactured units (2.5% population). The

maximum number required under this specification is 12 per 120 manufactured units (10% population).

Where the number of rejected units does not meet the minimum above, specimens are to be sampled from a

manufactured unit selected by a person independent from the manufacturing team. This by preference may be

the client, client’s representative or external compliance inspector etc. Alternatively it shall be selected by the

independent quality control person.

Resultant flexural strengths, after removal of any facing coat by grinding, must meet those used within the

engineering calculations produced for any given project adjusted in accordance with the safety factor ɣb

determined by the project engineer.

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The ɣb safety factor as provided to the design engineer on Addendum B is to be based on historical test records

and is not mix specific.

Section 24: Records & Documentation

Records and documentation of all aspects of the various processes are always to be maintained. These can

either be in written or electronic form. These records are to be retained for a period of not less than 10 years.

Tested samples are to be retained by either the manufacturer or the testing laboratory for a period not less

than 2 years.

Section 25: Non-Conformities and Corrective Actions

A documented process must be in place for all non-conformities and associated corrective actions.

Any non-conformities relating to the flexural strength of the material must be reported to the client and the

engineer who must be participants in the associated corrective actions.

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ADDENDUM A – SUMMARY OF TEST REQUIREMENTS

Test Method Frequency Testing Body

Aggregates and sand loss on ignition

EN 1097-5:2008 Each consignment Accredited ISO/IEC 17025:2017 laboratory (CAB)

Sieve analysis sands and aggregates

EN 993-1: 2012 Each consignment Accredited ISO/IEC 17025:2017 laboratory (CAB)

Compressive Strength – Facing Mixes

EN 12390-3: 2019 Each new facing mix -proof test

Accredited ISO/IEC 17025:2017 laboratory (CAB)

Differential movement GRC Synergies LDM 1203

Each new facing mix – proof test

Factory

Equipment calibration EN 1170-3: 1998 (simplified permitted)

Once per day each spray machine and after any work interruptions or breakdowns

Factory

Slump test EN 1170-1: 1998 Every mix Factory

Wash out test EN 1170-2:1998 Once per day each spray machine

Factory

Flexural test – 1 day old EN 1170-5:1998 Once per day each spray machine


Flexural test – 7 days old EN 1170-5:1998 Once per day each spray machine


Flexural test – 28 days old

EN 1170-5:1998 Once per day each spray machine


Density and water absorption

EN 1170-6:1998 Once per week each spray machine


Anchor pull out GRC Synergies LDM 1201

Once per week each spray machine


Volumetric movement EN 1170-7: 1998 (Modified)

Every new facing/GRC combination and thereafter annually


Ageing EN 1170-8: 2008 (Modified)

Every new GRC mix and thereafter annually


Fire Classification EN 1305:2007+A1:2009 Every new GRC mix and thereafter 5 years


Product Testing EN 1170-5:1998 1 element per 100 produced


A CAB is a Conformity Assessment Body (laboratory) accredited by the International Laboratory Accreditation Cooperative (ILAC) to carry

out the tests in accordance with the requirements of ISO/IEC 17025:2017

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ADDENDUM B – MANUFACTURERS DECLARATION OF MATERIAL PROPERTIES (ENGINEERING

DESIGN)

PROJECT TITLE

FACING MIX

Reference

Maximum aggregate size

Compressive strength to EN 12390-3

Water absorption to EN 1170-6

Differential bow to GRCS LDM 1203

GRC MIX

Reference

Characteristic flexural strength at yield (LOP) to EN 1170-5. 1 day testing



Characteristic flexural strength at ultimate (MOR) to EN 1170-5. 28 day testing



Minimum age for de-moulding

Minimum age for shipping

Anchor type to be used

Characteristic axial pull out to GRCS LDM 1201

Expansion to EN1170-7 Modified

Shrinkage to EN 1170-7 Modified

Flexural strength at ultimate (MOR) after 50 cycle ageing EN 1170-8 Modified

Estimated ɣb factor based on full scale panel testing

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ADDENDUM C – INSTALLATION

Installation of UHQGRC must only be undertaken by experienced operatives who have a demonstrable

understanding of the material properties. Fixing details provided by the engineer must be followed absolutely

and precisely ensuring any detailed assembly items are not omitted from the assembly.

All tightening torques are to be observed with all such work being carried out using suitably calibrated

equipment certified within the preceding 12 months.

Substitution of named materials such as sealants etc. for different brands must only be permitted after

consultation with the engineer.

There is to be no cutting, grinding or drilling of any GRC element without first consulting the engineer.

Any deviations in the work must be approved in writing by the engineer.

The installed works must be periodically inspected by a person independent of the installation company to

ensure compliance with the fixing details prepared by the engineer. This person may be the client, clients

representative or other independent consultant.

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