PECIAL
S FEATURE
R Glass fibre r e i n f o r c e m e n t
in the building industry
If t h e c o m p o s i t e s market is ana-
lysed according to major 'end use'
s e c t o r s in 1990, t h e b u i l d i n g indu-
stry o c c u p i e d 2nd place in t h e USA
w i t h 2 1 2 0 0 0 t o n s , i.e. 18.2%
( s o u r c e : SPI C o m p o s i t e s Insti-
t u t e ) and 4th place in E u r o p e with
169 000 tons, i.e. 14.9% (source:
V e t r o t e x I n t e r n a t i o n a l ) . For t h e 10
last years, total growth was 48% in
t h e USA, and 51% in Europe, with
average a n n u a l rates respectively
÷ 5.8 and ÷ 4.8%. When t h e s e values
are c o m p a r e d w i t h t h e d e v e l o p m e n t
o f t h e c o m p o s i t e s m a r k e t as a
w h o l e , for t h e same period: total
growth: 40% in t h e USA and 88% in
E u r o p e , a v e r a g e a n n u a l growth:
r e s p e c t i v e l y ÷ 3 . 4 % a n d ÷6.5%,
t h e picture in America was more
favourable t h a n in E u r o p e since, in
t h e USA, b u i l d i n g a p p l i c a t i o n s grew
faster t h a n c o m p o s i t e s as a w h o l e ,
w h i l e in E u r o p e t h e o p p o s i t e t o o k
place, says J D a u d e n s o f Vetrotex
I n t e r n a t i o n a l , Chambery, France.
However, for Europe, for the per-
iod u n d e r c o n s i d e r a t i o n , t h e build-
ing c o m p o s i t e s s e g m e n t s h o w e d an
increase while the building segment
as a w h o l e did not.
s early as the 1950s, the industriali-
A zation of glass fibre manufacture led
to the development of glass rein-
forced plastics, particularly for the building
industry, because of their good performance:
-- dimensional stability,
REINFORCED PLASTICS OCTOBER 1991 0034-3617/91/$3.50 © 1991, Elsevier Science Publishers Ltd.
-- strength, rigidity and impact resistance;
-- lightness;
-- durability;,
--low inflammability given an appropriate
choice of resin and additives;
--quality of surface finish, transparency or
possibility of through pigmentation; and
-- design freedom.
All these properties have given t h e m a
foothold in numerous applications, outside,
inside and in close proximity to buildings.
Cladding
• Composites f o r exterior design
The first impression we get of a building is
t h a t of its facade. "Whatever your architec-
tural dream, we can bring it to life with glass
fibre reinforced composites and we will do it
practically and economically," says an Amer-
ican builder who has been erecting office
buildings, universities, hotels and casinos for
more t h a n 25 years.
Another industrialist adds t h a t the prime
reason for the penetration of composites into
the building market is t h a t they represent a
cheap alternative in maintenance terms, to
wood, stone, marble and even concrete. They
have the strength, texture and look of the
original material but owing to their low
weight and long life they are much cheaper.
Columns, p e d i m e n t s , d o m e s a n d o t h e r
exterior design elements are being used in
historic building renovation.
Durability, pigmentation, eliminating the
necessity of painting or repainting external
skins, are among the most obvious advant-
ages. Owing to t h e i r negligible w e i g h t
compared to other materials they reduce
scaffolding, fixing and labour costs. Adjust-
ments in situ are easy and economical. One
additional feature for the renovation or
reproduction of historic monuments is the
ease with which composites can imitate
existing details.

T h e d e c i s i v e a d v a n t a g e of g l a s s f i b r e
c o m p o s i t e s for a r c h i t e c t s is u n l i m i t e d free-
d o m of design. It is t h e only m a t e r i a l w h i c h
c a n a s s u m e all s h a p e s , w i t h i n t h e f r a m e w o r k
of a given d e s i g n a t t h e s a m e t i m e as offering
all t h e e c o n o m i c a d v a n t a g e s of low t o o l i n g
a n d e r e c t i o n costs.
• Composites for panelling, cladding and
covering
Glass fibre c o m p o s i t e s c o n t r i b u t e to t h e
c r e a t i o n of flat or c u r v e d s u r f a c e s to clad
and/or insulate the walls of dwellings,
offices, f a c t o r i e s or s p o r t s facilities. C o m p o -
sites with p o l y m e r m a t r i x or w i t h c e m e n t
m a t r i x m a y be u s e d for:
--panelling: exterior insulation without a
f r a m e w o r k , c o m p o s e d of t h e panel, a n d
i n s u l a t i n g m a t e r i a l fixed directly to t h e
wall;
--covering: s i m p l e c l a d d i n g by t h e f a c i a
panel either using a coating on an
i n s u l a t i n g m a t e r i a l w h i c h is d e t e r i o r a -
ting, or on a wall w i t h an a p p e a r a n c e in
n e e d of a t t e n t i o n ; a n d
- - c l a d d i n g : f i x e d on a f r a m e w o r k w i t h
m o u n t e d insulation.
Several c o m b i n a t i o n s a r e possible:
--a facing system consisting, from the
o u t s i d e to t h e inside, of a layer of s t o n e
or m a r b l e a g g r e g a t e , a layer of p o l y e s t e r -
i m p r e g n a t e d glass fibre, a layer of low cost
c o m p o u n d and, on t h e back, of p o l y e s t e r /
glass fibre l a m i n a t e ;
- - l i g h t w e i g h l facia p a n e l s s u c h as a s a n d -
wich m a d e of two s h e e t s of g l a s s - c e m e n t
with a p o l y i s o c y a n a t e core a n d a s t o n e
c h i p or p o l y v i n y l c h l o r i d e (PVC) finish, or
a p a n e l l i n g s y s t e m c o n s i s t i n g of m o d u l a r
e l e m e n t s of m o u l d e d p i g m e n t e d g l a s s
cement composite imitating stone or
concrete and combining an insulation
p a n e l with a d e c o r a t i v e facia. This t y p e
of p a n e l is u s e d in t h e c o n s t r u c t i o n of
t o w e r blocks w i t h a m e t a l frame, in t h e
USA a n d ,Japan;
- - I h e i n g s m a d e of glass fibre r e i n f o r c e d
p o l y e s t e r c o m p o u n d . S m a l l m o d u l e s (less
t h a n 1 m 2) a r e m a n u f a c t u r e d by injection
or compression moulding. The grain
(stone, slate, c e m e n t ) is p r o d u c e d by t h e
mould, q ~ e y a r e e a s y to install a n d a l l o w
a d a p t a t i o n to every p o s s i b l e shape;
-- a new s o l u t i o n c o n s i s t s of a t h i n s h e e t of
m a r b l e or a n o t h e r p o l i s h e d s t o n e b o n d e d
to a rigid l a m i n a t e (a h o n e y c o m b core a n d
a layer of p o l y e s t e r - i m p r e g n a t e d g l a s s
fibre) :
PECIAL
S FEATURE
-- shingles; a n d
- - t r a n s l u c e n t fiat or c o r r u g a t e d sheeting,
allowing s u n l i g h t to flood into s w i m m i n g
pools, s p o r t s halls, w o r k s h o p s a n d agri-
c u l t u r a l buildings, or t h e s a m e type, in
f i r e - r e s i s t a n t o p a q u e quality, fully p i g m e n -
ted, for i n d u s t r i a l buildings.
O Facia renovation using glass cement
composites
Old b u i l d i n g s often no longer m e e t c u r r e n t
standards for insulation, aesthetics and
q u a l i t y of life, a n d n e e d r e n o v a t i o n work.
Glass c e m e n t c o m p o s i t e s p e r m i t t h e addi-
tion of cornices, m o u l d i n g s a n d o t h e r such
d e t a i l s w h i c h are e a s y to fit a n d c o n t r i b u t e to
an i m p r o v e d a p p e a r a n c e .
• External insulation and coatings
Glass fibre s c r e e n s p r o v i d e a key for a d h e -
sion of t h e c o a t i n g to t h e i n s u l a t i n g m a t e r i a l ,
give it d i m e n s i o n a l stability, seal cracks, a n d
p r e v e n t falls of large p i e c e s of plastering.
This s y s t e m of e x t e r n a l i n s u l a t i o n for new
buildings or r e f u r b i s h m e n t w o r k is b e i n g
i n c r e a s i n g l y used. The c o a t i n g s t h e m s e l v e s
are occasionally reinforced with chopped
s t r a n d s to p r e v e n t cracking.
• Composite formwork and moulds for
con(mete
C a s t in situ or p r e - c a s t c o n c r e t e r e m a i n s t h e
m o s t - u s e d m a t e r i a l in b u i l d i n g f a c a d e s .
C o m p o s i t e s , w h i c h can a s s u m e a n y r e q u i r e d
s h a p e to e m b e l l i s h t h e m , a r e s u i t a b l e for t h e
m o u l d s . Glass fibre r e i n f o r c e d p l a s t i c s free
the architect from the technical constraints
linked w i t h m o u l d s m a d e of t r a d i t i o n a l
m a t e r i a l s . A d v a n t a g e s are n u m e r o u s : poss-
ibility of s o p h i s t i c a t e d s h a p e s , r e m a r k a b l e
r o u g h - c a s t c o n c r e t e finishes, w i t h o u t risk of
staining, m u l t i p l e re-use w i t h o u t m a i n t e -
nance, p o s s i b i l i t y of low cost d u p l i c a t i o n ,
i m p r o v e m e n t in p r o d u c t i v i t y d u e to insula-
tion p r o p e r t i e s .
Roofing
Glass fibre in v a r i o u s f o r m s is also p r e s e n t in
t h e roofing of i n d u s t r i a l a n d a g r i c u l t u r a l
b u i l d i n g s a n d even in houses.
• Sealing and waterproofing
A g r e a t n u m b e r of roofs a n d t e r r a c e s are
c o v e r e d w i t h b i t u m i n o u s felt r e i n f o r c e d w i t h
g l a s s f i b r e to i m p r o v e t h e d i m e n s i o n a l
s t a b i l i t y a n d t h e r e s i s t a n c e to t e a r i n g a n d
REINFORCED PLASTICS OCTOBER 1991
S
m
P E C I A L
FEATURE
p u n c t u r i n g , while being rot proof. The
bituminous layer is generally covered with
gravel or a n o t h e r m a t e r i a l to p r e v e n t
abrasion or to improve t he aesthetic appear-
ance. Some felts are p r o d u c e d using PVC
reinforced with layers of glass fibre. In some
cases a complete s t r u c t u r e incorporating
insulation, seal and finish makes up the
entire r oof covering.
• Roofs
For several decades the roofs of industrial
and agricultural buildings and sports instal-
lations have been cons truct ed with panels of
glass fibre reinforced polyester manufac-
t ur ed by continuous impregnation process.
Flat, c or r uga t e d or ribbed these panels can
be linked to profiles of o t h e r materials (steel,
fibre cement). Their advantages are:
- - light weight;
- - e x c e l l e n t mechanical characteristics;
- - ease of installation; and, above all,
-- translucence.
There are o t h e r forms of composite struc-
tures which provide at the same time cover
and natural lighting:
- - c u p o l a s with one, two or even t h r e e
thicknesses providing insulation and pre-
venting condensation. The supports and
bases are also m a d e from glass fibre
composite; and
- - m o v a b l e sections which allow roofs to
open.
Shingles or Canadian clapboard are more
specific to t he roofs of individual dwellings.
Particularly used in North America, they are
becoming more c o m m o n in Europe. Consist-
ing of a layer of glass fibre i ncorporat ed in
layers of bi t um e n and granulated fillers t hey
provide a lightweight, w at ert i ght covering
with various shapes and colours which meet
architects' aesthetic requirements. They are
easily nailed to a c h i p b o a r d or t i m b e r
support. Heavier versions imitate slate or
o t h e r traditional materials.
Developed in t he USA, foam-core pultru-
ded roof panels, assembled with interlocking
edges, are not only self-supporting but also
allow access to personnel. They are highly
resistant to corrosion: their light weight and
rigidity make installation easier, and there-
fore less costly, and the absence of main-
tenance makes them more economical
overall.
• Stretched veils
Woven glass fibre c o a t e d w i t h PVC or
p o l y t e t r a f l u o r o e t h y l e n e (PTFE) makes it
REINFORCED PLASTICS OCTOBER 1991
possible to create roof structures, which are
very light, for stadiums, recreational areas or
pathways between buildings.
• Rooffittings
Gutters, downpipes and outlets are made
from sheet moulding c o m p o u n d (SMC) or
p u l t r u d e d composites, for applications in
which zinc, copper or PVC exhibit th e ir
weaknesses: corrosion, difficult shapes, ther-
mal constraints.
In s t r u c t u r e s
To date, this area of use of composites
r e m a i n s very r e s t r i c t e d . P r e - s t r e s s e d or
reinforced concrete s t r u c t u r e s with glass
fibre composite reinforcement remain limi-
t e d to specific cases w h e r e t h e r e a re
considerable risks of corrosion.
On the o t h e r hand, beam structures and
floor gratings m ade of p u l t r u d e d glass fibre/
polyester are widely used in the chemical
industry for corrosion resistance. There are
also examples of laboratories or the top p a r t
of buildings with problems of wave transmis-
sions, where p u l t r u d e d profiles with their
permeability to electromagnetic waves find a
very specific application.
Doors and windows
Applications remain fairly limited in this
field:
- - c o m p o s i t e garage doors, with or without
t r a n s p a r e n t panels, which have b e e n
successful in the USA are beginning to
find m a r k e t s in Europe, p r o d u c e d by
c o n t i n u o u s laminating, or from press-
m oul ded SMC elements. They combine
solidity, light weight, insulation and easy
maintenance;
- - c o m p o s i t e front doors and shutters are
also available but are hardly progressing
at the moment. They are made from SMC
or structural reaction injection mouldings
(SRIM) with two skins bonded to an
insulating foam core; and
- - n u m e r o u s a t t e m p t s have been made to
m a n u f a c t u r e door and window frames. To
date, t here are few industrial-scale pro-
ducts available. This type of relatively
expensive solution is possible only in
e x t r e m e cases of thermal gradients or
corrosion.

Inside
Glass fibre is p r e s e n t everywhere: in decora-
tion a n d furnishings~ p a r t i t i o n s a n d facings,
s a n i t a r y w a r e , etc. Glass fibre, b e i n g of
m i n e r a l origin, is fire proof, non-toxic, rot-
p r o o f a n d r e s i s t a n t to r o d e n t a n d insect
attack. In all its forms, e i t h e r as a textile or
as a r e i n f o r c e m e n t for p l a s t e r or p o l y m e r s it
trees the creativity of i n t e r i o r designers.
In decoration
• Blinds"
T h e i r m a i n f u n c t i o n :is to filter t h e sun's rays,
a n d to control t e m p e r a t u r e levels in rooms.
A s e c o n d a r y f u n c t i o n is b e c o m i n g i m p o r t a n t ,
t h e i r role as d e c o r a t i v e f i x t u r e s in windows
naturally, b u t also as p a r t i t i o n i n g elements.
They are of two types: vertical s l a t t e d or
a u t o m a t i c roller blinds, and are u s e d in
h o m e s and offices. T h e i r m a i n f e a t u r e s are:
d i m e n s i o n a l stability, fire resistance, variety
of t e x t u r e s , colours, etc.
• Coverings
They are suitable for use on all substrates:
walls, partitions, ceilings, d o o r s a n d furni-
ture. Options of coloured, plain or p r i n t e d
f a b r i c s or n a t u r a l for p a i n t i n g c a n be
selected a c c o r d i n g to taste. T h e i r d u r a b i l i t y
and fire r e s i s t a n c e m a k e t h e m particulagly
suitable for public places.
• Plaster
Glass f i b r e - r e i n f o r c e d p l a s t e r is u s e d in
p a r t i t i o n s a n d a wide variety of shapes:
columns, p e d e s t a l s , ceiling roses, m o u l d -
ings, alcoves a n d s t a t u e s . Fire safety is
absolute.
O Decor and furnishings in reinforced
plastics
Glass r e i n f o r c e d plastics can be u s e d to
p r o d u c e d e c o r a t i v e e l e m e n t s similar to t h o s e
m a d e from plaster, generally m a n u f a c t u r e d
by spray-up. A careful choice of resins and
additives can e n d o w fire-resistant p r o p e r t i e s .
C o m p o s i t e s allow m a n y d e c o r a t i v e forms:
f u r n i s h i n g s , c o u n t e r s a n d m o d u l a t i o n of
interior space.
• Decorations in glass cement composite
Glass fibre-reinforced m o r t a r s can be u s e d to
m a k e bas-reliefs w h e r e t h e fineness of the
m o r t a r grain a n d fibres is s o u g h t after.
S PECIAL
FEATURE
Partitions and facings
• Glass reinforced gypsum and cement
In g y p s u m b o a r d s the a d d i t i o n of glass-fibre
has several advantages:
--reduction in b r e a k a g e s d u r i n g m a n u f a c -
ture, t r a n s p o r t a t i o n a n d installation:
- - c u t t i n g , nailing, etc., are possible; and
- - m a i n t e n a n c e of fire-break capability by
p r e s e r v a t i o n of s t r u c t u r a l integrity.
The light weight of p a n e l s in glass-cement
c o m p o s i t e p a r t i t i o n i n g of i n d u s t r i a l o r
public buildings in c o n d i t i o n s similar to
t h o s e o b t a i n e d with p l a s t e r partitions.
• Composite panels
C o m p o s i t e panels, often of t h e d o u b l e - s i d e d
insulating type can be f o u n d in hospitals,
airports, a d m i n i s t r a t i v e buildings. Module
assembly, ease of installation a n d mainte-
n a n c e are t h e keys to t h e i r success.
Sanitaryware
S a n i t a r y w a r e in c o m p o s i t e m a t e r i a l s can be
m a n u f a c t u r e d using: c o m p r e s s i o n m o u l d i n g
of SMC, s p r a y - u p o n t o a g e l - c o a t or a
t h e r m o f o r m e d acrylic sheet, resin t r a n s f e r
m o u l d i n g (RTM) on a Unifilo p r e f o r m .
P r o d u c t s include:
- - b a t h s , of various styles and shapes;
- - w a s h b a s i n s : a new concept, t h a t of the
v a n i t y unit with an i n t e g r a t e d bowl, which
first a p p e a r e d in hotel fittings, is gradually
t e n d i n g to replace the p e d e s t a l washbasin;
- - s h o w e r s : trays, partitions, c o m p l e t e units;
- - sinks; and
--toilets: l a m i n a t e d partitions, urinal wall
units, self-contained toilets.
Flooring
• Flexible flooring
Often d i m e n s i o n a l stability, r e s i s t a n c e to
t e a r i n g or h e e l - m a r k s of synthetic m a t e r i a l s
is i n a d e q u a t e . R e i n f o r c e m e n t with glass fibre
veils or m e s h mitigates t h e s e inadequacies.
• Hard flooring
C o m p u t e r r o o m s r e q u i r e the use of light
easT-lay floor tiles w h i c h allow the p a s s a g e of
cables. S o m e SMC or g l a s s - c e m e n t c o m p o s i t e
tiles have been used, or m o r e recently tiles of
injected d o u g h m o u l d i n g c o m p o u n d (DMC)
i n c o r p o r a t i n g g r o u n d w a s t e composite. M
REINFORCED PLASTICS OCTOBER 1991 L