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- -- strength, rigidity and impact resistance;

lysed according to major 'end use' -- lightness;
-- durability;,
s e c t o r s in 1990, t h e b u i l d i n g indu-
--low inflammability given an appropriate
stry o c c u p i e d 2nd place in t h e USA choice of resin and additives;
w i t h 2 1 2 0 0 0 t o n s , i.e. 18.2% --quality of surface finish, transparency or
( s o u r c e : SPI C o m p o s i t e s Insti- possibility of through pigmentation; and
t u t e ) and 4th place in E u r o p e with -- design freedom.
169 000 tons, i.e. 14.9% (source: All these properties have given t h e m a
foothold in numerous applications, outside,
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
inside and in close proximity to buildings.
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
Cladding
÷ 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 • Composites f o r exterior design
o f t h e c o m p o s i t e s m a r k e t as a The first impression we get of a building is
w h o l e , for t h e same period: total t h a t of its facade. "Whatever your architec-
tural dream, we can bring it to life with glass
growth: 40% in t h e USA and 88% in
fibre reinforced composites and we will do it
E u r o p e , a v e r a g e a n n u a l growth: practically and economically," says an Amer-
r e s p e c t i v e l y ÷ 3 . 4 % a n d ÷6.5%, ican builder who has been erecting office
t h e picture in America was more buildings, universities, hotels and casinos for
favourable t h a n in E u r o p e since, in more t h a n 25 years.
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 Another industrialist adds t h a t the prime
reason for the penetration of composites into
faster t h a n c o m p o s i t e s as a w h o l e ,
the building market is t h a t they represent a
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 cheap alternative in maintenance terms, to
place, says J D a u d e n s o f Vetrotex wood, stone, marble and even concrete. They
I n t e r n a t i o n a l , Chambery, France. have the strength, texture and look of the
However, for Europe, for the per- original material but owing to their low
iod u n d e r c o n s i d e r a t i o n , t h e build- 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
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
exterior design elements are being used in
increase while the building segment historic building renovation.
as a w h o l e did not. 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
s early as the 1950s, the industriali- scaffolding, fixing and labour costs. Adjust-

A zation of glass fibre manufacture led

to the development of glass rein-
forced plastics, particularly for the building
ments in situ are easy and economical. One
additional feature for the renovation or
reproduction of historic monuments is the
industry, because of their good performance: ease with which composites can imitate
-- dimensional stability, existing details.

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 PECIAL
S FEATURE

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 -- shingles; a n d
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- - - t r a n s l u c e n t fiat or c o r r u g a t e d sheeting,
d o m of design. It is t h e only m a t e r i a l w h i c h allowing s u n l i g h t to flood into s w i m m i n g
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 pools, s p o r t s halls, w o r k s h o p s a n d agri-
of a given d e s i g n a t t h e s a m e t i m e as offering c u l t u r a l buildings, or t h e s a m e type, in
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 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 -
a n d e r e c t i o n costs. ted, for i n d u s t r i a l buildings.

• Composites for panelling, cladding and O Facia renovation using glass cement
covering composites
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 Old b u i l d i n g s often no longer m e e t c u r r e n t
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 standards for insulation, aesthetics and
and/or insulate the walls of dwellings, 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.
offices, f a c t o r i e s or s p o r t s facilities. C o m p o - 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-
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 tion of cornices, m o u l d i n g s a n d o t h e r such
m a t r i x m a y be u s e d for: 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
--panelling: exterior insulation without a an i m p r o v e d a p p e a r a n c e .
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 • External insulation and coatings
wall; Glass fibre s c r e e n s p r o v i d e a key for a d h e -
--covering: s i m p l e c l a d d i n g by t h e f a c i a 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 ,
panel either using a coating on an give it d i m e n s i o n a l stability, seal cracks, a n d
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 - p r e v e n t falls of large p i e c e s of plastering.
ting, or on a wall w i t h an a p p e a r a n c e in 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
n e e d of a t t e n t i o n ; a n d 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
- - 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 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
m o u n t e d insulation. are occasionally reinforced with chopped
Several c o m b i n a t i o n s a r e possible: s t r a n d s to p r e v e n t cracking.
--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 • Composite formwork and moulds for
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 - con(mete
i m p r e g n a t e d glass fibre, a layer of low cost 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
c o m p o u n d and, on t h e back, of p o l y e s t e r / 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 .
glass fibre l a m i n a t e ; 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
- - 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 - 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
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 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
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 the architect from the technical constraints
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 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
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 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-
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 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
cement composite imitating stone or 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
concrete and combining an insulation staining, m u l t i p l e re-use w i t h o u t m a i n t e -
p a n e l with a d e c o r a t i v e facia. This t y p 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 ,
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 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-
t o w e r blocks w i t h a m e t a l frame, in t h e tion p r o p e r t i e s .
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
Roofing
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 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
(stone, slate, c e m e n t ) is p r o d u c e d by t h e 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
mould, q ~ e y a r e e a s y to install a n d a l l o w b u i l d i n g s a n d even in houses.
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 • Sealing and waterproofing
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 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
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 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
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 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
fibre) : 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

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P E C I A L
FEATURE

p u n c t u r i n g , while being rot proof. The possible to create roof structures, which are
bituminous layer is generally covered with very light, for stadiums, recreational areas or
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 pathways between buildings.
abrasion or to improve t he aesthetic appear-
ance. Some felts are p r o d u c e d using PVC • Rooffittings
reinforced with layers of glass fibre. In some Gutters, downpipes and outlets are made
cases a complete s t r u c t u r e incorporating from sheet moulding c o m p o u n d (SMC) or
insulation, seal and finish makes up the p u l t r u d e d composites, for applications in
entire r oof covering. which zinc, copper or PVC exhibit th e ir
weaknesses: corrosion, difficult shapes, ther-
• Roofs mal constraints.
For several decades the roofs of industrial
and agricultural buildings and sports instal- In s t r u c t u r e s
lations have been cons truct ed with panels of
glass fibre reinforced polyester manufac-
t ur ed by continuous impregnation process. To date, this area of use of composites
Flat, c or r uga t e d or ribbed these panels can 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
be linked to profiles of o t h e r materials (steel, reinforced concrete s t r u c t u r e s with glass
fibre cement). Their advantages are: fibre composite reinforcement remain limi-
- - light weight; t e d to specific cases w h e r e t h e r e a re
- - e x c e l l e n t mechanical characteristics; considerable risks of corrosion.
- - ease of installation; and, above all, On the o t h e r hand, beam structures and
-- translucence. floor gratings m ade of p u l t r u d e d glass fibre/
There are o t h e r forms of composite struc- polyester are widely used in the chemical
tures which provide at the same time cover industry for corrosion resistance. There are
and natural lighting: also examples of laboratories or the top p a r t
- - c u p o l a s with one, two or even t h r e e of buildings with problems of wave transmis-
thicknesses providing insulation and pre- sions, where p u l t r u d e d profiles with their
venting condensation. The supports and permeability to electromagnetic waves find a
bases are also m a d e from glass fibre very specific application.
composite; and
- - m o v a b l e sections which allow roofs to
open. Doors and windows
Shingles or Canadian clapboard are more
specific to t he roofs of individual dwellings.
Particularly used in North America, they are Applications remain fairly limited in this
becoming more c o m m o n in Europe. Consist- field:
ing of a layer of glass fibre i ncorporat ed in - - c o m p o s i t e garage doors, with or without
layers of bi t um e n and granulated fillers t hey t r a n s p a r e n t panels, which have b e e n
provide a lightweight, w at ert i ght covering successful in the USA are beginning to
with various shapes and colours which meet find m a r k e t s in Europe, p r o d u c e d by
architects' aesthetic requirements. They are c o n t i n u o u s laminating, or from press-
easily nailed to a c h i p b o a r d or t i m b e r m oul ded SMC elements. They combine
support. Heavier versions imitate slate or solidity, light weight, insulation and easy
o t h e r traditional materials. maintenance;
Developed in t he USA, foam-core pultru- - - c o m p o s i t e front doors and shutters are
ded roof panels, assembled with interlocking also available but are hardly progressing
edges, are not only self-supporting but also at the moment. They are made from SMC
allow access to personnel. They are highly or structural reaction injection mouldings
resistant to corrosion: their light weight and (SRIM) with two skins bonded to an
rigidity make installation easier, and there- insulating foam core; and
fore less costly, and the absence of main- - - n u m e r o u s a t t e m p t s have been made to
tenance makes them more economical m a n u f a c t u r e door and window frames. To
overall. date, t here are few industrial-scale pro-
ducts available. This type of relatively
• Stretched veils expensive solution is possible only in
Woven glass fibre c o a t e d w i t h PVC or e x t r e m e cases of thermal gradients 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 corrosion.

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Inside Partitions and facings

Glass fibre is p r e s e n t everywhere: in decora- • Glass reinforced gypsum and cement

tion a n d furnishings~ p a r t i t i o n s a n d facings, 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
s a n i t a r y w a r e , etc. Glass fibre, b e i n g of has several advantages:
m i n e r a l origin, is fire proof, non-toxic, rot- --reduction in b r e a k a g e s d u r i n g m a n u f a c -
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 ture, t r a n s p o r t a t i o n a n d installation:
attack. In all its forms, e i t h e r as a textile or - - c u t t i n g , nailing, etc., are possible; and
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 - - m a i n t e n a n c e of fire-break capability by
trees the creativity of i n t e r i o r designers. 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
In decoration 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.
• Blinds"
• Composite panels
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. 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
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 , insulating type can be f o u n d in hospitals,
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 airports, a d m i n i s t r a t i v e buildings. Module
naturally, b u t also as p a r t i t i o n i n g elements. assembly, ease of installation a n d mainte-
They are of two types: vertical s l a t t e d or n a n c e are t h e keys to t h e i r success.
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: Sanitaryware
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.
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
• Coverings 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
They are suitable for use on all substrates: of SMC, s p r a y - u p o n t o a g e l - c o a t or a
walls, partitions, ceilings, d o o r s a n d furni- t h e r m o f o r m e d acrylic sheet, resin t r a n s f e r
ture. Options of coloured, plain or p r i n t e d m o u l d i n g (RTM) on a Unifilo p r e f o r m .
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 P r o d u c t s include:
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 - - b a t h s , of various styles and shapes;
and fire r e s i s t a n c e m a k e t h e m particulagly - - w a s h b a s i n s : a new concept, t h a t of the
suitable for public places. 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
• Plaster 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;
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
- - sinks; and
p a r t i t i o n s a n d a wide variety of shapes:
--toilets: l a m i n a t e d partitions, urinal wall
columns, p e d e s t a l s , ceiling roses, m o u l d -
units, self-contained toilets.
ings, alcoves a n d s t a t u e s . Fire safety is
absolute.
Flooring
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 • Flexible flooring
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 Often d i m e n s i o n a l stability, r e s i s t a n c e to
m a d e from plaster, generally m a n u f a c t u r e d 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
by spray-up. A careful choice of resins and 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
additives can e n d o w fire-resistant p r o p e r t i e s . veils or m e s h mitigates t h e s e inadequacies.
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 • Hard flooring
interior space. 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
• Decorations in glass cement composite 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
Glass fibre-reinforced m o r t a r s can be u s e d to
injected d o u g h m o u l d i n g c o m p o u n d (DMC)
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. 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

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