Introduction: Addressing Industry Concerns about Silica Dust
In recent years, growing awareness of respirable crystalline silica (RCS) exposure has prompted regulatory shifts across Australia’s construction and manufacturing sectors. Prolonged inhalation of fine silica particles, often generated when cutting traditional concrete or engineered stone, can lead to silicosis—a chronic and potentially fatal lung disease. Safe Work Australia classifies crystalline silica dust as a Group 1 carcinogen and enforces stringent workplace exposure limits (WES) of 0.05 mg/m³ over an 8-hour time-weighted average.
In light of these regulations, architects, engineers, and fabricators are increasingly seeking safer, low-silica alternatives that don’t compromise on strength, aesthetics, or performance. ShapeShift Technologies has responded with a groundbreaking solution: ShapeShell™ RC Green GRC, a crystalline silica-free reinforced material tailored for modern construction.
What is ShapeShell™ RC Green GRC?
ShapeShell™ RC Green GRC is an advanced fibre-reinforced concrete material that replaces the silica-laden sand typically used in GRC with recycled glass. Developed by ShapeShift Technologies, this variant retains the high strength, lightweight nature, and formability of traditional GRC, but removes the primary health risk associated with crystalline silica.
Designed for thin-walled applications with panel thicknesses between 15–25 mm, ShapeShell™ RC Green is ideal for architectural forms that demand both strength and detail. It’s manufactured using precision CNC moulds and can be finished in a wide range of textures and colours to meet bespoke design intent.
Material Innovation – Replacing Sand with Recycled Glass
Traditional glass fibre reinforced concrete (GRC) relies heavily on fine silica sand as the aggregate component. While this has long been standard practice, it carries serious health implications—particularly when panels are cut, drilled, or abraded on-site, releasing hazardous crystalline silica dust. ShapeShift Technologies has addressed this risk by replacing sand with finely processed recycled glass. This change does not merely eliminate crystalline silica; it transforms the entire lifecycle and performance profile of the material.
Recycled glass is chemically inert and does not contain respirable silica particles, making it a non-hazardous alternative. Unlike engineered stone or silica-based concrete, recycled glass aggregate does not release dangerous dust when processed, significantly reducing the occupational health risks for construction workers, installers, and fabricators. This aligns with new WHS regulations and the growing momentum in Australia to restrict or phase out high-silica products from the market.
From a technical standpoint, recycled glass also enhances the internal microstructure of the GRC matrix. The angular geometry and fine grading of the glass particles contribute to superior particle packing and a denser, more cohesive matrix. This results in increased compressive strength, better flexural resistance, and reduced porosity—critical benefits for exterior cladding and high-performance elements exposed to weathering.
Moreover, the thermal and chemical stability of recycled glass improves the material’s durability over time. Unlike some natural aggregates, glass does not contain impurities or mineral variations that can lead to unpredictable behaviour under thermal cycling or moisture ingress.
From an environmental perspective, the use of post-consumer glass represents a closed-loop solution. Glass that might otherwise end up in landfill is reintroduced into the construction industry, reducing demand for virgin sand—a non-renewable resource that is rapidly depleting worldwide. This not only diverts waste but also cuts down on the carbon emissions associated with sand mining, processing, and transport.
The result is a material that delivers on all fronts—eliminating a major health hazard, enhancing structural performance, and reducing environmental impact—all without sacrificing the design freedom or aesthetic versatility that architects expect from high-end facade solutions.
Mechanical and Sustainability Benefits
Mechanically, ShapeShell™ RC Green GRC outperforms many conventional facade materials. It boasts:
- Flexural Strength: 25 MPa
- Compressive Strength: 45 MPa
- Tensile Strength: 12 MPa
- Fire Rating: Non-combustible (AS 1530.1) and Group 1 (AS 5637.1)
- Durability: Rated Class 4 (EN 12467), with excellent freeze-thaw and UV resistance
Environmentally, the use of recycled content dramatically reduces CO₂ emissions, with ShapeShell™ products achieving up to 400% lower emissions than traditional materials. The panels are lightweight (30–50 kg/m²), contributing to reduced structural loads and transport costs.
Use Cases and Usability
ShapeShell™ RC Green GRC is designed with architectural flexibility and construction practicality in mind, offering a crystalline silica-free solution for both interior and exterior applications. Its strength, lightweight form, and ability to be shaped into complex geometries make it an ideal material for a wide range of use cases—from high-performance building envelopes to customised furniture and interior features.
Facades
In façade design, ShapeShell™ RC Green GRC offers the rare combination of visual freedom and structural performance. The material’s thin-wall design—typically between 15 to 25 mm—reduces dead loads on the building envelope, allowing for lighter substructure systems and cost savings in structural framing. Despite its reduced thickness, it provides high compressive and flexural strength, suitable for both ventilated façade systems and direct-fixed cladding.
Beyond performance, ShapeShell™ RC supports a variety of finishes: from off-form smooth surfaces to exposed aggregate, pigmented oxides, and even anti-graffiti coatings. Architects can specify virtually any visual language—from minimal monoliths to textural expressions or sculptural features. Because of its silica-free composition, the material is also safer during on-site adjustment or cutting, a practical benefit during installation.
In large-scale public projects like Brisbane’s Cross River Rail, ShapeShell™ RC panels have already demonstrated their resilience and adaptability—providing weather resistance, visual quality, and ease of integration with mechanical systems such as ventilation or lighting.
Rainscreens
Rainscreen cladding systems benefit from the breathable yet protective qualities of ShapeShell™ RC Green GRC. The panels can be engineered to allow for air and moisture movement behind the façade, supporting thermal comfort and building envelope performance while maintaining visual continuity.
Their high dimensional stability and low water absorption rate (<25%) make them particularly suited to climate-adaptive façades, especially in coastal or high rainfall regions. Panel sizes and fixing points are pre-engineered for standardised systems but can also be adapted for project-specific geometries and wind loading conditions.
The material’s robustness under freeze-thaw cycles, UV exposure, and acid rain environments ensures it performs over decades, not just years.
Architectural Furniture and Elements
In addition to cladding applications, ShapeShell™ RC Green GRC is increasingly being used in architectural furniture and joinery applications such as benchtops, bar fronts, seating, planter boxes, and sculptural furniture.
Its smooth, high-finish surfaces and ability to be shaped into curves or folds make it ideal for furniture that doubles as architectural statement. Compared to traditional precast concrete or natural stone, ShapeShell™ RC Green GRC offers a lighter, thinner alternative with equivalent strength and vastly improved sustainability.
This opens new possibilities for built-in elements in commercial interiors, hospitality venues, civic spaces, and public landscapes. Finishes can be tailored from polished or honed to textured or matte, depending on use and aesthetic direction.
Because it is reinforced, the material can achieve thinner profiles than traditional concrete while maintaining load-bearing capacity—allowing designers to push formal and spatial boundaries without compromising structural safety.
Conclusion: Safer & Smarter Material Choice
ShapeShell™ RC Green GRC represents a significant step forward in material safety and environmental responsibility. By removing crystalline silica and integrating recycled inputs, it offers architects and building consultants a product that aligns with both occupational health standards and sustainable design principles.
In an industry navigating tighter safety regulations and rising performance demands, ShapeShell™ RC Green GRC stands out as a forward-thinking alternative—safe for workers, smart for projects, and sustainable for the future.
