The Evolution from Cast Stone to GFRC to Insulated GFRC
Cast stone is known to have existed in various forms since as early as 1138 in France. In all cultures, since man began building structures, natural stones were used
as the time-tested material of choice. However, the weight of cast stone has traditionally made it very difficult and expensive to attach to buildings.
The Colosseum, Rome, Italy
Completed in 70 A.D.
Building Material: Natural Limestone
Created in Russia during the 1940s, GFRC (Glass Fiber Reinforced Concrete) was engineered to mimic precast concrete and cast stone. To eliminate the cost of integral frames, GFRC shells were often produced to be mechanically fastened to a field-built frame with screws. Since GFRC is commonly manufactured unfinished and then painted in the field, the appearance of an aesthetic limestone finish is often lost or compromised.
In the early 2000s, Insulated GFRC was created and engineered by Georgia Precast Solutions. Our proven product eliminates the need
for steel framing and attachment through the finished face. Insulated GFRC weighs, on average, 15-20 percent of cast stone and precast
concrete, eliminating the need for expensive steel and equipment for installation.
Jackson Healthcare, Alpharetta, GA
Completed in 2018
Building Material: Insulated GFRC
Patent Pending
GFRC Insulated Brick System
Available in a Wide Variety of Colors and Textures
| Test Method | Matrix Property Tests | Age | Average Test Results |
|---|---|---|---|
| ASTM C109 | Compressive Strength (psi) | 28 days | 6.600 |
| ASTM C1583 | Tensite Bond (psi) | 28 days | 20 (100% Substrate Failure) |
| ASTM C666 | Freeze/ Thaw Durability (Relative Dynamic Modulas, %) | 300 Cycles | 100 |
| ASTM C666 per C1364 - all sides saw cut to ex-pose aggregate | Freeze/Thaw Durability (CPWL, %) | 300 Cycles | 0 |
| Test Method | Brick Pull-Out Tests | Age | Avg Bond Strength (psi) |
|---|---|---|---|
| ASTM C 1583 | Brick to Matrix Bond | 28 Days | 181 |
| ASTM C 1583 | Foam to Matrix Bond | 28 Days | 20 |
GFRC Insulated Brick System Details
GFRC Insulated Brick System – Encompassing the best of past and current technology
- Pre-grouted Insulated brick panel
- Standard R-16 @ 4” Insulation with Modular Brick Panels which
eliminates attachment of 2” rigid insulation board - Panels applied directly over water-borne weather barrier
- Lightweight – 10 to 12 pounds per square foot
- Brick Panels are considered 75 year product (.01% degradation in
300 cycle freeze/thaw test) - Faster installation requires less equipment and manpower
- All connections are engineered and stamped
- Eliminates costly heavy gauge metal attachments
GFRC Insulated Brick System and Panels
Georgia Precast Solutions’ Insulated Modular Brick System is an addition to our wide range of GFRC insulated wall cladding systems. Brick panels are manufactured in a climate-controlled factory, ensuring consistent quality, and replace the old method of installing masonry, one brick at a time.
The Installation Method
Panels are installed using adhesive and mechanical attachments. Installation times are significantly faster than traditional brick, requiring a fraction of the field labor. The adhesive is applied to the back of the panel, and positioned on the building per engineered shop drawings. Once the panel is positioned it is mechanically attached and clipped back to the structure. At certain levels of the building, normally at floor lines, a J-track mechanical attachment method is used to carry the weight of the panel. The brick panels will be positioned on a spacer (placed at both horizontal/vertical joints) to control the joint size and maintain uniformity.
Insulated Flat Panel and Brick System
- Brick and flat panels have an insulated value of R-16 @ 4” thickness
- Panel size is 2’ x 4’ x 4”
- Panels will have an integrated color; pre-finished or smooth grey and painted onsite
Brick and straight panel system
Brick and running bond system
