GFRC panels are thin, lightweight architectural concrete panels reinforced with alkali-resistant glass fibre rather than steel. ShapeShift Technologies manufactures them as ShapeShell-RC at its factory on Batam Island, Indonesia, and has delivered more than 350 projects across 18 countries.
The short version. Typical panel thickness of 15 to 25 mm gives the appearance and surface of mass concrete at a small fraction of the dead load of precast. Because the reinforcement is glass fibre rather than steel, there is no cover requirement, so the panel can be thin and can follow curves that precast cannot.
What GFRC actually is
GFRC stands for glass fibre reinforced concrete. Outside the United States the same material is usually called GRC, and both names describe a cement and sand matrix reinforced with alkali-resistant glass fibre containing 16 percent or more zirconia, which is what allows the fibre to survive in an alkaline cement environment. Ordinary E-glass does not.
It is made two ways. Sprayed GRC lays the matrix and chopped fibre into the mould simultaneously and gives the highest fibre content and strength. Premix GRC blends the fibre into the mix before casting and suits smaller or more intricate sections. Stud frame GRC bonds the skin to a steel frame for large panels.
Where GFRC panels are the right answer
Curvature is the usual reason. A double-curvature or freeform facade is a tooling problem before it is a casting problem, and GFRC follows geometry that precast and stone cannot. ShapeShift makes its own moulds and runs CNC formwork in-house, so complex panel schedules are quoted without a separate tooling supplier in the chain.
Weight is the second reason. On a refurbishment, a tower over a podium, or any structure where the facade dead load drives the frame, replacing heavy cladding with a 15 to 25 mm GFRC skin changes the structural sum. Size a panel for your own project with the panel weight and crane calculator.
Surface is the third. GFRC takes acid-etched, sandblasted, polished, exposed aggregate and off-form finishes, with integral colour through the mix rather than a coating that weathers off.
Fire and compliance
Fire test regimes differ by country and no result transfers automatically between them. ShapeShell-RC holds an AS/NZS 1530.1 non-combustibility result from Ignis Labs. Other regimes, including EN 13501-1 in Europe, NFPA 285 in the United States and BS 8414 in the United Kingdom, test different things in different ways. The facade fire test evidence page sets out what is held against each, and the fire standards atlas compares nine jurisdictions side by side.
The pathway for any building is set by its fire engineer and approving authority, and compliance is assessed on the complete wall system rather than the panel alone.
At a glance
| Property | ShapeShell-RC |
|---|---|
| Typical panel thickness | 15 to 25 mm |
| Reinforcement | Alkali-resistant glass fibre, 16 percent or more zirconia |
| Stiffness | 50 percent higher than standard GFRC |
| Geometry | Single and double curvature, freeform, perforated |
| Finishes | Acid-etched, sandblasted, polished, exposed aggregate, off-form, integral colour |
| Manufacturing | Batam Island, Indonesia. 100,000 sq ft, around 40,000 sq ft a month |
| Quality system | ISO 9001 accredited for ten years |
| Industry body | GRCA Full Member, International Glassfibre Reinforced Concrete Association, graded as a sprayed GRC manufacturer |
| Warranty | Up to 50 years |
Full material detail, including the fixing systems and substructure options, sits on the ShapeShell-RC page. For stocked formats and short lead times see the standard GFRC facade panel range, and for geometry outside the standard range see bespoke facade panels.
Terms explained
Short definitions of the terms on this page, in our facade materials encyclopedia.
Common questions
What is the difference between GFRC and GRC?
None. They are the same material. GFRC is the usual term in the United States and GRC is the usual term in the United Kingdom, the Gulf, Australia and Asia. Both mean a cement and sand matrix reinforced with alkali-resistant glass fibre.
How thick is a GFRC panel?
Typically 15 to 25 mm for the concrete skin. Because the reinforcement is glass fibre rather than steel there is no cover requirement, which is why the panel can be far thinner than precast.
Is GFRC lighter than precast concrete?
Substantially. A 15 to 25 mm GFRC skin carries the appearance of mass concrete at a small fraction of the dead load of a precast panel, which is why it is often specified where the facade load drives the structural frame.
Can GFRC be curved?
Yes, including double curvature and freeform shapes. The limit is the mould rather than the material. ShapeShift makes its own moulds and runs CNC formwork in-house.
Is GFRC non-combustible?
ShapeShell-RC holds an AS/NZS 1530.1 non-combustibility result from Ignis Labs. Other jurisdictions test differently and results do not transfer automatically. See the facade fire test evidence page for what is held against each regime.
Where are the panels made?
On Batam Island, Indonesia, across 100,000 sq ft of factory space producing around 40,000 sq ft a month, with the Australian office in Newstead, Brisbane.
Reviewed by Richard Halvorsen, General Manager, ShapeShift Technologies.